Ametek POWER PRO FERRO 100 Series Owner's Manual
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Ametek POWER PRO FERRO 100 Series Owner's Manual

Ametek POWER PRO FERRO 100 Series Owner's Manual

Silicon diode ferroresonant transformer type battery charger
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OWNER'S MANUAL 193111-049
Revised December 10, 2008
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
POWER PRO
FERRO 100 SERIES CHARGERS
Silicon Diode Ferroresonant
Transformer Type
Battery Charger
DO NOT DESTROY

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Summary of Contents for Ametek POWER PRO FERRO 100 Series

  • Page 1 OWNER’S MANUAL 193111-049 Revised December 10, 2008 IMPORTANT: Read these instructions before installing, operating, or servicing this system. POWER PRO FERRO 100 SERIES CHARGERS Silicon Diode Ferroresonant Transformer Type Battery Charger DO NOT DESTROY...
  • Page 3 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 8-hour ampere-hour capacity, case size, input power phase, and number of cells in battery for which charger is intended.

  • Page 5: Table Of Contents

    193111-049 TABLE OF CONTENTS INTRODUCTION ............................1 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 ......................3 INSTALLATION ............................4 Location .............................. 4-1 Environmental Characteristics ......................
  • Page 6 193111-049 TABLE OF CONTENTS This page intentionally left blank. Page 2 August 9, 2002...

  • Page 7: Introduction

    Additional copies of this manual may be purchased by WARNING gives information contacting Ametek/Prestolite Power Troy OH 45373, regarding possible personal include the Owner's Manual number and equipment injury. Warnings will be identification numbers.
  • Page 8 193111-049 INTRODUCTION This page intentionally left blank. August 9, 2002...

  • Page 9: Safety Instructions And Warnings

    193111-049 SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION OF BATTERY the National Electrical Code, NFPA 70, and local codes. A power disconnect switch must be CHARGING EQUIPMENT 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.
  • Page 10 193111-049 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 11: Initial Set-Up & Description

    193111-049 INITIAL SET-UP & DESCRIPTION INITIAL SET-UP & DESCRIPTION Charger output. Place the corresponding DIP switch (S1) on the Control in the “Closed” position. The basic charging circuit is the silicon diode, S1-1 12 Volts rectifier-type with ferroresonant transformer (s). This ferroresonant transformer design regulates S1-2 24 Volts charging current by allowing the battery to...
  • Page 12 193111-049 INITIAL SET-UP & DESCRIPTION Charger Control All front panel information (including operation instructions) is back printed on a polycarbonate overlay which is resistant to damage from oils, gas- The Control has an on board microcontroller to oline, and frequent operator handling. The Control monitor and control the charging process.

  • Page 13: Installation

    193111-049 INSTALLATION INSTALLATION Location electrical charges which tend to build up on the surfaces of equipment. These static charges can For best operating characteristics and longest unit life, cause painful shock to personnel, and can lead to the take care in selecting an installation site. Avoid erroneous conclusion that an electrical fault exists in locations exposed to high humidity, dust, high ambient the equipment.

  • Page 14: Line Voltage Changeover Instructions

    193111-049 INSTALLATION DISCONNECT BRANCH FUSE SIZE COPPER CABLE SIZE AWG * * 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 15: Charging Cable Connectors

    193111-049 INSTALLATION 4. Route AC power input cable in through knock-out Pre-operation Checks provided in side panel of charger cabinet. Securely fasten cable wires to a power input terminal inside 1. Inspect charger thoroughly for damage; loose charger. Refer to Grounding section of this manual screws, nuts, or electrical connections.
  • Page 16 193111-049 INSTALLATION This page intentionally left blank. August 9, 2002...

  • Page 17: Operation

    193111-049 OPERATION OPERATION A. Preliminary B. Normal or Daily Charge Make sure the charger is installed and grounded as WARNING: DO NOT connect a battery to instructed in the INSTALLATION chapter of this this charger if the “Charge in Progress” manual.

  • Page 18: Equalize Or Weekend Charge

    193111-049 OPERATION C. Equalize Or Weekend Charge charge cycle, press the STOP key. All four LEDs will flash. The Control features Auto Equalize on every 5th 2. To restart the charger, disconnect and charge cycle. Closing S1-6 can disable the feature. reconnect the battery.

  • Page 19: Maintenance

    193111-049 MAINTENANCE MAINTENANCE WARNING: ELECTRICAL SHOCK Fuse Replacement HAZARD — Before inspecting or cleaning inside cabinet, turn OFF The silicon diodes in this charger are protected by a and remove fuses of disconnect “fast-clearing” type fuse. switch (supplying AC power to charger), disconnect battery, and CAUTION: The use of any other type check for voltage on capacitors.
  • Page 20 193111-049 MAINTENANCE terminals. 3. If capacitor is good, pointer will deflect, indicating capacitor is being charged, followed by a deflection in the opposite direction indicating partial discharge. If there is no deflection, capacitor is “open” and must be replaced. Also, if meter needle moves and stops at one value, replace capacitor.

