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AMETEK/PRESTOLITE POWER ULTRA CHARGE Owner's Manual

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OWNER'S MANUAL 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.

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Summary of Contents for AMETEK/PRESTOLITE POWER ULTRA CHARGE

  • Page 1: Battery Charger

    OWNER’S MANUAL 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 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 maximum number of cells in battery for which charger is intended.

  • Page 3: Table Of Contents

    193111-068 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 ....................Operating Modes ........................ 3-1 User Selectable Output Curves ..................3-1 UC2000 Control ........................
  • Page 4 193111-068 TABLE OF CONTENTS TROUBLESHOOTING ........................Troubleshooting Table..................... 10-1 Action ..........................10-10 PARTS LIST ....................... 11 ELECTRONIC PRINTED CIRCUIT BOARD EXCHANGE SERVICE POLICY DIAGRAMS WARRANTY March 31, 2005...

  • Page 5: Introduction

    193111-068 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 When you receive the equipment, check it against the...

  • Page 6: Safety Instructions And Warnings

    193111-068 SAFETY INSTRUCTIONS AND WARNINGS SAFETY INSTRUCTIONS AND WARNINGS FOR OPERATION OF BATTERY 1. Installation and Grounding of Electrically Powered Equipment – Electrical equipment must be installed CHARGING EQUIPMENT and maintained in accordance with the National Electrical Code, NFPA 70, and local codes. A power disconnect switch must be located at the equipment.
  • Page 7 193111-068 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 DANGER: ELECTRICAL SHOCK with any metal conductor that is carrying this current. Do not permit rings on fingers to come in contact with CAN BE FATAL.

  • Page 8: Description Of Equipment

    Operating Modes The Ultra Charge can be set to default to any one of three operating modes. The Multi-Cell mode allows the charger to automatically adjust its output to match the cell size of the battery.

  • Page 9: Uc2000 Control

    The extreme flexibility of the Ultra Charge lies in the mately 8 hours. Batteries of smaller or larger ampere- state of the art micro controller used in the UC2000 hour capacities can also be charged, but will require charger control.

  • Page 10: Installation

    193111-068 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 11: Line Voltage Changeover Instructions

    193111-068 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 12: Charging Cable Connectors

    193111-068 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 13: Maintenance

    193111-068 MAINTENANCE MAINTENANCE Lubrication WARNING: ELECTRICAL SHOCK HAZARD — Before inspecting or None required. cleaning inside cabinet, turn OFF and remove fuses of disconnect switch (supplying AC power to Fuse Replacement charger) and disconnect battery. The SCRs and silicon diodes in this charger are protected by a “fast-clearing”...

  • Page 14: Operation

    OPERATION The operating procedure given here explains the 6. When the charge termination point is reached, the operation of a Prestolite Ultra Charge equipped with the charger will turn off and the “Charge Complete” LED Prestolite UC2000 Control. will be lit. If an equalize charge has been selected, the “Equalize”...

  • Page 15: Equalize Or Weekend Charge

    193111-068 OPERATION Equalize or Weekend Charge AC Power Fail Batteries may need periodic equalizing to correct for The UC2000 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 16 193111-068 OPERATION 4. Low Current Shutdown 9. High Amp Hour Returned Shutdown If the charger output falls below a predetermined If the cycle amp hours returned exceed the BID AH level, a low current shutdown will occur. All 4 setting or charger maximum AH rating for a prede- LEDS will be flashing and the display will read “Low termined amount, the charger will shutdown.
  • Page 17 193111-068 OPERATION ULTRA CHARGE RECHARGING CAPABILITY Figure 6-1 March 31, 2005...

  • Page 18: Uc2000 Control Features

    193111-068 UC2000 CONTROL FEATURES UC2000 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 19: Description Of Features

    A 24 cell Ultra Charge will safely charge 24, UC2000 Control is capable of modifying the output volt- 18, 12, 9, and 6 cell batteries. An 18 cell Ultra Charge age to compensate for ranges of battery electrolyte will safely charge 18, 12, 9, and 6 cell batteries. A 12 temperatures from 32 to 132 degrees F.
  • Page 20 193111-068 UC2000 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 21 193111-068 UC2000 CONTROL FEATURES One Part Number Control — The standard UC2000 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 Ultra Charges with 100, 200, and 400 amp continue to run for a period of time if the shunts.

