Ametek Deka PowerForce User manual

OWNER MANUAL – MOTIVE POWER CHARGER
IMPORTANT: Read these instructions before installing, operating, or servicing this system.

22
INTRODUCTION................................................3
How To Use This Manual ........................................... 3
Equipment Identication............................................. 3
Receipt Of Equipment ................................................ 3
SAFETY INSTRUCTIONS
AND WARNINGS ...............................................4
DESCRIPTION OF EQUIPMENT......................5
Operating Modes........................................................ 5
Opportunity/Fast Charging ........................................ 5
PowerForce Control.................................................... 5
INSTALLATION ..................................................6
Location ...................................................................... 6
Environmental Characteristics ................................... 6
Grounding ................................................................... 6
Line Connections to Battery Charger........................ 7
Mounting Pattern ........................................................ 7
Charging Cable Connectors....................................... 8
Pre-operation Checks ................................................ 8
Pre-Operation Changes to the
Factory Control Settings ............................................ 8
MAINTENANCE .................................................8
OPERATION.......................................................9
Preliminary .................................................................. 9
Normal Or Daily Charge ............................................. 9
Equalize Or Weekend Charge .................................... 9
Manual Stop................................................................ 9
AC Power Fail ............................................................. 9
Abnormal Shutdowns................................................10
POWERFORCE CONTROL FEATURES ........10
Main Features ............................................................10
Description of Features .............................................11
NAVIGATING THE
POWERFORCE CONTROL.............................13
Home Screen.............................................................13
Dashboard .................................................................13
Archive Records ........................................................13
Statistics App.............................................................17
Settings App ..............................................................18
PROGRAMMING SETTINGS..........................19
WARRANTY .....................................................24
TABLE OF CONTENTS

3
INTRODUCTION
How To Use This Manual
IMPORTANT: It is especially important that all charger internal
components be kept clean and dry, and all electrical connec-
tions tightened. Replace any precautionary or instruction label
that cannot be easily read.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAUTION, and
NOTE may appear. Pay particular attention to the information
provided under these headings. These special annotations are
easily recognized as follows:
WARNING gives information regarding possible personal injury.
CAUTION refers to possible equipment damage.
NOTE offers helpful information concerning certain operating
procedures.
Equipment Identification
The unit’s identification number (specification, model, serial number)
appears on a nameplate attached to the front panel.
Receipt Of Equipment
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for pos-
sible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to the company
shown on the cover of this manual. Include all equipment iden-
tification numbers and group part numbers (if any) as described
above, along with a full description of the parts in error.
Move the equipment to the site of installation before uncrating.
Use care to avoid damaging the equipment when using bars,
hammers, etc., to uncrate the unit.
Additional copies of this manual are available on the company
website www.eastpennmanufacturing.com.
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 ampere-hour capacity, module
count, and number of cells in battery for which charger is
intended. The following example explains the basic model
numbering arrangement.
NOTE: This information is required for ordering certain
replacement/service parts.
3
MODEL NUMBER 750 EB 2 18 P
Rated: P = Opportunity, F = Fast
Number of Cells
Module Count (1-8)
Case Type
Nominal AH Size

4
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.
A 5 minute delay is required after AC power removal for
full discharge.
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.
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. Do not permit rings, watches, or jew-
elry to come in contact with battery terminals or the cell connec-
tors on top of the battery.
Battery acid is very corrosive. Always wear correct eye and body
protection when near batteries.
D. Fire and Explosion Prevention
Batteries give off explosive flammable gases which easily ignite
when coming in contact with an open flame or spark. Do not
smoke, cause sparking, or use open flame near batteries. Charge
batteries only in locations which are clean, dry, and well venti-
lated.
Do not lay tools or anything that is metallic on top of any battery.
All repairs to a battery must be made only by experienced and
qualified personnel.
E. Arcing and Burning of Connector
CAUTION: To prevent arcing and burning of the connector con-
tacts, be sure the charger is OFF before connecting or discon-
necting the battery (If the charger is equipped with an ammeter,
the ammeter should not indicate current flow).
F. Medical and First Aid Treatment
First aid facilities and a qualified first aid person should be avail-
able for each shift for immediate treatment of electrical shock
victims.
EMERGENCY FIRST AID: Call physician and ambulance imme-
diately. Use First Aid techniques recommended by the American
Red Cross.
DANGER: ELECTRICAL SHOCK CAN BE FATAL. If person is
unconscious and electric shock is suspected, do not touch the
person if he or she is in contact with charging leads, charging
equipment, or other live electrical parts. Disconnect (open) power
at wall switch and then use First Aid. Dry wood, wooden broom,
and other insulating material can be used to move cables, if
necessary, away from person. IF BREATHING IS DIFFICULT, give
oxygen. IF NOT BREATHING, BEGIN ARTIFICIAL BREATHING, such
as mouth-to- mouth. IF PULSE IS ABSENT, BEGIN ARTIFICIAL
CIRCULATION, such as external heart massage.
IN CASE OF ACID IN THE EYES OR ON THE BODY, flush with clean
water and obtain professional medical attention immediately.
SAFETY INSTRUCTIONS
AND WARNINGS
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 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 y
trained and 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 a certified electrician verify that the equip-
ment is adequately grounded and learn what terminals and parts
are electrically energized.
The body’s electrical resistance is decreased when wet, permit-
ting 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 ac-
cordance with the National Electrical Code, NFPA 70, and local
codes. A power disconnect switch must be located at the equip-
ment. 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
energized, 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 for long
periods of time without overheating.

