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AMETEK/PRESTOLITE POWER AC500 Owner's Manual

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OWNER'S MANUAL 193111-035
Revised July 14, 2003
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
AC500
CHARGE CONTROL
DO NOT DESTROY
AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

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Summary of Contents for AMETEK/PRESTOLITE POWER AC500

  • Page 1 OWNER’S MANUAL 193111-035 Revised July 14, 2003 IMPORTANT: Read these instructions before installing, operating, or servicing this system. AC500 CHARGE CONTROL DO NOT DESTROY AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

  • Page 3: Table Of Contents

    193111-035 TABLE OF CONTENTS INTRODUCTION ........................... How To Use This Manual ....................1-1 Equipment Identification ..................... 1-1 Receipt Of Equipment......................1-1 SAFETY INSTRUCTIONS AND WARNINGS ...............2 INITIAL SET-UP & DESCRIPTION ....................Cell Size Selection......................3-1 Description.......................... 3-1 LOCATION DIAGRAM ........................OPERATION ............................
  • Page 4 193111-035 TABLE OF CONTENTS This page intentionally left blank. April 28, 1999...

  • Page 5: Introduction

    193111-035 INTRODUCTION INTRODUCTION How To Use This Manual CAUTION refers to possible equipment damage. Cautions will be shown in bold type. IMPORTANT: It is especially important that all charger internal components be kept NOTE offers helpful information concerning clean and dry, and all certain operating procedures.
  • Page 6 193111-035 INTRODUCTION This page intentionally left blank. April 28, 1999...

  • Page 7: Safety Instructions And Warnings

    193111-035 SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS AND WARNINGS Equipment – Electrical equipment must be installed FOR OPERATION OF BATTERY and maintained in accordance with the National CHARGING EQUIPMENT Electrical Code, NFPA 70, and local codes. A power disconnect switch must be located at the equipment.
  • Page 8 193111-035 SAFETY INSTRUCTIONS AND WARNINGS C. Burn and Bodily Injury Prevention DANGER: ELECTRICAL SHOCK The battery produces very high currents when short circuited, and will burn the skin severely if in contact CAN BE FATAL. If person is with any metal conductor that is carrying this current. unconscious and electric shock Do not permit rings on fingers to come in contact with is suspected, do not touch...

  • Page 9: Initial Set-Up & Description

    AC500 without Ammeter this manual. The AC500 Control uses a single chip microcontroller For proper operation, the AC500 Control must be set to to both monitor and control the battery charging proc- match the charger in which it is installed.

  • Page 10: Location Diagram

    193111-035 LOCATION DIAGRAM – AC500 CONTROL LOCATION DIAGRAM – AC500 CONTROL September 7, 2000 Revised...

  • Page 11: Operation

    Normal or Daily Charge Equalize or Weekend Charge WARNING: DO NOT connect The AC500 features Auto Equalize every fifth charge cycle. Closing S1-9 disables the auto equalize feature; a battery to this charger and an equalize charge request can be performed by if any LED is lit.

  • Page 12: Manual Stop

    “Refresh” feature has been is lit. Do not disconnect a battery incorporated into the AC500 Control. If a battery is left from this charger while a charge connected to the charger for 72 hours after a “Charge is in progress.

  • Page 13: Battery Disconnect Shutdown

    AC Power Failure If the battery is disconnected from the charger during a During an AC power failure, the AC500 Control stores charge cycle, the charger will be shut down. All LEDs key information about the charge cycle. The informa- will be off.

  • Page 14: Troubleshooting

    193111-035 TROUBLESHOOTING TROUBLESHOOTING If a problem is suspected with the AC500 Control, Also, an improperly connected or faulty control wire always check that the cell selection switch on the side harness could cause erratic operation. Inspect the of the control is set correctly (see Location Diagram on control wire harness connections for proper mating and page 4-1).
  • Page 15 193111-035 TROUBLESHOOTING SYMPTOM PROBABLE CAUSES PARAGRAPH PAGE All 4 LEDs Flash. 1) Someone has pressed the Manual Stop Key 6.01 Manual Stop 2) Bad Control PCB 6.02 All 4 LEDs Flash then 1) Bad Battery 6.03 Charge In Progress 2) Bad Control PCB 6.02 LED Flashes.
  • Page 16 193111-035 TROUBLESHOOTING 6.01 Repeated manual disconnecting of the battery from the charger before charge complete can cause long term battery damage and lead to inefficient truck/battery/charger operations. When it is necessary to stop the charge cycle before charge complete, always terminate the charge cycle by pressing the STOP key before disconnecting the battery from the charger.
  • Page 17 193111-035 TROUBLESHOOTING 6.13 If Charger repeatedly shuts down a few seconds after initial contactor closure, perform the following for each (1, 2, or 3) power transformer. Disconnect battery and monitor the voltage at terminals 1 to 6 of each transformer. Reconnect battery, after 5 seconds. Line Voltage should be present from terminals 1 to 6 of each transformer.
  • Page 18 193111-035 TROUBLESHOOTING This page intentionally left blank. April 28, 1999...
  • Page 19 193111-035 PARTS LIST PARTS LIST FOR AC500 CONTROL (WITHOUT AMMETER) ITEM NO. DESCRIPTION PART NUMBER CONTROL ASSEMBLY, AC500 194214-001 WIRE HARNESS 191303 PARTS LIST FOR AC500 CONTROL (WITH AMMETER) ITEM NO. DESCRIPTION PART NUMBER CONTROL ASSEMBLY, AC500 100A 194217-101 200A...

  • Page 20: Parts List

    193111-035 PARTS LIST This page intentionally left blank. April 28, 1999...

  • Page 21: Electronic Printed Circuit Board Exchange Service Policy

    193111-035 ELECTRONIC PRINTED CIRCUIT BOARD EXCHANGE SERVICE POLICY ELECTRONIC PRINTED CIRCUIT BOARD EXCHANGE SERVICE POLICY Because of the definite superiority of certain solid-state A standard exchange price has been established for control components over conventional electromechani- each printed circuit board without regard to the amount cal relays and regulators, the company product lines of repair required to the original turned in, which is now incorporate solid-state controls for applications in...
  • Page 23 193111-035 DIAGRAMS DIAGRAMS DESCRIPTION PART NUMBER AC500 WIRING DIAGRAM (WITHOUT AMMETER) 194214 SHEET 2 AC500 WIRING DIAGRAM (WITH AMMETER) 194217 SHEET 2 REMOTE CONTROL WIRING DIAGRAM 191143 April 28, 1999...
  • Page 29 AND LIABILITY RESULTING FROM USE OF THE GOODS. AMETEK/PRESTOLITE POWER NEITHER ASSUMES NOR AUTHORIZES ANY PERSONS TO ASSUME FOR AMETEK/PRESTOLITE POWER ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF THE GOODS SOLD, AND THERE ARE NO ORAL AGREEMENTS OR WARRANTIES COLLATERAL TO OR AFFECTING THIS WRITTEN WARRANTY.

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