AMETEK/PRESTOLITE POWER 193111-038 User manual

OWNER’S MANUAL 193111-038
Revised January 30, 2009
IMPORTANT: Read this manual before installing,
operating, or servicing this product.
DO NOT DESTROY
IMPORTANT: SAVE THIS SAFETY AND INSTRUCTION MANUAL.
IMMEDIATELY REPLACE WHEN WORN OR LOST.
AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.
BATTERY CHARGER
LTD Products
Troy, Ohio
45373

GENERAL SAFETY PRACTICES FOR ANY ELECTRICAL EQUIPMENT
1. READ THE SPECIFIC SAFETY INSTRUCTIONS AND WARNINGS CHAPTER OF THIS MANUAL
BEFORE INSTALLING AND USING THE EQUIPMENT.
2. READ AND RETAIN THE OWNER’S MANUAL – All the safety and operating instructions should be read
and understood before using the equipment.
3. FOLLOW INSTRUCTIONS – All installation, operating and maintenance instruction should be followed.
4. WATER AND MOISTURE – The equipment should not be used near water – for example, near a
washbowl, steam cleaning equipment or in any wet or damp area.
5. VENTILATION – The equipment should be situated such that its location or position does not interfere with
its required ventilation.
6. HEAT – The equipment should be situated away from heat sources such as radiators, heat registers, or any
other equipment that produces heat.
7. POWER SOURCE – The equipment should be connected to a source of power only as described in the
Owner’s Manual.
8. GROUNDING – Precautions should be taken to insure the equipment grounding means is not defeated.
9. POWER CORD AND CHARGING CABLES PROTECTION – Power supply and charging cables should be
routed to prevent them from being walked on, pinched by other equipment, or driven over.
10. CLEANING – Cleaning should only be performed as instructed in the Owner’s Manual.
11. NON-USE PERIODS – The power cord should be unplugged from the outlet and the battery should be
disconnected from the charger if the equipment is to be left unused for a long period of time.
12. OBJECT AND LIQUID ENTRY – Care should be taken so objects do not fall or liquids are not spilled into
cabinet openings.
13. DAMAGE REQUIRING SERVICE – The equipment should be serviced by qualified service personnel
when:
A. Power cord or plug, charging cables or connector have been damaged.
B. Objects have fallen into, or liquid has been spilled into the equipment.
C. The equipment has been dropped, or the cabinet damaged.
D. The equipment does not appear to operate normally or exhibits a marked change in performance.
14. REPLACEMENT PARTS – When replacement parts are needed, be sure only replacement parts specified
by the manufacturer are used. Unauthorized substitutions may result in fire, electric shock, or other
hazards.

GENERAL SAFETY PRACTICE
FOR ANY ELECTRICAL EQUIPMENT Inside Front Cover
SAFETY INSTRUCTIONS AND WARNINGS...............................................................1
A. GENERAL .....................................................................................................................1-1
B. SHOCK PREVENTION ................................................................................................. 1-1
C. BURN AND BODILY INJURY PREVENTION............................................................... 1-2
D. FIRE AND EXPLOSION PREVENTION ....................................................................... 1-2
E. ARCING AND BURNING OF CONNECTOR ............................................................... 1-2
F. MEDICAL AND FIRST AID TREATMENT..................................................................... 1-2
G. EQUIPMENT WARNING LABELS................................................................................ 1-2
INTRODUCTION...................................................................................................................................2
A. HOW TO USE THIS MANUAL ...................................................................................... 2-1
B. EQUIPMENT IDENTIFICATION ................................................................................... 2-1
C. RECEIPT OF EQUIPMENT .......................................................................................... 2-1
INITIAL SET-UP & DESCRIPTION ................................................................................................3
A. DIP SWITCH SELECTION............................................................................................ 3-1
B. DESCRIPTION ............................................................................................................. 3-1
LOCATION DIAGRAM .......................................................................................................................4
INSTALLATION ....................................................................................................................................5
A. LOCATION ....................................................................................................................5-1
B. SAFETY ........................................................................................................................ 5-1
C. GROUNDING................................................................................................................ 5-1
D. ELECTRICAL INPUT REQUIREMENTS ...................................................................... 5-1
E. AC INPUT VOLTAGE CHANGEOVER ........................................................................ 5-1
F. CHARGING CABLE CONNECTORS............................................................................ 5-2
G. CONNECTION TO AC POWER ................................................................................... 5-2
OPERATION ..........................................................................................................................................6
A. PRELIMINARY .............................................................................................................. 6-1
B. NORMAL OR DAILY CHARGE..................................................................................... 6-1
C. EQUALIZE OR WEEKEND CHARGE ......................................................................... 6-2
D. MANUAL STOP ............................................................................................................ 6-2
E. REFRESH CHARGE..................................................................................................... 6-2
F. BACK-UP TIMER SHUTDOWN .................................................................................... 6-2
G. BATTERY DISCONNECT SHUTDOWN ..................................................................... 6-2
H. AC POWER FAIL.......................................................................................................... 6-2
I. 6-HOUR TERMINATION OPTION ............................................................................... 6-3
J. ON-BOARD UTILITY OPTION ...................................................................................... 6-3
MAINTENANCE....................................................................................................................................7
SERVICE.................................................................................................................................................8
TROUBLESHOOTING........................................................................................................................9
April 3, 2000
193111-038
TABLE OF CONTENTS