5
Conventional Charging
In applications utilizing conventional charging, the output of the
PowerForce returns recharges a battery over a long break period.
PowerForce conventional models are for rates up to 16.3% and
are not rated for lithium battery charging.
Opportunity Charging
In applications utilizing opportunity charging, the high current out-
put of the PowerForce returns significant capacity to the battery
during short periods such as breaks, lunch and shift changes. In
many applications battery changing can be eliminated completely.
PowerForce opportunity models are for rates up to 25% charging
or lithium battery charging with or without CAN bus communica-
tions.
Fast Charging
In applications utilizing fast charging, the high current output of
the PowerForce returns significant capacity to the battery during
short periods such as breaks, lunch and shift changes. In many
applications battery changing can be eliminated completely.
PowerForce Fast models are for rates up to 50% charging or
lithium battery charging with or without CAN bus communications.
POWERFORCE Control
The PowerForce control is the standard charge control for the
PowerForce Charger. It utilizes either a voltage/time (VT) charge
termination or a patented delta voltage / delta time (dV/dT) charge
termination technique which eliminates excessive gassing return-
ing approximately 107% of the amp hours removed from the lead
battery.
Features of the PowerForce Control include auto start/stop, man-
ual equalize, manual stop, back-up timer protection, two charge
termination methods, manual or automatic (with optional BID
module) battery temperature compensation, AC power fail recov-
ery, selectable output profiles, and charge cycle data archiving.
The backlit touch screen display indicates the status of a normal
charge cycle. The screen will display “80% Charged” when the
battery current is reduced to approximately 8.2 amps per 100 AH
of battery rating. The battery voltage at the 80% charged point
will vary with charge profile setting and/or manual or automatic
temperature settings. “Charge Complete” will display only if the
battery has completed the charge cycle and is ready for use.
WARNING: Do not connect a battery to this charger if the screen
is not on and charger indicator light is not illuminated. Do not dis-
connect 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 explo-
sive gases. Keep sparks, flame, and cigarettes away. Ventilate
when charging in an enclosed area. Always shield eyes when
working near batteries.
G. Equipment Warning Labels
Inspect all precautionary labels on the equipment. Order and re-
place all labels that cannot be easily read.
DESCRIPTION OF EQUIPMENT
The basic charging circuit is the IGBT inverter high frequency-type
with isolating transformer (s). This design regulates charging
current by allowing the battery to determine its own charge cycle
rate in accordance with its state of discharge. It provides a con-
stant current-constant voltage-constant current (IEI) charge that
eliminates the possibility of overcharging, even with line voltage
variations of ± 10% and allows the battery to finish at the proper
current regardless of battery age or gravity type.
The PowerForce provides battery charging over a wide range of
environmental conditions. The charger will precisely charge your
battery based on battery temperature, type, and size; by auto-
matically adjusting its own output charge characteristic within the
power limits of the charger’s power circuit.
When applied with the PowerForce optional Battery Identification
Module (BID), the PowerForce Charger identifies the battery se-
lected for charging at the time of connection and adjusts its out-
put for that specific battery. During the charge cycle, or duration
of connection, the PowerForce continuously monitors the battery’s
temperature via the BID and adjusts its output to match the bat-
tery temperature as it changes throughout the charge cycle.
Upon connection of the battery, the PowerForce control 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 adjusts its output curve
based on this information.
The PowerForce is internally protected against overload and
short circuits by both input and output fusing, plus PowerForces’s
unique curve monitoring circuit measures the output curve to
ensure that the voltage and current are within the limits set at the
factory.
Operating Modes
The PowerForce reads the information that was programmed
into the BID Module during installation and charges the battery
based on an opportunity charging profile or a profile designed to
recharge a fully discharged battery in 8 hrs. Valve regulated bat-
teries of several types can also be recharged at the 8 hour rates
when equipped with a properly programmed BID Module.
The PowerForce always reads the BID module first when an in-
stalled BID Module is detected and enabled in charger settings.
The charger automatically adjusts its output to match the battery
information programmed into the module.
The BID module allows users with various cell size batteries to
charge any battery on any charger without the fear of mismatch-
ing batteries and chargers.

