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AMETEK/PRESTOLITE POWER ULTRA CHARGE, Owner'S Manual, Page: 63 / 70

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AMETEK/PRESTOLITE POWER ULTRA CHARGE Owner'S Manual Download Page 63

Summary of Contents for ULTRA CHARGE

Page 1: ...193111 068 Revised October 31 2005 IMPORTANT Read these instructions before installing operating or servicing this system ULTRA CHARGE Battery Charger DO NOT DESTROY AMETEK PRESTOLITE POWER TROY OHIO 45373 1099 U S A ...

Page 2: ...ur ampere hour capacity case size input power phase and maximum number of cells in battery for which charger is intended The following example explains the basic model numbering arrangement Model 1050 T 1 12 Maximum Number of Cells Input Power Phase 3 Three Phase 1 Single Phase Case Size 16 3A 100AH Start Rate 8 Hour Ampere Hour Capacity NOTE This information is required for ordering certain repla...

Page 3: ...e Connectors 4 3 Pre operation Checks 4 3 Pre Operation Changes to the Factory Control Settings 4 3 MAINTENANCE 5 OPERATION 6 Preliminary 6 1 Normal Or Daily Charge 6 1 Equalize Or Weekend Charge 6 2 Manual Stop 6 2 AC Power Fail 6 2 UC2000 CONTROL FEATURES 7 Main Features 7 1 Description of Features 7 2 UC2000 Charge Archive Function 7 5 UC2000 Charge Cycle Review Function 7 6 PROGRAMMING YOUR UC...

Page 4: ...March 31 2005 193111 068 TABLE OF CONTENTS TROUBLESHOOTING 10 Troubleshooting Table 10 1 Action 10 10 PARTS LIST 11 ELECTRONIC PRINTED CIRCUIT BOARD EXCHANGE SERVICE POLICY DIAGRAMS WARRANTY ...

Page 5: ...rating procedures Notes will be shown in italics Equipment Identification The unit s identification number specification model serial number usually appears on a nameplate attached to the front panel Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify...

Page 6: ...t be installed and maintained in accordance with the National Electrical Code NFPA 70 and local codes A power disconnect switch must be located at the equipment Check nameplate for voltage and phase requirements If only 3 phase power is available connect single phase equipment to only two wires of the 3 phase line DO NOT CONNECT the equipment grounding conductor lead to the third live wire of the ...

Page 7: ... the battery If the charger is equipped with an ammeter the ammeter should not indicate current flow Always connect battery before turning charger ON F Medical and First Aid Treatment First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical shock victims EMERGENCY FIRST AID Call physician and ambulance immediately Use First Aid ...

Page 8: ...e based on this information The Ultra Charge is internally protected against overload and short circuits by both input and output fusing plus Prestolite s unique curve monitoring circuit periodically measures the output curve to ensure that the voltage and current are within the limits set at the factory Operating Modes The Ultra Charge can be set to default to any one of three operating modes The...

Page 9: ...so provides the user with plain English messages concerning charge cycle status Four bright LEDs molded into the keypad keep the user informed of charge status at a glance even from long distances LEDs notify you that a charge is in pro gress that the battery is 80 charged equalize cycle charge complete and fault indication When charging lead acid batteries with the same number of cells and ampere...

Page 10: ...o discharge the static electrical charges which tend to build up on the surfaces of equipment These static charges can cause painful shock to personnel and can lead to the erroneous conclusion that an electrical fault exists in the equipment If a charger is to be connected to the AC power supply with a flexible jacketed cable one having a separate grounding conductor should be used When included i...

Page 11: ... the charger is factory connected 2 If charger is not connected correctly check serial nameplate to determine that charger is equipped to be connected for available line voltage If charger is suitably equipped make voltage changeover connections by following instructions on AC input label inside charger 3 If charger is reconnected check input fuse s ratings with ratings specified on label and repl...