  • Page 22: Uc2000 Charge Archive Function

    193111-068 UC2000 CONTROL FEATURES Time-of-Day Blockout — The UC2000 Control can be Programmable Cool Down Time — A 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 23 193111-068 UC2000 CONTROL FEATURES The charge cycle data will automatically scroll through TERM The reason for charge cycle the display along with the charge cycle number. The 19 termination. All possible codes archive data items are described in detail below (see are listed below: Figure 7-2).

  • Page 24: Uc2000 Charge Cycle Review Function

    193111-068 UC2000 CONTROL FEATURES BID START TEMP The temperature of the 01. AMP HOURS RET The total ampere-hours battery sensed by the returned during the charge Prestolite Battery Identification cycle. This number includes Module at the start of the ampere-hours delivered to charge cycle.
  • Page 25 193111-068 UC2000 CONTROL FEATURES 09. TERM The reason for charge cycle 17. BID START TEMP The temperature of the battery termination. All possible codes sensed by the Prestolite are listed below: Battery Identification Module at the start of the charge cycle 1-Charge Comp Normal Charge Complete (degrees F).
  • Page 26 193111-068 UC2000 CONTROL FEATURES 27. BLOCK START The beginning time of the 32. SPECIAL OPTION Special option modes see time of day blockout below. function (AM/PM). See START MODE “P.T.S.“ = Push to start mode. 28. BLOCK END The ending time of the time The charger will not start of day blockout function.
  • Page 27 193111-068 UC2000 CONTROL FEATURES 38. BATTERY TYPE The battery type the charger 45. DVDT DISABLE Disables the automatic uses to select the proper DV/DT charge termination output voltage and current feature and enables Voltage characteristic, if the charger Time charge termination. does detect a Prestolite BID.
  • Page 28 193111-068 UC2000 CONTROL FEATURES 54. BID BATTERY If a connected battery is 57. CYCLE KWH The number of kilowatt hours TYPE equipped with a Battery I.D. used during the last charge module, the battery type cycle. may be programmed into the BID.
  • Page 29 193111-068 UC2000 CONTROL FEATURES Figure 7-2 7-12 Revised October 31, 2005...

  • Page 30: Programming Your Uc2000 Control

    The programming function allows 38 functions to be The type of auto equalize EQUALIZE TYPE programmed to customize your Prestolite Ultra Charge selected. The types that can to your battery charging application. Programming is not be selected are listed below.
  • Page 31 193111-068 PROGRAMMING YOUR UC2000 CONTROL Sets the ending time of the Sets special option modes, BLOCK END SPECIAL OPTION time of day blockout function see below: (0000 to 2359 military time). OFF factory setting See START MODE. “P.T.S.” Push to start mode Sets the start override func- START OVERIDE tion that allows the operator...
  • Page 32 193111-068 PROGRAMMING YOUR UC2000 CONTROL . The ampere-hour size the NOTE: Functions 39 through 42 apply only to the FIXED AMP HRS charger will operate at if the custom curve and cannot be changed unless the charger does not detect a custom curve has been selected in Function 38.
  • Page 33 Types) 5 = Sealed Lead Acid Curve 6 = Sealed Lead Acid Curve 7 = Sealed Lead Acid Curve 8 = ULTRA CHARGE Curve 55. PASSWORD OFF = Factory Setting On = Password Enabled Use the up or down arrow to select the proper setting.
  • Page 34 193111-068 PROGRAMMING YOUR UC2000 CONTROL 56. MAX BATT TEMP The maximum battery 58. MAX CELL SIZE Programs the Max Cell Size temperature for charging to available on 40 cell chargers proceed. (For use with BID in the multi-cell mode. The only) (080 to 150 degrees F) charger cannot automatically recognize the difference...
  • Page 35 Program Review Menu Tree 1 – 4 The Multi AH Feature of the UC2000 Control allows the user to customize his Ultra Charge to fit his multi– Multi AH Mode OFF battery application. Using this feature, the flexibility of Enter...
  • Page 36 Timer Start Mode. Listed to the right is an example of Enter Battery Type FLD programming an Ultra Charge to constant current Battery Type CTM. charge a battery for 20 hours at a 5 amp/100AH rate. Enter Battery Type CTM.
  • Page 37 193111-068 PROGRAMMING YOUR UC2000 CONTROL Figure 8-1 Revised August 30, 2005...