6
Grounding
The frame of the power source must be grounded for personnel
safety. Where grounding is mandatory under state or local codes,
it is the responsibility of the user to comply with all applicable
rules and regulations. Where no state or local codes exist, it is
recommended that the National Electrical Code be followed.
In addition to the usual function of protecting personnel against the
hazard of electrical shock due to fault in the equipment, grounding
serves to discharge the static electrical charges which tend to build
up on the surfaces of equipment. These static charges can cause
painful shock to personnel, and can lead to the erroneous conclu-
sion that an electrical fault exists in the equipment.
If a charger is to be connected to the AC power supply with a
flexible jacketed cable, one having a separate grounding conduc-
tor should be used. When included in cable assembly, grounding
conductor will be green, green with a yellow stripe, or bare.
When connecting input power to charger (as instructed in Line
Connection to Battery Charger section of this manual), connect
grounding conductor to equipment grounding terminal, taking
care to make a good electrical connection. Connect other end of
grounding conductor to the system ground.
If, for any reason, an input cable which does not include a ground-
ing conductor is used, the equipment must be grounded with
separate conductor. Minimum size and color coding requirements
must be in accordance with any applicable state or local code, or
the National Electrical Code.
If metallic armored cable or conduit is used, the metal sheathing
or conduit must be effectively grounded as required by state or
local code, or the National Electrical Code.
WARNING: ELECTRIC SHOCK HAZARD- Under no circumstance
should you use a grounding conductor with a current carrying ca-
pacity less than the ampere rating shown in Table 4-1.
If a system ground is not available, the charger frame must
be connected to a driven ground rod (at least 8 ft [2438 mm]
long), or to a water pipe that enters the ground not more than
10 ft (3048 mm) from the charger. A grounding conductor must
be connected to the rod or pipe in a manner that will assure a
permanent and effective ground. The conductor must be sized
in accordance with any applicable state or local code, or by the
National Electrical Code. If in doubt, use the same size conductor
as is used for the conductors supplying power to the charger.
INSTALLATION
Location
For best operating characteristics and longest unit life, take care
in selecting an installation site. Avoid locations exposed to high
humidity, dust, high ambient temperature, or corrosive fumes.
Moisture can condense on electrical components, causing corro-
sion or shorting of circuits, especially when dirt is also present.
Adequate air circulation is needed at all times in order to assure
proper operation. Provide a minimum of 12 inches of free air
space at the side and front of the unit. Make sure that ventilation
openings are not obstructed.
Always remove the charger shipping skid from the unit before
installation. The charger must be installed over a noncombustible
surface such as concrete or metal. Keep the charging area clear
of all combustible material such as wood, paper, and cloth. When
moving the charger after the packing skid and box have been
removed, make sure that lifting forks do not damage the charger
panels or cables.
WARNING: SPARKS OR MOLTEN METAL falling through open bottom
can cause fire or explosion.
• Install over noncombustible material such as concrete or metal.
• Keep charging area clear of combustible material.
Stacking
Units with a single door can be stacked up to two units vertically.
Applications that require more than two units vertically stacked
will require shelf or rack systems not offered by E.P.M. Units with
two doors are not designed to be stacked. See options list for
stacking kits.
Environmental Characteristics
Operating Characteristics -20°C to 45°C (-4°F to 113°F)
Operating Altitude To 2000 Meters (6562 Feet)
Operating Humidity
80% up to 31°C, decreasing to
50% at 45°C, non-condensing
80% up to 88°F decreasing to
50% at 113°F, non-condensing

7
Warning: At all times, safety must be considered an important factor
in the installation, servicing and operation of the product and skilled,
qualified technical assistance should be utilized.
AC Supply Input Conditions:
Supply voltage should not exceed +/-10% of rated input voltage
value. Consistent power should be provided with fluctuations
not to exceed 1200VAC (850Vrms) for a duration longer than 25
Microseconds.
Mounting Pattern
This is an excerpt from the 199740 and 199752 outline drawings.
Please request if you need further mechanical information (utilize
a 3/8” or 9.5 mm drill bit) The fasteners are M8 -1.25 with a
maximum thread depth of 7.5mm. Please consider your rack or
shelf thickness as well as your washer thickness when selecting
an appropriate length
Note: remember to maintain 12” of free airspace between and in
front of each charger
Mounting pattern should be 4.53” (115 mm) square.
Line Connections to Battery Charger
Follow local code requirements if different than instructions in this
manual.
1. Turn charger OFF.
2. Be sure charger is connected correctly for available line voltage as
instructed above.
3. On charger nameplate, note the AC input amperes corresponding
to the line voltage to which charger is to be connected. Use that
ampere value to select the proper disconnect switch, fuse, and
power cable sizes from Table 4-1.
4. Route AC power input cable in through knockout provided in side
panel of charger cabinet. Securely fasten cable wires to a power
input terminal inside charger. Refer to Grounding section of this
manual for proper connection of grounding conductor.
5. With disconnect switch (on AC input power line) in “OPEN” or
“OFF” position, connect power cable coming from charger, to the
switch. Install fuses in switch.
LINE AMPS DISCONNECT SWITCH * BRANCH FUSE SIZE
(AMPERES)
COPPER CABLE SIZE AWG**
POWER GROUND
0-2.5 30A 5No. 14 No. 14
2.6-4.5 30A 7No. 14 No. 14
4.6 -7.5 30A 10 No. 14 No. 14
7.6-12 30A 15 No. 14 No. 14
12.1-16 30A 20 No. 12 No. 12
16.1-18 30A 25 No. 10 No. 10
18.1-22 30A 30 No. 10 No. 10
22.1-24.5 60A 35 No. 8 No. 10
24.6-32.5 60A 40 No. 8 No. 10
32.6-40 60A 50 No. 8 No. 10
40.1-45 60A 60 No. 6 No. 10
45.1-57.5 100A 80 No. 4 No. 8
57.6 -78 100A 100 No. 2 No. 8
78.1-102.5 200A 125 No. 2 No. 6
102.6-135 200A 150 No. 1/0 No. 6
Table 4-1 Recommended AC Input and Branch Fusing
The above table (Table 4-1) is based on 75°C (167°F) rated conductors and 40°C (104°F) ambient temperatures.
Refer to National Electrical Code (2008) Tables 310-16 corrected to 40°C (104°F).
* For 115, 208, and 230-volt lines, use 250-volt disconnect switch. For 440-480, 575-volt lines, use 600-volt disconnect
switch.
** Two conductors and ground conductor required for single phase. Three conductors and ground conductor required for three
phase.
Recommended minimum size of grounding conductors (based on National Electrical Code 2008 – Table 250-95).