193111-038
TABLE OF CONTENTS
April 3, 2000
BATTERY CHARGING QUESTIONS AND ANSWERS....................................................... 10
PARTS LIST........................................................................................................................................ 11
DIAGRAMS
WARRANTY

FOR OPERATION OF BATTERY
CHARGING EQUIPMENT
IMPORTANT – READ AND
UNDERSTAND THESE
INSTRUCTIONS. DO NOT
LOSE THEM. ALSO READ
OPERATING/INSTRUCTION
MANUAL BEFORE
INSTALLING, OPERATING,
OR SERVICING THIS
EQUIPMENT.
A. General
Battery charging products can cause serious
injury or death, or damage to other equipment or
property, if the operator does not strictly observe
all safety rules and take precautionary actions.
Safe practices have developed from past experience
in the use of charging equipment. These practices
must be learned through study and training before
using this equipment. Anyone not having
extensive training in battery charging practices
should be taught by experienced operators.
Only qualified personnel should install, use, or
service this equipment.
B. Shock Prevention
Bare conductors, or terminals in the output circuit,
or ungrounded, electrically-live equipment can
fatally shock a person. To protect against shock,
have competent electrician verify that the
equipment is adequately grounded and learn what
terminals and parts are electrically HOT.
The body’s electrical resistance is decreased when
wet, permitting dangerous current to flow through the
body. Do not work in damp area without being
extremely careful. Stand on dry rubber mat or dry
wood and use insulating gloves when dampness or
sweat cannot be avoided. Keep clothing dry.
1. Installation and Grounding of Electrically Powered
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
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. DO NOT CONNECT
the equipment grounding conductor (lead) to the
third live wire of the 3-phase line as this makes the
equipment frame electrically HOT, which can cause
a fatal shock.
If a grounding lead (conductor) is part of the power
supply cable, be sure to connect it to a properly
grounded switch box or building ground. If not part
of the supply cable, use a separate grounding lead
(conductor). Do not remove a ground prong from
any plug. Use correct mating receptacles. Check
ground for electrical continuity before using
equipment.
The grounding conductor must be of a size equal
to or larger than the size recommended by Code or
in this manual.
2. Charging Leads – Inspect leads often for damage
to the insulation. Replace or repair cracked or worn
leads immediately. Use leads having sufficient
capacity to carry the operating current without
overheating.
3. Battery Terminals – Do not touch battery terminals
while equipment is operating.
4. Service and Maintenance – Shut OFF all power at
the disconnect switch or line breaker before
inspecting, adjusting, or servicing the equipment.
Lock switch OPEN (or remove line fuses) so that
the power cannot be turned ON accidentally.
Disconnect power to equipment if it is to be left
unattended or out of service.
Disconnect battery from charger. Measure voltage
on capacitors and discharge through an insulated
screwdriver if there is any voltage reading.
Keep inside parts clean and dry. Dirt and/or
moisture can cause insulation failure. This failure
can result in high voltage at the charger output.
SAFETY INSTRUCTIONS AND WARNINGS
193111-038
SAFETY INSTRUCTIONS AND WARNINGS
April 3, 2000 1-1