  • Page 38: Options

    193111-068 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 Parallel Charging ................9-1 Series Charging................9-1 Fused Disconnect Switch and 24-V Control Circuit ....9-2 Parallel Charging This option provides cables allowing two batteries to be charged at the same time (batteries connected in...

  • Page 39: Fused Disconnect Switch

    396143-78 No. 4/0 size for 1051-1270 AH 396143-76 396143-88 CDAC Expansion Kit Ultra Charge CDAC Expansion Kit……..192355-1 This option is required for communications with the Host Computer of a Prestolite CDAC (Charger Data Acquisition and Control) System. Remote Display Kit Ultra Charge Remote Display Kit……….192356-1...

  • Page 40: Wall Mounting Bracket

    Prestolite Data Link Kit……………..………..193026 This kit is available 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.

  • Page 41: Troubleshooting

    193111-068 TROUBLESHOOTING TROUBLESHOOTING Troubleshooting Table ACTION SYMPTOM PROBABLE CAUSES STEPS (1) No AC Voltage To Charger No Display And (2) Input Fuse(s) Blown No LED’s (3) Control Trans. Breaker Tripped (4) Control Trans. Bad (5) Wrong Control Trans. Connection (6) Bad Harness/Connection – Loose or Incorrect (7) Bad Control Board (1) Keypad Not Connected No Keypad...

  • Page 42: Action

    193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS (1) Inadequate Ventilation Unit Smells Hot (2) Ambient Too Hot (3) Lack of Maintenance (4) Bad Transformer (5) Bad Control Transformer (6) Bad Internal Power Connection (7) Bad Control Board (8) Bad Inductor (9) Wrong Amp/Hour Jumper (10) Bad Expansion Board Battery has...
  • Page 43 193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS (1) Faulty Lift Interrupt Low Number Of (2) Battery Not Fully Discharged A.H.’s Returned To Battery (3) Manual Disconnect (4) Rates Set Incorrectly (5) Fixed Temperature Set Incorrectly (6) Charge Curve Incorrect (7) Battery Not Providing Nameplate Rating (8) Bad Control Board (9) Bad BID Battery...
  • Page 44 193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS (1) Control Set For Forming Cycles Doesn’t Shutdown When Battery (2) Bad Control Board Is Disconnected (3) Bad/Incorrect Shunt Noisy Unit (1) Loose Sheet Metal (2) Bad Contactor (3) Loose Transformer Mounting (4) Loose Inductor Mounting (5) Noisy Inductor (6) Noisy Transformer (7) Placed On Rack That Makes Noise...
  • Page 45 193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS (1) Incorrect Wiring To Primary Of Transformer Display reads Unbalance Line (2) Incorrect Cabling To Transformer Secondary Fault (3) Bad Harness/Connections – Loose Or Incorrect (4) Bad SCR (5) Bad Diode (6) Bad Control Board (7) Gate Lead Connections (8) AC Supply (9) Bad Transformer...
  • Page 46 193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS Display Reads (1) Bad Harness/Connections – Loose Or Incorrect (Curve Error Fault) (2) Bad SCR (3) Bad Diode (4) Bad Control Board (5) Incorrect Wiring To Primary Of Transformer (6) Bad Shunt Display Reads (1) Fixed Temperature Set Incorrectly (Backup Timer (2) Bad A.H.
  • Page 47 193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS Display Reads (1) Fixed Cell Setting Incorrect (2) Bad Harness/Connections – Loose Or Incorrect (Low Battery Fault) (3) Bad Battery (4) Bad Control Board (5) Bad Output Cables/Connector (6) BID not Programmed Properly Display Reads (1) Fixed Cell Setting Incorrect (Hi Battery Fault)
  • Page 48 193111-068 TROUBLESHOOTING ACTION SYMPTOM PROBABLE CAUSES STEPS Display Reads (1) Noise (Supply) (Control Error COP) (2) Bad Control Board (3) Bad Suppressor Core Display Reads (1) Noise (Supply) (Control Error Clock Monitor) (2) Bad Control Board Display Reads (1) Noise (Supply) (Control Error Illegal Opcode) (2) Bad Control Board (3) Bad Suppressor Core...
  • Page 49 The only exception will be the Equalize and Stop keys. To test them, connect a battery and allow the charger to start, then press the button. The ULTRA CHARGE was shipped set for automatic equalize which means unless this was changed, the Equalize button will not respond. To find out if the Status LED’s on the keypad are okay, press key number “0”...
  • Page 50 193111-068 TROUBLESHOOTING Temporarily shut down any equipment on the same voltage supply line and see if the charger starts to respond normally. If the charger does, then check all grounds going to the equipment that is shut down. If the problems still exist, then return power to all the other equipment and call your local PRESTOLITE POWER Representative.
  • Page 51 Temperature Setting. If not, enter the correct setting. If battery electrolyte temperatures are well below 32° F, the ULTRA CHARGE will not be able to adequately charge the battery. Battery insulation or heaters would be required to keep the battery electrolyte temperatures close to 32°F.
  • Page 52 193111-068 TROUBLESHOOTING If the application requires a larger AH battery than is presently in use, the only long term solution is to replace the battery with one of the proper AH rating. If the control is set to perform forming cycles , DV/DT termination is disabled, and the low current shutdown is disabled. To return to normal operation, program the control to “00”...
  • Page 53 193111-068 TROUBLESHOOTING 53. Check the SCR as described below. If it tests faulty, replace with an SCR of the proper type. Connect a VOM set on the 1k Ohms scale; positive to SCR anode (stud), negative to SCR cathode (heavy red lead).