8
NO GASSING HOURS
Factory Setting is 2 hours
MAX BATTERY TEMPERATURE
Factory Setting is 150° F
AUTO EQUALIZE
Factory setting is ON
AUTO EQUALIZE TYPE
Factory setting is by Cycle
AUTO EQUALIZE COUNT
Factory setting is 05
START MODE
Factory Setting is automatic start
BID COMMUNICATIONS ENABLE
Factory setting is ON
REFRESH
Factory setting is on with 96 hour setting
Other functions are available for programming the PowerForce
Control to meet your specific charging needs. Programming these
functions is described in the Programming the PowerForce Control
chapter of this manual.
MAINTENANCE
WARNING: ELECTRICAL SHOCK HAZARD — Before inspecting or
cleaning inside cabinet, turn OFF and remove fuses of disconnect
switch (supplying AC power to charger) and disconnect battery.
Inspection And Cleaning
For uninterrupted, satisfactory service from this charger, it’s nec-
essary to keep unit clean, dry, and well ventilated. At least every
three months, or more often as necessary, wipe and blow out
all dirt from unit’s interior components, with clean, dry air of
not over 25 psi (172 kPa) pressure. Use a hand bellows if com-
pressed air isn’t available.
A certified technician can remove modules and clean the heat sink
with compressed air or a wire brush, if necessary.
Check and tighten all electrical connections as necessary to elim-
inate unnecessary losses and to avoid subsequent trouble from
overheating or open circuits. Check for broken wiring or damaged
Insulation on wiring.
WARNING: ELECTRICAL SHOCK HAZARD — Failure to keep in-
ternal parts clean and dry may allow transformer(s) to short out,
causing secondary circuits to carry dangerously high voltage.
Be sure to close all charger cabinet panels after any servicing, to
assure proper flow of cooling air through unit and to protect internal
components.
WARNING: ELECTRICAL SHOCK HAZARD — All cabinet panels
must be closed to protect personnel from contact with hazardous
voltages.
Lubrication
None required.
Special Considerations
Generators and Backup Power Systems
On site power generation and backup power systems create spe-
cial considerations both because of the power quality itself and
the way the load is transferred between mains and backup (and
reversion to mains).
If this installation will incorporate either on – site generation or
some other form of backup power, please consult E.P.M Engineering
for a review of the planned system prior to implementation.
Charging Cable Connectors
If connectors are already attached to charging cables, make
sure that they are attached so that positive charger polarity will
connect to positive battery terminal.
If connectors must be attached to charging cables, follow
instructions supplied with connectors.
CAUTION: Make sure connector contacts are securely attached to
cables (good solder joint or crimps, whichever is applicable). Be
certain that positive charger cable will connect to positive battery
terminal. If necessary, trace cables into charger to determine
polarity. The use of a DC voltmeter may show polarity. Improper
connections will “blow” output fuse and may cause other damage.
Pre-operation Checks
1. Inspect charger thoroughly for damage; loose screws, nuts, or
electrical connections
WARNING: ELECTRICAL SHOCK HAZARD – Before inspecting or
cleaning inside cabinet, turn OFF and remove fuses of disconnect
switch (supplying AC power to charger) and disconnect battery.
2. Remove all special tags that are tied to charger. Keep tags with
this manual for future reference. Leave all precautionary and
instruction labels in place on charger. Carefully read and follow
instructions on all tags and labels. Make sure all labels remain
visible to anyone operating charger.
3. Make sure all charger cabinet panels are fastened in place, to
assure proper flow of ventilating air through cabinet.
Pre-Operation Changes To
The Factory Control Settings
Typically few changes are required to be made if the amp hour
rating is sized to the battery and the voltage rating is equal to or
greater than the battery. However, in some applications, some
changes to the programmable control settings may be desirable.
The most common changes are listed below:
TIME
Factory Setting for Time can be set to the desired time zone
NOTE: It is advisable to check the day of the week, date, month,
and year for accuracy
VOLTAGE SETTING
Factory Setting for Maximum Rating of charger
CAPACITY SETTING
Factory Setting for Maximum Rating of charger
CURVE SETTING
Factory Setting for Conventional is “FLD”, Factory Setting for
opportunity is “MAX”, Factory Setting for FAST is “MAX”

9
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.
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.

