Ametek PRESTOLITE POWER EQUINOX Owner's Manual
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Ametek PRESTOLITE POWER EQUINOX Owner's Manual

Opportunity battery charger
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OWNER'S MANUAL 193111-075
Revised October 20, 2008
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
EQUINOX
Opportunity
Battery Charger
DO NOT DESTROY
AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

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  • Page 1 OWNER’S MANUAL 193111-075 Revised October 20, 2008 IMPORTANT: Read these instructions before installing, operating, or servicing this system. EQUINOX Opportunity Battery Charger DO NOT DESTROY AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.
  • Page 2 NOTE: Information regarding obtaining additional copies of this manual is located in the Introduction chapter of this manual. A battery charger is identified by model number. Incorporated into the model number is the maximum power rating, and maximum number of cells in battery for which charger is intended. The following example explains the basic model numbering arrangement.

  • Page 3: Table Of Contents

    193111-075 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 DESCRIPTION OF EQUIPMENT ....................3 Operating Modes ..........................3-1 Opportunity Charging .........................3-1 EQUINOX Control ..........................3-2 INSTALLATION ......................... 4 Location ..............................4-1 Environmental Characteristics......................4-1 Grounding ............................4-1...

  • Page 4: Introduction

    193111-075 INTRODUCTION INTRODUCTION How To Use This Manual Equipment Identification The unit's identification number (specification, model, serial number) usually appears on a nameplate IMPORTANT: It is especially attached to the front panel. important that all charger internal components be kept Receipt Of Equipment clean and dry, and all electrical connections...

  • Page 5: Safety Instructions And Warnings

    193111-075 SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION OF BATTERY 1. Installation and Grounding of Electrically Powered CHARGING EQUIPMENT Equipment – Electrical equipment must 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 IMPORTANT –...
  • Page 6 193111-075 SAFETY INSTRUCTIONS AND WARNINGS C. Burn and Bodily Injury Prevention The battery produces very high currents when short circuited, and will burn the skin severely if in contact with any metal conductor that is carrying this current. DANGER: ELECTRICAL SHOCK Do not permit rings on fingers to come in contact with battery terminals or the cell connectors on top of the CAN BE FATAL.

  • Page 7: Description Of Equipment

    193111-075 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT Upon connection of the battery, the EQUINOX reads the information programmed into the BID and identifies the battery’s AH rating, cell size, type of construction, electrolyte temperature, and programmed method of charge and start rate, and adjusts its output curve based on this information.

  • Page 8: Equinox Control

    193111-075 DESCRIPTION OF EQUIPMENT EQUINOX Control The extreme flexibility of the EQUINOX lies in the state of the art micro controller used in the EQUINOX charger control. WARNING: Do not connect a The EQUINOX control is made up of three main battery to this charger if any LED components: the Control and Regulator Boards, and the Keypad/Display.

  • Page 9: Installation

    193111-075 INSTALLATION INSTALLATION Location In addition to the usual function of protecting personnel against the hazard of electrical shock due to fault in the For best operating characteristics and longest unit life, equipment, grounding serves to discharge the static take care in selecting an installation site. Avoid electrical charges which tend to build up on the locations exposed to high humidity, dust, high ambient surfaces of equipment.

  • Page 10: Line Voltage Changeover Instructions

    193111-075 INSTALLATION COPPER CABLE SIZE AWG * * DISCONNECT BRANCH FUSE SIZE LINE AMPS SWITCH * (AMPERES) POWER GROUND 0-2.5 No. 14 No. 14 2.6-4.5 No. 14 No. 14 4.6-7.5 No. 14 No. 14 7.6-12 No. 14 No. 14 12.1-16 No.

  • Page 11: Charging Cable Connectors

    193111-075 INSTALLATION 5. With disconnect switch (on AC input power line) in Pre-Operation Changes To The Factory “OPEN” or “OFF” position, connect power cable Control Settings coming from charger, to the switch. Install fuses in Typically few changes are required to be made if the switch.

  • Page 12: Maintenance

    193111-075 MAINTENANCE MAINTENANCE Be sure to replace all charger cabinet panels after WARNING: ELECTRICAL SHOCK any servicing, to assure proper flow of cooling air HAZARD — Before inspecting or through unit and to protect internal components. cleaning inside cabinet, turn OFF and remove fuses of disconnect switch (supplying AC power to charger) and disconnect battery.

  • Page 13: Operation

    193111-075 OPERATION OPERATION The operating procedure given here explains the 5. The “80% Charged” LED will light when the battery operation of a Prestolite EQUINOX. has reached the gassing point. NOTE: If this charger is equipped with 6. When the charge termination point is reached, the certain optional features, the operating charger will turn off and the “Charge Complete”...