  • Page 54: Parts List

    193111-068 PARTS LIST Figure 11-1 THREE PHASE 11-1 March 31, 2005...
  • Page 55 Cover, Neoprene 378234-13 Cable, Output 396263-80 396263-81 396263-81 396263-81 396263-81 Label, Prestolite Power 196038 Overlay, Door, Ultra Charge 196219 Label, UL & CUL 404079 Label, Disc. Sw. (-2 & -5 Spec only) 407250 Latch, Door 194530 August 30, 2005 Revised 11-2...
  • Page 56 Cover, Neoprene 378234-13 Cable, Output 396263-82 396263-82 396263-80 396263-81 Label, Prestolite Power 196038 Overlay, Door, Ultra Charge 196219 Label, UL & CUL 404079 Label, Disc. Sw. (-2 & -5 Spec only) 407250 Latch, Door 194530 11-3 Revised August 30, 2005...
  • Page 57 Cover, Neoprene 378234-13 Cable, Output 396263-81 396263-82 396263-80 396263-81 Label, Prestolite Power 196038 Overlay, Door, Ultra Charge 196219 Label, UL & CUL 404079 Label, Disc. Sw. (-2, -5 & -7 Spec only) 407250 Latch, Door 194530 August 30, 2005 Revised...
  • Page 58 193111-068 PARTS LIST Fuses for Three-Phase Ultra Charge Units 500363D-1 500134D-1 500135D-1 500136D-1 500137D-1 Item Description 500363D-2 500134D-2 500135D-2 500136D-2 500137D-2 500363D-3 500134D-3 500135D-3 500136D-3 500137D-3 500134D-5 500136D-4 500137D-4 500136D-5 500137D-5 500363D-6 Item 500137D-6 500T3-12 750T3-12 1050T3-12 750T3-18 1050T3-18 Fuse, AC Input (208 V.) (-1, -2 & -6 Spec only)
  • Page 59 193111-068 PARTS LIST Figure 11-2 Single Phase 11-7 March 31, 2005...
  • Page 60 Cable, Output 396263-1 396263-2 396263-4 396263-2 396263-2 Door, Hinged 196189 Label, Prestolite Power 196036 Overlay, Door, Ultra Charge 196191 Label, UL & CUL 404079 Label, Disc. Sw. (-2 & -5 Spec only) 407250 Latch, Door 194530 March 31, 2005 11-8...

  • Page 61: Electronic Printed Circuit Board Exchange Service Policy

    193111-068 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 each printed circuit board without regard to the amount electromechanical relays and regulators, the company of repair required to the original turned in, which is product lines now incorporate solid-state controls for...
  • Page 62 193111-068 DIAGRAMS DIAGRAMS INPUT DIAGRAMS DIMENSIONAL VOLTAGE OUTLINE 1 PHASE 3 PHASE 208/240/480 196695 196675 196377 240/480/575 196695 196675 196377 480/575 196675 196377 220/380/415 196695 196377 196677 196377 March 31, 2005...
  • Page 70 AMETEK/PRESTOLITE POWER “SCR” INDUSTRIAL BATTERY CHARGERS Ametek/Prestolite Power (hereinafter called “Prestolite”) warrants that each new and unused Industrial 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 operated...

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