10
Arcless Subsystem Error- A problem was detected in the
arcless detection circuit that prevents the unit from charging.
Charge indicator: Solid Red. On screen message: “Arcless
Subsystem Error”
POWERFORCE CONTROL
FEATURES
Main Features
1. Up to 50 A/100AH high rate fast charging output.
2. Multi-Voltage Charging Capability
3. Multi-Ampere-Hour Charging Capability
4. Automatic or Manual Battery Temperature Compensation
5. 15 Minute Minimum DV/DT Charge Termination and VT
Termination
6. Touch Screen Display
7. Manual Stop Capability
8. Review of Current Charge Cycle Statistics Information during
charge cycle or after charge complete
- 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)
- Finish current
- Finish voltage (volts/cell)
- Charge termination code
- Battery and Charger Module Temperature
- Time/Date of Charge Cycle
- Charger curve type
Abnormal Shutdowns:
High Battery Reject- Initial battery voltage higher than expected
per the charger’s capabilities or cell count setting. The charge
indicator will turn red and screen will display “High Battery voltage
detected unable to Charge”
Battery Overtemperature- Battery has exceeded the max tem-
perature setting and is cooling down. The charge indicator will
show solid Red and screen will display “Battery Over Temperature
Detected Cooling Down”. Once the battery cools down, charging
will continue.
Low Voltage Shutdown- This shutdown will occur if cell volt-
age does not rise above the following levels in the indicated time
frame: On screen message: “Charge Curve Error Minimum Charge
Slope Not Met”
Charge Curve Voltage Error- On screen message text: “Charge
Curve Error Unable to Reach Tar-get CV”. This is to indicate to the
user that the charger cannot charge the battery properly due to
battery problems, charger problems or mis-matched equipment.
Low Current Shutdown- Predetermined level is below 2 amps
for greater than 30 seconds. On screen message: “Charge Curve
Error Low Current”
High Current Shutdown- Charger output current is higher than
expected. This error is triggered when output is 5 amps above the
desired out-put for longer than 30 seconds and the charge con-
troller is unable to compensate for it. The charge indicator is solid
red. On screen message: “Charge Curve Error Over Current”.
Manual Stop- On screen message: “Manual Stop”. This should
only be present if the Manual Stop button has been pressed while
the charger is running.
Backup Timer- Charger recognizes that the battery is not
charging properly due to a lack of increased voltage as the charge
occurs. On screen message: “Charge Session Timeout”.
Over Max AH Returned- Without a BID this will trip at 125% of
total battery amp hour. 150% with a BID. For an equalize charge,
it is 150% without a bid and 175% with a BID. On screen mes-
sage: “Charge Error Over AH Returned”
Charger Overtemperature Shutdown- Charger cabinet tem-
perature high, charging stopped. The charge indicator is solid
red, on-screen message: “Charger Over Temperature Error”
Charge Curve Error DiDt- Indicates an increase in current over
time. Current should decrease when it hits gassing voltage. On
screen message “Charge Curve Error DI/DT”
Charge Engine Error- All power modules are offline, unable to
charge. The charge indicator is solid red, on screen message:
“Charge Engine Error”
BID Battery Reject- Battery type described by BID/ WBID device
is not compatible with this charger. The charge indicator is solid
red, on screen message reads: “BID Battery Reject”
Voltage Charge Time (Minutes)
> 1.7VPC 30
>1.8VPC 60
>1.9VPC 90

11
17. 5 Programmable Start Modes
- Automatic Start
- Delayed Start
- Time-of-Day Start
- Time-of-Day Blockout
- Timer Mode
18. Programmable Manual Override of Start Modes
19. Password Protection
20. Automatic Equalize by Number of Charges or BID Cycles, Day of
Week
21. Programmable Cool Down Time
22. Staggered Start on A/C Fail Recovery
Description of Features
Multi-Voltage Charging — The PowerForce provides the capa-
bility to charge batteries of different voltage sizes. With the Multi-
volt Mode ON, the charger automatically selects the proper charge
curve based on battery voltage. A 48V PowerForce will safely
charge 48V, 36V, and 24V cell batteries. An 36V PowerForce will
safely charge 36V and 24V batteries.
Fixed mode operation can be selected by programming Multi-volt
mode to OFF. In this mode the charger will charge only batteries
of the volt setting programmed into the Fixed-volt setting.
If the battery is equipped with BID Module, the Multi-volt ON or
OFF function will be overridden and the charger will charge the
battery if it is within the charger output rating.
Temperature Compensation — The PowerForce Control is ca-
pable of modifying the output voltage to compensate for ranges
of battery electrolyte temperatures from 32 to 150 degrees F.
Because the 80% percent point is based on reaching a point on
the charge curve rather than a single voltage, it is automatically
adjusted with the output voltage.
CAUTION: Consult your batteries manufacturer for the recom-
mended maximum battery temperature for your battery.
When the battery is equipped with a PowerForce BID module, the
charger automatically reads the battery temperature throughout
the charge cycle and adjusts the output voltage to match the bat-
tery temperature.
Manual adjustment of the charger output voltage to match the
temperature of the battery is performed by programming the
proper battery electrolyte temperature into the Fixed Battery
Temperature function (BID readings automatically override the
Fixed Battery Temperature setting).
Max Battery Temperature—The PowerForce Control mon-
itors the battery temperature throughout the charge cycle.
Programming the MAX BATT TEMP setting of the control to the
desired maximum battery temperature will cause the charger to
shut down if the battery on charge is equipped with a BID and the
temperature exceeds the set point. It will wait until the battery
temperature has decreased to 5 degrees F below the set point
before restarting the charge cycle.
9. Review of Archived Charge Cycle Data for the
Last 1000 Charge cycles.
- Battery ID
- Amp hours returned during charge cycle
- Total time on charge
- 80% point to end of charge time
- Battery open circuit voltage
- Start current
- Start voltage (volts/cell)
- Finish current
- Finish voltage (volts/cell)
- Charge termination code
- Equalize time
- Start time
- End time
- Battery I.D.
- Battery I.D. start temperature
- Battery I.D. end temperature
- Cycle battery voltage
- Curve Type
- Month
- Date
10. Automatic start operation
11. Manual or Automatic Equalize Operation
12. Refresh Charge
13. Back-up Timer Shutdowns
14. Failure Mode Diagnostics
- High Battery Reject
- Low Battery Reject
- Module Temperature Warnings (IGBT / DIODE)
- Battery Over-temperature
- Low Voltage Shut Down
- Charge Curve Error
- Low Current Shut Down
- Backup Timer
- Manual Stop
- Over Maximum Amp Hour Returned Shut Down
- Charger Overtemperature Shutdown
- DIDT Shut Down
- Phase warning
-Arcless Subsystem fault
-Warning/Error Count
15. Programmed Features and Archive Data maintained for a mini-
mum of 10 Years
16. Charge Cycle Data and Time-of-Day/Date maintained for a mini-
mum of 10 Years