Page 12: ...refully read and follow instructions on all tags and labels Make sure all labels remain visible to anyone operating charger 3 Make sure all charger cabinet panels are fastened in place to assure proper flow of ventilating air through cabinet Pre Operation Changes To The Factory Control Settings Typically few changes are required to be made if the amp hour rating is sized to the battery and the vol...

Page 13: ...inate unnecessary losses and to avoid subsequent trouble from overheating or open circuits Check for broken wiring or damaged Insulation on wiring WARNING ELECTRICAL SHOCK HAZARD Failure to keep internal parts clean and dry may allow transformer s to short out causing secondary circuits to carry dangerously high voltage Be sure to replace all charger cabinet panels after any servicing to assure pr...

Page 14: ... 2 to 7 seconds as the data is read into the charger 4 After a short delay the charger will turn on and the Charge in Progress LED will light The alphanumeric display will indicate the cell size amp hour and phase settings for the upcoming charge cycle Then it will display current charging cycle information Verifying Battery may appear for several minutes if the multi cell mode is on 5 The 80 Char...

Page 15: ...s flame and cigarettes away Ventilate when charging in an enclosed area Always shield eyes when working near batteries AC Power Fail The UC2000 Control will resume the charge where it left off when the AC power failure occurred virtually unaffecting charge time As power is returned if a charge cycle was in progress the display may show ACFAIL RESTART The charger is staggering the restart based on ...

Page 16: ...ow Voltage Shutdown If a battery on charge does not reach a minimum on charge voltage in a predetermined period of time the charger will be shutdown All 4 LEDS will be flashing and the display will read Low Voltage Fault 9 High Amp Hour Returned Shutdown If the cycle amp hours returned exceed the BID AH setting or charger maximum AH rating for a prede termined amount the charger will shutdown All ...

Page 17: ...6 4 March 31 2005 193111 068 OPERATION ULTRA CHARGE RECHARGING CAPABILITY Figure 6 1 ...

Page 18: ...t 99 Charge cycles Amp hours returned during charge cycle Total time on charge 80 point to end of charge timer Battery open circuit voltage Start current Start voltage volts cell Finish current Finish voltage volts cell Charge termination code Equalize time Start time End time Truck I D Battery I D Battery I D start temperature Battery I D end temperature Cycle ampere hours Cycle cell size Battery...

Page 19: ...eplate rating The output current will be adjusted to deliver current at the proper rate Attempts to program ampere hour sizes larger than the nameplate rating will not be accepted by the control If the battery is equipped with a Prestolite BID Module the Fixed Ampere Hour function will be overridden and the charger will charge the battery at the rate programmed into the BID Module BID Module progr...

Page 20: ...key After displaying the information from memory the unit will return to the normal Ultra Charge display All status LEDs will be Illuminated during the review of function number one thus providing a lamp test feature Nine functions are displayed during a standard review If the charger is idle the information in all 58 review functions can be displayed See the UC2000 Charge Cycle Review Feature sec...

Page 21: ...t Kilowatt Hour Feature The Control will calculate the approximate input kilowatt hour usage for each charge cycle This feature may be helpful in determining the cost of charging given various charging scenarios with known electricity costs 80 Charged Point A standard UC2000 Control will light the 80 Charged LED and enable the charge termination routine when the battery voltage reaches the gassing...

Page 22: ...ze charges with out constant attention by the operators The third type of equalize is by BID count When programmed for this mode the current complete cycle count is read from the BID at connect and compared to that of the equalize cycle counter An equalize will be requested when the BID count equals the equalize cycle count programmed into function 22 For further information on programming and rev...

Page 23: ...tery at the end of the charge cycle FINISH VOLTS The value of the battery voltage at the end of the charge cycle TERM The reason for charge cycle termination All possible codes are listed below 1 Charge Comp Normal Charge Complete 2 Low Current Low Current Error shutdown 3 Manual Stop Manual stop 4 Battery Dis Battery disconnected while charging 5 80 Backup 0 80 Back up Timer Error shutdown 7 Cool...

