AMETEK/PRESTOLITE POWER ULTRA CHARGE, Owner'S Manual, Page: 49 / 70

March 31, 2005 10-9
193111-068
TROUBLESHOOTING
Action Steps
1. Reference the INSTALLATION chapter (pg. 4-1).
2. Disconnect AC power and replace the bad AC fuse. Reapply AC power to the charger. If the fuse (s) blows instantly,
check the connections on the input side of the contactor to make sure there are no shorts between any of the input
wires . If that’s okay, then check or change the control transformer. If the fuse(s) blow after the contactor closes,
then check the input wiring from the contactor to the main transformer (s). Refer to the DIAGRAM chapter and locate
the diagram for your charger to confirm that the charger is wired correctly. Also check the wires going up to the
terminal block on the transformer; the wires will have numbers that correspond to the number on the terminal block.
If they are incorrect, change them and start over. If it still blows fuse (s), the transformer will have to be replaced.
3. Reset the breaker. Disconnect the control and reapply AC power to the charger. Measure to see if 24VAC is on the
output side of the control transformer. If there is, the control has failed. If there isn’t 24VAC, then replace the
control transformer. It is still possible that the control has failed; so once the control transformer is replaced,
measure to see if the 24VAC drops once the control is connected.
4. Check and see if any input fuses are blown. Visually inspect the control transformer for discoloration on the casing
of the input side of the control transformer. Disconnect the control before applying AC power. Once AC power is
reapplied, measure the input voltage to the control transformer; it should be the AC supply voltage (208/240/480).
If not, check the control transformer input wiring. If you did read the supply voltage, then measure the output side and
you should read 24VAC. If not, replace the control transformer.
5. Look at the casing of the control transformer on the input side. Reference the DIAGRAM chapter to determine the
input. There will be four pins and each one will be labeled as follows: COM (common), 208 (208VAC), 240 (240VAC),
and 480 (480VAC). Some models may have a 575 (575VAC) pin. There should always be a wire on the common pin
no matter what voltage is applied to the charger, and the second wire will go to the pin labeled as the voltage that is
applied to operate the charger. Measure the voltage on the output side of the control transformer, it should read
approximately 24VAC.
6. A bad harness/connection can cause many different problems. The best way to confirm a bad harness/connection
problem is to take measurements where the harness is connected to the charger and then follow the wire (s) up the
harness to the PC boards and measure there also. The measurement should match what was measured at the
charger connection. If it doesn’t, check the following: Check the connectors at the square plugs where the control
harness connects to the charger harness; the connectors could be pressed out of the plugs. Make sure the
connectors look okay inside the edge mount connector at the PC board (s). Make sure the harness connections are
tight where they connect to the charger. Make sure the wires are crimped to the terminals tightly and also check to
make sure that they are crimped to the bare wire and not to the insulation only.
7. To check the Control Board for proper operation, first check the DIP Switch settings of S1. Make sure the shunt size
and cell selections match the charger , see the nameplate. For a 200A shunt, the 100A and 400A switches should be
open. They should both be closed for a 600A shunt. Check the voltages between J10-1 (gnd) and the following points,
they should be within 5% of the voltages given: J10-2 = 3.00V, J10-3 = 12.00V, and J10-4 = 5.00V. J10 is located at
The bottom left of the PCB.
If the charger operates normally except there is no alphanumeric display, the check the connection from the display
to the Control Board. Replace the Control Board if the connection is correct.
If the charger still does not work properly even though the above settings and voltages are correct, the Control Board
may need replaced. However, this is unlikely and all other possibilities should be checked before taking this step.
8. Look at the inside of the door and locate the Control Board . (Reference the illustrated Parts List
for locations). The keypad is connected to the Control Board. Look up between the Control Board and the inside of
the door. You should be able to see the keypad ribbon cable. The ribbon cable should be connected to a pin header
on the Control Board. If it’s not connected, or looks questionable, remove the Control Board and correct it.
9 . With no battery connected to the charger, press all of the keys on the keypad and the display should indicate that the
button did function. The only exception will be the Equalize and Stop keys. To test them, connect a battery and
allow the charger to start, then press the button. The ULTRA CHARGE was shipped set for automatic equalize
which means unless this was changed, the Equalize button will not respond. To find out if the Status LED’s on the
keypad are okay, press key number “0” and a complete review will occur that starts out by performing a lamp test
which lights all the Status LED’s.