  • Page 14: Equalize Or Weekend Charge

    193111-075 OPERATION Equalize or Weekend Charge AC Power Fail Batteries may need periodic equalizing to correct for The EQUINOX Control will resume the charge where it inequalities between cells that result from daily or left off when the AC power failure occurred, virtually frequent cycling.
  • Page 15 193111-075 OPERATION 4. Low Current Shutdown If the charger output falls below a predetermined level, a low current shutdown will occur. All 4 LEDS will be flashing and the display will read “Low Current Fault”. 5. Curve Error Shutdown If the charger output becomes uncontrolled and falls above or below the proper level for predetermined period of time, the charger will shutdown.

  • Page 16: Equinox Control Features

    193111-075 EQUINOX CONTROL FEATURES EQUINOX CONTROL FEATURES 12. Review of Archived Charge Cycle Data for the Last 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)

  • Page 17: Description Of Features

    193111-075 EQUINOX CONTROL FEATURES 18. One Part Number Control is User/Factory Multi-Ampere-Hour Charging — The EQUINOX programmable for 6-9-12-18-24 Cells Charger provides the capability of charging and 100-200-400-600 Amp Digital Ammeter batteries of different cell sizes at the proper charge rates.
  • Page 18 193111-075 EQUINOX CONTROL FEATURES Manual adjustment of the charger output voltage to All status LEDs will be Illuminated during the review match the temperature of the battery is performed by of function number one, thus providing a lamp test programming the proper battery electrolyte feature.
  • Page 19 193111-075 EQUINOX CONTROL FEATURES One Part Number Control — The standard EQUINOX WARNING: Enabling the Finish Cell Control is user/factory programmable for 6, 9, 12, 18, Forming feature will cause the charger to and 24 cell EQUINOXS with 100, 200, 400, and 600 continue to run for a period of time if the amp shunts.
  • Page 20 193111-075 EQUINOX CONTROL FEATURES Time-of-Day Blockout — The EQUINOX Control can Programmable Cool Down Time — A be programmed to disable the charger during a specific programmable cool down feature allows the battery to time of day. The charger will turn off at the beginning of cool down for 0 to 8 hours before the charger the blockout period, and resume the charge cycle at the signals charge complete.

  • Page 21: Equinox Charge Archive Function

    193111-075 EQUINOX CONTROL FEATURES EQUINOX Charge Archive Function START VOLTS The value of the battery voltage (in volts/cell) of the The archive function allows up to 21 items of charge battery at the start of the charge cycle. cycle information to be retrieved and displayed. The last 99 charge cycles are stored, with the most recent cycle FINISH AMPS labeled #1 and earlier cycles labeled in ascending...

  • Page 22: Equinox Charge Cycle Review Function

    193111-075 EQUINOX CONTROL FEATURES BID START TEMP 01. AMP HOURS RET The temperature of the battery sensed by the Prestolite The total ampere-hours returned during the charge Battery Identification Module at the start of the charge cycle. This number includes ampere-hours delivered to cycle.
  • Page 23 193111-075 EQUINOX CONTROL FEATURES 10. EQUALIZE TIME 23. EQ. DAY The time of the equalize portion of the charge cycle. The day of the week that an equalize charge cycle is Equalize can be automatically or manually selected. performed when the auto equalize function is “ON” and the auto equalize type is set to “DAY”.
  • Page 24 193111-075 EQUINOX CONTROL FEATURES 32. SPECIAL OPTION 38. BATTERY TYPE Special option modes see below. The battery type the charger uses to select the proper output voltage and current characteristic, if the charger does detect a Prestolite BID. “P.T.S.“ = Push to start mode. = Standard flooded lead acid industrial type The charger will not start until the “ENTER”...
  • Page 25 193111-075 EQUINOX CONTROL FEATURES 46. PRESENT MONTH MAX BATT TEMP The current month (1 to 12) The maximum battery temperature for charging to start or continue. Once interrupted, the charge will 47. PRESENT DATE restart after the temperature drops 5 degrees F. (For The current day of the month (1 to 31).
  • Page 26 193111-075 EQUINOX CONTROL FEATURES 63. BATTERY CYCLES 65. MAX CELL SIZE The number of battery discharge cycles, based on the Programs the Max Cell Size available on 40 cell total discharge amp hours and 80% of the BID amp Chargers in the multi-cell mode. The charger cannot hour setting.