Page 24: ...ey sequence is used to access charge cycle review data functions Keys Display Program Review Enter 1 REV 2 PROG Function 3 MAH 4 ARCH 1 Enter Rev Func 01 Key in function number and press enter or scroll using arrow keys to review entire charge cycle see Fig 7 2 You may re enter a new function number at any time to jump through the menu quickly 01 AMP HOURS RET The total ampere hours returned durin...

Page 25: ...t was charged in the charge cycle Requires Prestolite Battery Identification Module BID 15 BATTERY VOLTS The present voltage of the battery connected to the battery charger volts DC 16 FAN RUN The number of hours HOURS k thousands that the charger fan if equipped has run 17 BID START TEMP The temperature of the battery sensed by the Prestolite Battery Identification Module at the start of the char...

Page 26: ... battery connected 33 CYC AMP HOURS The ampere hour setting of the charger during the charge cycle This value cannot exceed the maximum charger output rating 34 CYCLE CELLS The cell size setting of the charger during the charge cycle This value cannot exceed the maximum charger output rating 35 FIXED CELL SIZE The cell size the charger will operate at if the multi cell mode is not selected and the...

Page 27: ...arts and refresh charges a battery that has not been disconnected 8 to 99 hours Factory Setting 72 hours 45 DVDT DISABLE Disables the automatic DV DT charge termination feature and enables Voltage Time charge termination OFF DV DT Mode ON VT mode 46 PRESENT The current month 1 to 12 MONTH 47 PRESENT The current day of the month DATE 1 to 31 48 PRESENT The current year 00 to 99 YEAR 49 MULTICELL En...

Page 28: ...ired to program if turned on 56 MAX BATT TEMP The maximum battery temperature for charging to start or continue Once interrupted the charge will restart after the temperature drops 5 degrees F For use with BID only 57 CYCLE KWH The number of kilowatt hours used during the last charge cycle 58 MAX CELL SIZE Programs the Max Cell Size available on 40 cell chargers in the multi cell mode The charger ...

Page 29: ...193111 068 UC2000 CONTROL FEATURES 7 12 Revised October 31 2005 Figure 7 2 ...

Page 30: ...display will show to Change Data Use the arrow keys to increment or decrement the data Again press the Enter key when programming of that function is complete 19 PRESENT TIME The current time Program in 24 hour military time format 0000 to 2359 military time 20 WEEK DAY The present day of week SUN through SAT Use the up or down arrow to select the proper setting 21 EQUALIZE TYPE The type of auto e...

Page 31: ...charger will not restart until any faults are reset by pressing the ENTER key and no battery is connected Use the up or down arrow to select the proper setting 33 CYC AMP HOURS The ampere hour setting of the charger during the last charge cycle This value cannot exceed the maximum charger output rating Not programmable 34 CYCLE CELLS The cell size setting of the charger during the last charge cycl...

Page 32: ...select the proper setting NOTE Functions 39 through 42 apply only to the custom curve and cannot be changed unless the custom curve has been selected in Function 38 39 START AMPS 100 The custom output curve start current setting 10 0 to 16 3 amps per 100 ampere hours Factory setting 16 3 40 FINISH AMPS 100 The custom output curve finish current setting 0 0 to 7 9 mps per 100 ampere hours Factory s...

Page 33: ...splayed for the entered data If the BID properly accepts the data the programmed number will be returned to the display 51 BID CELLS Programs the Cell Size into the BID Once programmed the charger will recognize the battery upon connection bypass the battery cell size verify function and charge to the programmed BID cell size 06 6 Cells 09 9 Cells 12 12 Cells 18 18 Cells 24 24 Cells 36 36 Cells 40...

Page 34: ...i cell mode The charger cannot automatically recognize the difference between 40 and 36 cell sizes and therefore the Max Cell Size in that mode must be programmed to 36 or 40 cells Regardless of this setting 36 or 40 cell batteries with properly programmed Prestolite BID modules will correctly be charged 36 36 Cells 40 40 Cells Use the up or down arrow to select the proper setting NOTE The Max Cel...