  • Page 21: Troubleshooting

    193111-049 MAINTENANCE Troubleshooting DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and remove fuses of disconnect switch (supplying AC power to charger), disconnect battery, and check for voltage on capacitors. Discharge through insulated screwdriver if there is any reading. CAUTION: HIGH VOLTAGE FROM TEST EQUIPMENT can damage silicon diodes and other parts.
  • Page 22 193111-049 MAINTENANCE Replace capacitor if can is ruptured or fails test. Refer to Capacitor Testing in Maintenance chapter. Check line voltage for connection to proper input voltage. Refer to Line Voltage Changeover instructions in Installation chapter. Check battery for one or more defective cells. Less than rated output on fully discharged battery (approximately 1/2 rated output) (3-phase chargers only) Check for either a shorted transformer, or wiring short circuit.
  • Page 23 193111-049 MAINTENANCE DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for voltage on capacitors. Discharge through insulated screwdriver if there is any reading. August 9, 2002...
  • Page 24 193111-049 MAINTENANCE DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for voltage on capacitors. Discharge through insulated screwdriver if there is any reading. August 9, 2002...
  • Page 25 193111-049 MAINTENANCE DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for voltage on capacitors. Discharge through insulated screwdriver if there is any reading. August 9, 2002...
  • Page 26 193111-049 PARTS LIST (3 PHASE) Figure 7-1 (3 PHASE) August 9, 2002...
  • Page 27 193111-049 PARTS LIST (3 PHASE) ITEM NO. PART NO. DESCRIPTION 195534 Base, Charger 195535 Panel, Rear 195537 Panel, Side, Left 195536 Panel, Side, Right 195540-002 Meter, DC Amps 195538 Panel, Top 195539 Panel, Front 195251 Overlay, Charger 195531 Label, DC Output 194002 Heat Sink, Flat 194122...
  • Page 28 193111-049 PARTS LIST (3 PHASE) ITEM NO. PART NO. DESCRIPTION Call Factory Block, Terminal 406434 Label, Warning, Sparks 405548 Label, Supply Connections See Table Label, AC Input 404099 Label, Danger 195532 Label, Caution, Input Service 406518 Label, Warning 402037-027 Grommet, Rubber 406593 Label, Input Service August 9, 2002...
  • Page 29 193111-049 PARTS LIST (3 PHASE) August 9, 2002...
  • Page 30 193111-049 PARTS LIST (3 PHASE) August 9, 2002...
  • Page 31 193111-049 DIAGRAMS (3 PHASE) DIAGRAMS - 3 PHASE DIAGRAM DIAGRAM MODEL NO. OUTPUT SCHEMATIC OUTPUT SCHEMATIC DIMENSIONAL INFORMATION 208/240/480 VOLTS 480/575V OUTLINE 3 PHASE 195432 195541 195542 (2 TRANSFORMERS) See model number description inside front cover. August 9, 2002...
  • Page 35 193111-049 DIAGRAMS (3 PHASE) This page intentionally left blank. August 9, 2002...
  • Page 36 193111-049 PARTS LIST (1 PHASE) Figure 8-1 SINGLE PHASE December 10, 2008...
  • Page 37 193111-049 PARTS LIST (1 PHASE) ITEM NO. PART NO. DESCRIPTION 191578 Panel, Rear 191580 Panel, Side, Right 191580 Panel, Side, Left 191581 192983 Panel, Front See Table Meter DC Amps 191574 Base 195251 Overlay, Charger 195532 Label, Caution AC Input 195529-001 Board, PC, Ay 357205-060...
  • Page 38 193111-049 PARTS LIST (1 PHASE) ITEM NO. PART NO. DESCRIPTION 404099 Label, Danger 406518 Label, Warning 195531 Label, DC Fuse 406593 Label, AC Input 405548 Label, Frame Ground 406748 Label, AC Line Connections, 120V 195856 Harness, Wire (Not Shown) December 10, 2008...
  • Page 39 193111-049 PARTS LIST (1 PHASE) December 10, 2008...
  • Page 40 193111-049 PARTS LIST (1 PHASE) December 10, 2008...
  • Page 41 193111-049 DIAGRAMS (1 PHASE) DIAGRAMS - 1 PHASE DIAGRAM DIAGRAM MODEL NO. OUTPUT SCHEMATIC OUTPUT SCHEMATIC DIMENSIONAL INFORMATION 208/240/480 VOLTS 480/575V OUTLINE 1 PHASE 195433 197871 195859 (1 TRANSFORMER) See model number description inside front cover. December 10, 2008...
  • Page 45 AMETEK/PRESTOLITE POWER “POWER PRO” BATTERY CHARGERS AMETEK/Prestolite Power (hereinafter called “Prestolite”) warrants that each new and unused Power Pro Battery Charger manufactured and supplied by it is of good workmanship and is free from any inherent mechanical defects, provided that (1) the product is installed and...

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