  • Page 28: Programming Your Equinox Control

    193111-075 PROGRAMMING YOUR EQUINOX CONTROL Programming Your EQUINOX Control The programming function allows 38 functions to be EQUALIZE COUNT programmed to customize your Prestolite EQUINOX to The number of complete charge cycles between equal- your battery charging application. Programming is not ize charges when the auto equalize function is pro available during an active charge cycle, and can only grammed “ON”...
  • Page 29 193111-075 PROGRAMMING YOUR EQUINOX CONTROL WARNING: Enabling the Finish Cell NOTE: Maximum setting is the charger nameplate Forming feature will cause the rating. charger to continue to run for a period of time if the battery has been FIXED AMP HRS disconnected before Charge The ampere-hour size the charger will operate at if the charger does not detect a Prestolite BID module...
  • Page 30 193111-075 PROGRAMMING YOUR EQUINOX CONTROL FINISH AMPS/100 COOL DOWN HOURS The custom output curve finish current setting The number of hours cool down from the end of charge (0.0 to 7.9 amps per 100 ampere-hours). until charge complete is indicated by the charger (0 to 8).
  • Page 31 193111-075 PROGRAMMING YOUR EQUINOX CONTROL 54. BID BATTERY TYPE Read the data “on demand” by pressing the “Stop” Programs the battery type into the BID. Once pro- key. * grammed, the charger will recognize the battery type Press and hold the “Equalize” button for 10 seconds to upon connection, and charge the battery with the proper reset all data.

  • Page 32: Using Extended Ah For Opportunity/Fast Charging

    193111-075 PROGRAMMING YOUR EQUINOX CONTROL 65. MAX CELL SIZE Programs the Max Cell Size available on 40 cell chargers in the multi-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.

  • Page 33: Multi Amp Hour Programming

    193111-075 PROGRAMMING YOUR EQUINOX CONTROL Multi AmpHour Programming Your Key Entry Display EQUINOX Control EQUINOX The Multi AH Feature of the EQUINOX Control allows Program Review Menu Tree 1 – 4 the user to customize his EQUINOX to fit his multi– Multi AH Mode OFF battery application.

  • Page 34: Timer Start Mode Programming

    193111-075 PROGRAMMING YOUR EQUINOX CONTROL On battery connection, the control will ask for the cycle Timer Start Mode Programming Your EQUINOX Control Key Entry Display EQUINOX The Timer Start Mode Feature of the EQUINOX Program Review Menu Tree 1 – 4 CONTROL allows the user the override the automatic start/stop features of the control and manually select Present Time 12:34...
  • Page 35 193111-075 PROGRAMMING YOUR EQUINOX CONTROL Expansion Board Connector Equinox Control PCB 100A SHUNT 400A 197123-001 (197123-002 for 40 Cell) CELLS Note 1: The cell size dip switch should always be set to the charger nameplate cell size rating. Note 2: 40 cell chargers are labeled as follows - 12, 18, 24, 36, 40, 400A and 100A.

  • Page 36: Options

    193111-075 OPTIONS OPTIONS The options listed in the following table of contents are those most commonly available. Special options not listed here will be covered by enclosed “addendum” sheets. OPTION DESCRIPTION PAGE Series Charging ................9-1 Remote Display Kit ................9-1 Floor Mounting Stand..............9-1 Archive Downloading Kit .............9-2 Arcless Disconnect (Opt.

  • Page 37: Archive Downloading Kit

    193111-075 OPTIONS Archive Downloading Kit Remote Stop Pushbutton Kit Prestolite Data Link Kit……………..………..193026 Remote Stop Pushbutton Kit……...…..196400-1 This kit is available to allow the user to download A Remote Stop Pushbutton Kit is available for EQUINOX archive data using the front door mounted applications where the charger control is not readily data port to a laptop PC via the PC’s Serial Port.
  • Page 38 193111-075 EQUINOX PARTS LIST Figure 10-1 10-1 Revised August 27, 2007...
  • Page 39 193111-075 EQUINOX PARTS LIST PARTS 500809-1 500854-1 Item Item Description COMMON TO ALL PAC320-24 PAC196-40 MODELS Panel, Top 197056 Module, Power Factor Correction, Assy. 196950-1 196950-1 Module, Inverter, Assy. 197000-1 197000-1 Support, Module, Input 197049 Bracket, Wall Mounting 197059 Insulator, Rectifier Module 197282 Panel, Rear 197052...

  • Page 40: Parts List

    193111-075 EQUINOX W/FAN PARTS LIST Parts List For Figure 10-1 (Continued) Parts 500809-1 500854-1 Item Common to Item Description Models PAC320-24 PAC196-40 Filter, Air 197082 Base, Mounting 197038 Panel, Access, Filter 197079 Label, Fuse, Fan 197522 Label, Transformer Setting 197523 Items Not Shown Cable, Transformer to Shunt 197147-1...
  • Page 41 193111-075 DIAGRAMS DIAGRAMS INPUT DIMENSIONAL VOLTAGE DIAGRAMS OUTLINE 480/575 197099 197100 April 26, 2007...

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