12
affected by a refresh charge. The charge termination technique
for a refresh charge will be DV/DT regardless of how the control
is user programmed, and the 0-80% back-up timer will be four
hours and fifteen minutes during a refresh charge. This feature
will insure that any battery left connected to the charger for ex-
tended periods of time will not be damaged due to self-discharge,
and will be kept in a fully charged state.
80% Charged Point — A PowerForce control will blink the LEDs
a faster green and enable the charge termination routine when the
battery voltage reaches the gassing voltage and the charging has
decreased below 8.2 amps/100AH. The gassing voltage is nomi-
nally 2.40 volts/cell and is adjusted automatically when the charger
output voltage is modified to charge batteries of different tempera-
tures.
Time-of-Day Start — The PowerForce Control can be pro-
grammed to delay the start of a charge cycle until a specific time
of day. Any time of day, in one minute increments, can be used for
the time-of-day start time.
When a control is programmed for time-of-day start, and a bat-
tery is connected to the charger, the programmed start time will
be displayed. This feature can be used to save on energy costs,
provide a battery cool down or warm up period, or to prevent op-
portunity charging.
Delayed Start — The PowerForce control can be programmed
to delay the start of a charge cycle for a specific period of time.
Any time period from 1 minute to 23 hours and 59 minutes, in one
minute increments, can be used for the delayed start period.
When an PowerForce is programmed for delayed start, and a bat-
tery is connected to the charger, the programmed delay time will
be displayed.
The time displayed will be decremented once per minute so that
the time displayed is always the amount of time remaining before
the start of charge. This feature can be used to save on energy
costs, provide a battery cool down or warm up period, or to pre-
vent opportunity charging.
Time-of-Day Blockout — The PowerForce control can be pro-
grammed to disable the charger during a specific time of day.
The charger will turn off at the beginning of the block-out period,
and resume the charge cycle at the end of the block-out period.
Any period of time of day, in one minute increments, can be
used for the time-of-day block-out period. When a PowerForce
is programmed for time-of-day block-out, and a battery is being
charged when the block-out period occurs, the programmed end
of block-out time will be displayed. This feature can be used to
save on energy costs, provide a battery cool down period, or to
prevent charging at certain times in the day.
Manual Override of Programmed Start Modes — A
PowerForce control, when programmed for time-of-day start, de-
layed start, or time-of-day block-out, can be manually overridden
by toggling the override switch on the display while the start of
the charge cycle is being automatically delayed by the control.
This manual override feature can be disabled through the “Start
Override” programming function. The manual override feature al-
lows the operator to start a charge cycle immediately if a battery
is needed sooner than the programmed start time would allow.
Charge Termination — The PowerForce control utilizes two
types of termination. VT, Voltage Time termination, will go to
charge complete after a timer. The other way to terminate a
charge cycle is to use DV/DT. DV/DT is a patented proportional
time DV/DT technique in order to determine the charge termi-
nation point. This technique returns approximately 107% of the
amp hours removed from a battery (regardless of the state of
discharge) and prevents variations in the incoming AC line voltage
from affecting the amount of energy returned to the battery. The
minimum time required for a DV/DT charge termination on the
PowerForce control is fifteen minutes. The control can be pro-
grammed to utilize a voltage-time charge termination technique.
If the DV/DT charge termination is disabled, the control will ter-
minate the charge cycle four hours after the battery reaches the
“80% Charged” point.
Touch Screen Display — A backlit touch screen display is
standard on the PowerForce control. Plain English and easy to un-
derstand abbreviations are used to indicate charge status, output
current, voltage and other functions including; archive information,
review information, programming information, fault information,
and operating status.
Review of Charge Cycle — When the charge cycle is in progress
or has been terminated, either by the control or the operator, the
charge cycle history can be automatically read out by Statistics App.
Automatic or Push-to-Start Operation — In the automatic
start mode, the charger will start a short time after the battery is
connected. The display will display “Reading BID Device Data” and
then display upcoming cycle information. In delayed, blockout, or
time-of-day start mode, the charger will not start the charge cycle
until “Start Mode Override” is toggled ON.
Manual or Automatic Equalize — An equalize charge is a pro-
longed charge cycle (by 3 hours) used to correct any inequalities
of voltage and specific gravity which may have developed be-
tween the cells during service. PowerForce controls are shipped
from the factory with the automatic equalize feature enabled.
There are three modes of automatic equalize. See the Equalize
section of chapter 9 of this manual for further details. When the
automatic equalize feature is active, the “Equalize” switch on the
touch screen display is disabled. When automatic equalize is dis-
abled, an equalize charge is requested by switching the “Equalize”
toggle on the touch screen display before or after the charge cycle
has started. If this toggle switch is turned off during the charge
cycle, the equalize request will be canceled if the equalize period
has not begun.
Refresh Charge Feature — A refresh charge of a storage battery
is a charge given to charged, wet type batteries, which are in
storage or inactive for long periods to replace losses due to limited
action and to be certain that every cell is brought periodically to a
full state of charge. The PowerForce control has an adjustable 0 to
99 hour refresh charge timer (programmed through the “Refresh”
icon in the settings app) which starts with a normal charge com-
plete, either DV/DT or voltage time. If a battery is left connected to
the charger for the programmed number of hours after a charge
complete, the control will automatically begin a refresh charge
cycle. The control will start automatically even if programmed for
time-of-day start, delayed start or push-to-start operation. The
PowerForce will not start the charge cycle during a time-of-day
blockout period. It will automatically request an equalize cycle if
it is programmed to equalize on that day. Charge cycle data is not