Page 35: ... cell battery that is connected to the charger at the proper 450AH rates for a Deka Dominator Sealed Gel Battery Any 12 cell battery con nected to the charger will be charged at the proper 680AH rates for a standard flooded battery Finally any 18 cell battery connected to the charger will be charged at the proper 744AH rates for a standard flooded battery By enabling the Multi AH function any 6 9 ...

Page 36: ...rs at a 5 amp 100AH rate Application 24 Cell 935AH Battery 1050T3 24 Ultra Charge When programmed and connected as shown to the right the charger will charge the battery at 48 amps for 20 hours before automatically shutting off It should be noted that any programming that is done to set up a special charge such as Timer Start Mode Custom Curve etc must be reset to allow resumption of normal chargi...

Page 37: ...193111 068 PROGRAMMING YOUR UC2000 CONTROL 8 8 Revised August 30 2005 Figure 8 1 ...

Page 38: ...ne of the batteries must be within the range of the charger Refer to charger nameplate for ratings For example two 12 volt 6 cell 225 ampere hour batteries would make a 12 volt 6 cell 450 ampere hour load Operate this charger as instructed in Operation chapter of this manual except that batteries are to be connected as shown in Figure 9 1 plus the total ampere hour capacity must be used to calcula...

Page 39: ...6 1050 AH 396143 75 396143 78 No 4 0 size for 1051 1270 AH 396143 76 396143 88 Fused Disconnect Switch Refer to Figure 9 3 To order JIC disconnect chargers add 002 to the base Spec No Example 680T3 12 w Opt 500 Spec 500659 002 This option is provided to meet certain JIC require ments The switch must be in the open OFF position to disconnect all AC power going into the charger and to allow front do...

Page 40: ...le to allow the user to download Ultra Charge archive data using the front door mounted data port to a laptop PC via the PC s Serial Port Data is stored in a text file format that can be imported into most popular spreadsheet programs Remote Stop Pushbutton Kit Remote Stop Pushbutton Kit 196400 1 A Remote Stop Pushbutton Kit is available for applications where the charger control is not readily ac...

Page 41: ...ad Not Connected 2 Keypad Connected Improperly 3 Bad Control Board 4 Bad Keypad 8 8 7 9 Display Illegible 1 Noisy Environment 2 Low Input Voltage 3 Bad Control Board 10 11 7 Charger Doesn t Respond To Battery Being Connected 1 Output Fuse Bad 2 Bad Harness Connections Loose Or Incorrect 3 Bad Control Board 4 Output Cables Reversed 5 Bad Output Connector 12 6 7 13 14 Control Not Responding Locked U...

Page 42: ... 9 Not Enough Charging Time 25 26 27 28 29 30 31 32 37 Battery Doesn t Last Full Shift 1 Faulty Lift Interrupt 2 Manual Disconnect 3 A H Required Battery Nameplate 4 Battery Not Providing Nameplate Rating 5 Equalize Schedule 6 Charge Curve Incorrect 7 Rates Set Incorrectly 8 Fixed Temperature Set Incorrectly 9 Bad BID 10 Charger Too Small For Battery 11 Not Enough Charging Time 33 34 35 26 27 28 2...

Page 43: ... Set Incorrectly 4 Fixed Temperature Set Incorrectly 5 Charge Curve Incorrect 6 Equalize Schedule 7 Control Set For Voltage Time 8 Control Set For Cell Forming 9 Bad BID 40 41 29 30 28 27 38 36 32 Incorrect Charge Rate 1 Rates Set Incorrectly 2 Fixed Temperature Set Incorrectly 3 Charge Curve Incorrect 4 Battery A H Not Equal To Charger A H 5 Battery Has Incorrect Size BID 6 Bad Control Board 7 BI...

Page 44: ...l Wiring Loose From Heat Sink 5 Bad Harness Connection Loose Or Incorrect 6 Bad Power Connection 7 Bad Output Cable Connector 8 Bad Inductor 9 Moisture Inside Cabinet 10 Lack of Maintenance 11 High Ambient Temperature 7 53 20 20 6 21 14 22 54 18 17 Meter Reading Wrong V C 1 Bad Output Connect 2 Bad Harness Connections Loose Or Incorrect 3 Internal Power Connection 4 Bad Control Board 14 6 21 7 Met...

