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Fuse Replacement
The input and output of the PowerForce modules are protected by
'fast clearing' fuses. Three AC fuses on the input and a DC fuse
on the output.
CAUTION:
The use of any other type fuse besides the "fast-
clearing" type may cause damage to silicon diodes.
OPERATION
The operating procedure given here explains the operation of a
PowerForce Charger equipped with the PowerForce Control.
NOTE: If this charger is equipped with certain optional features,
the operating procedure may be modified.
Preliminary
1. Make sure that charger is installed and grounded as instructed in
this manual.
2. Turn on main fused disconnect switch that supplies AC power to
charger.
3. Maintain electrolyte level in batteries to be charged, as instructed
by battery manufacturer. The volume of electrolyte will expand
during the charge. Therefore, to avoid overfilling, do not add water
until the battery has received a full charge.
Normal or Daily Charge
(For batteries with ampere-hour capacity within the range shown
on charger nameplate)
1. Verify that battery size matches the charger and/or charger
setting. (Number of cells is equal to or less than the charger
nameplate rating and ampere-hour capacity is within charger
nameplate rating.)
2. Securely engage the battery and charger connectors. The charger
will go to the Dashboard view.
3. The charger will display "Detecting BID Device" as it looks for a
BID module.
4. After a short delay, the charger will turn on, the fans will run and
the charge indicator of LEDs will blink green. The touch screen
display will indicate the cell size and amp hour settings for the
charge cycle.
5. The charge indicator will blink green slowly and become faster
when the battery reaches 80%.
6. When the charge termination point is reached, the charger
will turn off and the blinking green light will become solid. If
an equalize charge has been selected, the lights will blink fast
green/white during the Equalize portion of the charge cycle.
NOTE: To disconnect battery from charger before charge is
complete, press the "Stop" button on the charger front panel.
NOTE: While not normally required, the charging rate may be
adjusted to compensate for unusual ambient temperature, age of
battery, etc.
NOTE: Start up delays can occur with multi voltage modes
enabled, power fail recovery, and start mode settings.
WARNING: EXPLOSION HAZARD - Do not connect or disconnect
a battery unless the charge indicator is a solid Green: otherwise,
damage to charger, arcing and burning of connector parts or a
battery explosion may result (batteries produce explosive gases).
Keep sparks, flame, and cigarettes away. Ventilate when charging
in an enclosed area. Always shield eyes when working near
batteries. Disconnect battery if charger is to be turned off for pro-
longed periods of time.
Equalize or Weekend Charge
Batteries need equalizing every 5 to 7 cycles to correct for in-
equalities between cells that result from daily or frequent cycling.
An equalizing charge should be given if any of the following con-
ditions exist:
1. The specific gravity of any cell at the end of charge is 20 points
less than the average.
2. The on-charge voltage of any cell at the end of charge is 30 mV
less than the average.
3. The battery has been stored for 30 days.
4. A large volume of water has been added.
When the equalize mode is desired, follow the operation outlined for
a normal charge but switch the Equalize toggle to the on position.
NOTE: The PowerForce Control is shipped from the factory set to
the Auto Equalize by Cycle mode, and will automatically provide an
equalize charge every 5 complete cycles. Auto Equalize prevents
manual equalizing.
Manual Stop
To stop any charge cycle before charge complete, press the
"Stop" key.
WARNING: Do not connect a battery to this charger if any error
is displayed. Do not disconnect a battery from this charger while
a charge is in progress. Otherwise, damage to charger, arcing
and burning of connector parts or a battery explosion may result.
Batteries produce explosive gases. Keep sparks, flame, and ciga-
rettes away. Ventilate when charging in an enclosed area. Always
shield eyes when working near batteries.
AC Power Fail
The PowerForce 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 dis-
play will show "delayed start due to power failure" and will restart
based on cycle run times. This will prevent multiple chargers from
restarting all at once, minimizing peak restart power.
NOTE: If a battery is disconnected from the charger during an AC
power failure and discharged, reconnecting it or any other battery
may result in an incomplete charge cycle.
WARNING: ELECTRICAL SHOCK HAZARD – Before checking elec-
trical components, turn off and remove fuses of disconnect switch
(supplying AC power to charger) and disconnect battery.
9
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Questions and answers
battery charger not shutting off when charged and boils water out. Mod # 750H3-12C S/N 217CS582884
The Ametek Deka PowerForce battery charger may not be shutting off when charged and is boiling water out due to one or more of the following reasons:
1. Equalize Mode Active – The charger may be in Equalize Mode, which applies a prolonged charge to balance the battery cells. This mode extends charging time and increases voltage, which can cause excessive gassing and water loss.
2. No Gas Inhibit Not Active – If the No Gas Inhibit function is not enabled, the charger may continue charging at a higher rate, leading to excessive electrolyte boiling.
3. Improper Battery Maintenance – If the battery has been stored for 30 days or a large volume of water was added recently, the charger may be compensating, leading to overcharging.
4. Faulty Charger Settings – The charger may not be set up correctly, and its Auto Equalize by Cycle function may be triggering frequent equalization cycles, causing overcharging.
5. Defective Charger or Battery – A failure in the charger’s voltage regulation or a faulty battery with imbalanced cells could cause continuous charging beyond the required level.
To resolve this, check the charger settings, verify if Equalize Mode is needed, and ensure the battery is properly maintained. If the issue persists, inspect the charger and battery for faults.
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