13
NAVIGATING THE
POWERFORCE CONTROL
HOME SCREEN
The PowerForce control Home screen is the default screen. From
this interface, the user can select four different applications in the
control.
To return to the Home screen at any time, press the Home icon in
the top left of each screen. This can be done while the charger is
idle or while charging a battery.
Dashboard
The Dashboard app screen is active during a charge cycle. This
screen displays real time information to the user. This and the
Home screen are the most commonly used in normal operation.
Statistics
This app gives the user access to the charge data from the
current charge cycle. To use this during a charge cycle, click
the Home button on the top left of the Dashboard, and click
Statistics.
These records are the same as the archive records, but they
are updating in real time
Archive
The Archive app is where the control saves the charging records.
It tracks many parameters in the charger and the connected bat-
tery.
If BID or WBID modules are on the batteries, the records will save
those battery ID’s with the corresponding charge cycle.
Archive data can be aggregated into the IntelliFleet software to
get a detailed view of an entire facilities fleet of batteries and
chargers.
Settings
The Settings app is used for customizing the charger output to fit
the needs of a specific battery or fleet of batteries.
Each of these Apps will be explained in
further detail in this chapter.
Automatic Equalize — The PowerForce control can be pro-
grammed for 3 different types of automatic equalize. Controls are
shipped from the factory programmed to automatically provide an
equalize charge to every fifth complete charger cycle. The number
of cycles between equalize requests can be varied from 0 to 30.
If the PowerForce control is programmed to automatically provide
an equalize cycle every five cycles, then an equalize charge can-
not be requested manually. The second type of automatic equalize
mode is when an equalize charge is desired on a particular day
of the week. When programmed for automatic equalize by day
of week, the PowerForce will provide an equalize charge to any
battery which is connected to the charger on the programmed
equalize day. Additionally, any battery which is connected to the
charger previous to the day of week equalize day will be given an
equalize charge provided that it is at a charge complete status
when the PowerForce’s clock calendar switches to the equalize
day. The automatic equalize features allow for the consistent
application of equalize charges without constant attention by
the operators. The third type of equalize is by BID count. When
programmed for this mode, the current complete cycle count is
read from the BID at connect and compared to that of the equalize
cycle counter. An equalize will be requested when the BID count
equals the equalize cycle count programmed into the control.
For further information on programming and reviewing the
PowerForce control features, refer to the Programming Settings
chapter.
Programmable Cool Down Time — A programmable cool down
feature allows the battery to cool down for 0 to 8 hours before the
charger signals charge complete. During the cool down period the
display reads “Cool Down”. This feature allows the battery to cool
down before being returned to use and can be used to minimize
the battery maximum temperature during operation.
No Gassing Time– A programmable time that effects how long
from the start of a charge cycle before the gassing portion can
begin. If the battery on charge reaches the finish portion of the
curve and the gassing time has not elapsed, the charger will shut-
off and display “No Gassing”. This minimizes any battery gassing
that may occur during an opportunity charge cycle. Once the start
gassing time has passed, the charger will restart at the standard
finish current and complete the charge cycle.
WARNING: Enabling the Finish Cell forming feature will cause
the charger to continue to run for a period of time if the battery
has been disconnected before Charge Complete or pressing the
Manual Stop button. This condition will continue until the pro-
grammed number of cycles have been completed. The should
never be disconnected while charge is in progress.
Maximum Battery Temperature — The PowerForce Control
can be programmed to interrupt the charge cycle if the battery
temperature exceeds the limit programmed into function. The
temperature may be programmed from 80°F to 150°F. Once the
battery cools down past the trip temperature the charge cycle will
be resumed. The display will show “Battery Cooling” if the charge
has been interrupted and the cooling period is taking place. A BID
must be in use to utilize this function.
Password — The user can turn on a 4 number password for use
in keeping programming functions protected. Any time the user
tries to access the settings, they will be prevented from doing so
until the password is entered. The user will have to enter the pass-
word on the dashboard screen to enable settings modifications.

14
6. Battery State of Charge Icon: Indicates battery state at a
glance.
Each bar indicates the State of Charge (SOC) in 20% increments,
along with colors.
-Red – Start of Charge at battery connect
-Orange – SOC < 80%
-Yellow - > 80%
-Green – Finish to Charge Complete, Bars will flash
during equalize.
SOC text will indicate current status as follows:
-SOC will be displayed while charging is in progress
-CC is displayed when the it is Charge Complete
-EQ is displayed when battery has completed the initial
charge & is now Equalizing.
7. Battery Temperature Icon: Touching this icon will cycle
display between Celsius and Fahrenheit.
8. Help Icon: Pressing this icon twice while on the home
screen will show a table of system firmware revision
9. S tatus Icon: Indicates the status of the charger and charge
cycle at a glance. Touching this icon will recall any active warn-
ings/errors for review.
10. Charge VPC: Indicates On Charge volts per cell
11. Charge Amps: Indicates On Charge DC Amps
12. D ate & Time: Indicates current date & time
13. Wireless Icon: Indicates connected
POWERFORCE DASHBOARD
1. Home Icon: Touching icon will automatically return the unit to
the Home screen from any other screen.
2. Clock Icon: Indicates the charger has stopped the charge cycle
temporarily for one or more of the following functions:
Start Mode Delay
No Gassing Delay
Battery Cool Down
Multi-Cell mode new battery delay
3. Battery Icon: Indicates the battery connection state.
- Battery with no text in the center means that a battery is
connected with no BID installed.
- Battery with the word BID in the center indicates the charger
has detected a BID on the connected battery.
- Battery with the word BID flashing indicates the charger is
attempting communication with the BID device.
4. Battery Info Icon: Indicates battery AH size, cell size, start
rate, and AH returned.
5. Charge Time Icon: Indicates the charge time, idle time, & time
since Charge Complete.
NOTE: the wireless icon is shown on the top bar toward
the left if connected.
11 9 8
12
10
4
1
113
5
6
7
2 3