Page 45: ... 4 Bad SCR 5 Bad Diode 6 Bad Control Board 7 Gate Lead Connections 8 AC Supply 9 Bad Transformer 56 57 6 53 58 7 20 1 19 High Input Current 1 Incorrect Wiring To Primary Of Transformer 2 Incorrect Cabling To Transformer Secondary 3 Incorrect AC Input Jumper Setting 4 Bad Harness Connections Loose Or Incorrect 5 Bad SCR 6 Bad Diode 7 Bad Control Board 8 Gate Lead Connections 9 AC Supply 10 Bad Tran...

Page 46: ...ct Charge Curve Setting 5 Bad Battery 6 Bad BID 30 33 14 28 26 32 Display Reads Manual Stop Fault 1 Someone Pressed Manual Stop Button 2 Bad Connection Keypad Control 3 Bad Keypad 4 Bad Control Board 34 8 9 7 Display Reads Low Current Fault 1 Fixed Temperature Set Incorrectly 2 Bad Harness Connections Loose Or Incorrect 3 Battery Not Fully Formed 4 Bad Battery 5 Bad A H Charger A H 6 Bad Internal ...

Page 47: ... BID not Programmed Properly 62 26 7 32 Display Reads Setup Error Fault 1 Shunt Size Setting Has Been Changed On Control Board 2 Cell Size Setting Has Been Changed On Control Board 3 A H Resistor Has Been Changed On Control Board 4 Bad Keypad Connection Keypad Control 5 Bad Keypad 6 Bad Control Board 63 64 65 8 9 7 Display Reads Check AC Power 1 Intermittent AC Fail Supply 2 Control Transformer Co...

Page 48: ...ore 10 7 15 Display Reads DIDT Fault 1 Bad Battery 2 Bad Control Board 3 Bad BID 26 7 32 Display Reads High Amp Hour Fault 1 Bad Battery 2 Bad Control Board 3 Bad Incorrect Shunt 26 7 55 Display Reads Low Voltage Fault 1 Bad Battery 2 Bad Control Board 3 Bad Power Connection 4 Bad Harness Connections Loose or Incorrect 26 7 21 6 Display Reads Bad BID Fault 1 Bad BID 2 Bad Power Connection 3 Bad Ha...

Page 49: ...m 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 con...

Page 50: ...that it is not missing Visually inspect the suppressor core for missing pieces or cracks If so replace the suppressor core 16 Refer to the INSTALLATION chapter and go to the paragraph labeled LOCATION This will define the guide lines If a charger has inadequate ventilation many different problems can occur If a charger runs under extreme temperatures any component inside the charger could fall pre...

Page 51: ...ycle equalizing This can be programmed by the Auto EQ type function to the UC2000 Control See the Programming Your UC2000 Control chapter of this manual 28 Using the Review feature of the control See the Control Features chapter of this manual check the charge curve setting of the charger If it does not match the Battery Type Standard Sealed Custom reprogram the control to the proper curve Refer t...

Page 52: ...fied delay time between battery connection and the start on the charge See the Programming Your UC2000 Control chapter of this manual 41 Battery is being discharged at too high fast of a rate Consult the battery manufacturer or distributor for applications assistance 42 Check and repair reconnect connections between the last charger that is polling properly and the next charger connected See your ...

Page 53: ...le Connect the positive VOM lead to the anode cable lead and the negative VOM lead to the cathode stud The VOM should read a low impedance near short circuit Reverse the VOM leads The VOM should read high impedance near open circuit Replace any diodes that fail with the proper part 59 Reconnect the input primary jumpers to match the input voltage see the installation chapter of this manual Be sure...

Page 54: ...68 PARTS LIST 11 1 March 31 2005 Figure 11 1 THREE PHASE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 14 23 24 25 26 27 11 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 28 29 30 31 32 33 34 35 ...

Page 55: ... Connector Amp Hour 192302 1 192302 3 192302 1 192302 3 192302 1 18 Spacer Hex Threaded Alum 1 192262 2 19 Support PC Board Display 196603 20 Label Not For Telephone Use 196533 21 Door Hinged 196218 22 Grommet Mounting 194827 1 23 Panel Interior 194447 24 Transformer Control 208 240 480 Volt Transformer Control 240 480 575 Volt Transformer Control 400 Volt 406247 2 406247 4 406247 3 25 Label AC In...

Page 56: ...aded Alum 1 192262 2 19 Support PC Board Display 196603 20 Label Not For Telephone Use 196533 21 Door Hinged 196218 22 Grommet Mounting 194827 1 23 Panel Interior 194447 24 Transformer Control 208 240 480 Volt Transformer Control 240 480 575 Volt Transformer Control 400 Volt 406247 2 406247 4 406247 3 25 Label AC Input 208 240 480 Volt Label AC Input 240 480 575 Volt 406461 194140 26 Latch Disconn...

Page 57: ...oard Display 196603 20 Label Not For Telephone Use 196533 21 Door Hinged 196218 22 Grommet Mounting 194827 1 23 Panel Interior 194447 24 Transformer Control 208 240 480 Volt Transformer Control 240 480 575 Volt Transformer Control 400 Volt 406247 2 406247 4 406247 3 25 Label AC Input 208 240 480 Volt Label AC Input 240 480 575 Volt 406461 194140 26 Latch Disconnect 2 5 7 Spec only 194379 27 Reduce...

Page 58: ... AC Input 208 V 1 2 Spec only Fuse AC Input 240 V 1 2 Spec only Fuse AC Input 240 V 3 5 Spec only Fuse AC Input 400 V 4 Spec only Fuse AC Input 480 V 1 2 Spec only Fuse AC Input 480 V 3 5 Spec only Fuse AC Input 575 V 3 5 Spec only Requires Item 27 1 pair per fuse 196030 60 196030 45 196030 45 196030 25 196030 25 196030 25 196030 20 196030 60 196030 50 N A N A 196030 25 N A N A 196030 35 196030 30...

Page 59: ...068 PARTS LIST 11 7 March 31 2005 Figure 11 2 Single Phase 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 13 21 22 23 24 25 10 51 50 49 48 47 46 45 44 43 42 40 39 38 37 36 35 34 26 27 28 29 30 31 32 33 41 ...

Page 60: ...or 2 Pole 406240 1 406240 1 406241 1 406241 1 406241 1 16 Connector Amp Hour 192302 2 192302 1 192302 3 192302 2 192302 1 17 Spacer Hex Threaded Alum 1 192262 2 18 Support PC Board Display 196603 19 Label Not For Telephone Use 196533 20 Grommet Mounting 194827 1 21 Panel Interior 194447 22 Transformer Control 1 2 Spec only Transformer Control 5 Spec only Transformer Control 4 Spec only 406247 2 40...

Page 61: ... board s in which fault has developed for a replacement A standard exchange price has been established for each printed circuit board without regard to the amount of repair required to the original turned in which is applied against the cost of the replacement Exchange prices for a specific printed circuit board may be determined by contacting an authorized company distributor or by writing to the...

Page 62: ...68 DIAGRAMS DIAGRAMS INPUT VOLTAGE DIMENSIONAL OUTLINE 1 PHASE 3 PHASE 208 240 480 196695 196675 196377 240 480 575 196695 196675 196377 480 575 N A 196675 196377 DIAGRAMS 220 380 415 196695 N A 196377 400 N A 196677 196377 ...

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Page 70: ...ite s factory inspection and judgement Prestolite s liability is limited to repair of any defects found by Prestolite to exist or at Prestolite s option the replacement of the defective product F O B factory after the defective product has been returned by the purchaser at its expense to Prestolite s shipping place Replacement and exchange parts will be warranted for the remainder of the original ...

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