15
charge cycle.
EQUALIZE TIME
The time of the equalize portion of the charge cycle. Equalize can
be automatically or manually selected.
START TIME
The time at the start of the charge cycle.
END TIME
The time at the end of the charge cycle. Includes the equalize time
if it was automatically or manually selected format.
BATTERY I.D.
The Battery I.D. number of the battery that was charged in the
charge cycle. Requires PowerForce Battery Identification Module
(BID).
BID START TEMP
The temperature of the battery sensed by the PowerForce Battery
Identification Module at the start of the charge cycle.
BID END TEMP
The temperature of the battery sensed by the PowerForce Battery
Identification Module at the end of the charge cycle.
CYC. AMP HOURS
The Ampere-hour setting of the charger during the charge cycle.
This value cannot exceed the maximum charger output rating.
CYCLE CELLS
The Cell Size setting of the charger during the charge cycle. This
value cannot exceed the maximum charger output rating.
BATTERY TYPE
The Battery Type setting of the charger during the charge cycle.
This value cannot exceed the maximum charger output rating.
PRESENT MONTH
The month that the charge cycle occurred.
PRESENT DATE
The day of the month that the charge cycle occurred.
MODULE OUTPUT AND TEMPERATURE
Each module will display its maximum current and temperature as
POWERFORCE CHARGE ARCHIVE
The archive data can be selected on the main screen. After the
range of charge cycles is chosen, the archive will display on the
screen.
AMP HOURS RETURNED
The total ampere-hours returned during the charge cycle. This
number includes ampere-hours delivered to the battery during the
Verify, 0-80%, 80% to End, and Equalize portions of the charge
cycle.
CHARGE TIME
The total charging time of the charge cycle. This number includes
the time of the Verify, 0-80% 80% to End, and Equalize portions
of the charge cycle.
80% TO END
The time the battery was charged from the 80% charged point
until DV/DT or VT (depending on the control setting) charge termi-
nation. This time does not include any equalize charging time that
may have been automatically or manually selected.
BATTERY OCV
The open circuit voltage in volts per cell of the battery immedi-
ately before the beginning of the charge cycle.
START AMPS
The value of the current delivered to the battery at the start of the
charge cycle.
START VOLTS
The value of the battery voltage (in volts/cell) of the battery at the
start of the charge cycle.
FINISH AMPS
The value of the charge current delivered to the battery at the end
of the charge cycle.
FINISH VOLTS
The value of the battery voltage in volts per cell at the end of the

16
BID Detect – Charger is attempting to detect if the connected battery
contains a BID/WBID
BID Init – Charger has established communication with the BID/WBID
and is reading ALL of the available data.
BID Refresh – Charger is reading the latest Battery Temperature,
Battery VPC, and Accumulated Charge/Discharge data from the bat-
tery.
Mod X Over Temp – Module #X is reporting that it is overheating.
In this scenario, the system will attempt to cool down the module by
reducing power.
Mod X IGBT Err – Module #X is reporting a problem with
its IGBT drive
Mod X Short – Module #X is reporting a Short Circuit condition
on its output.
Mod X Phase Loss – Module #X is reporting a Phase Loss
Mod X Over Curr – Module #X is reporting an overcurrent issue
Mod X Offline – Module #X is offline and not providing power.
Hot Disconnect – Charge cycle aborted due to disconnecting the
battery while charging.
Manual Stop – User requested to stop the charge cycle by pressing
the red button on the front door.
Cell Validate – The charger is determining the correct cell count for
the battery when in Multi-Cell mode.
Writing BID – The charger is writing information to the BID.
Mod X Temp Err – Module #X has overheated and is shutdown.
well as any warnings or engine faults.
CHARGE STATUS
Statistics will have a real-time status. Archive records will have
the termination code.
Session Start – Charge Session started
Start Current – Charger is providing Start Current
Gassing – Charger is regulating voltage to the Battery
80 Percent – Charge session has passed the 80% complete point.
Finish Current – Charger is providing finishing current.
Lid – Charger is modulating LID voltage (maximum charge voltage).
Charge Complete – Charge Session Complete
High Battery – High Battery Volts Reject Error.
Batt Over Temp – Battery Overtemperature Error
Low Volt Shut – Low Voltage Shutdown Error
Charge Curve Err – Charge Curve Error
Low Curr Shut – Low Current Shutdown
High Curr Shut – High Current Shutdown
Backup Timer – Session timeout due to backup timer.
Over Max AH – Over Max AH returned.
Over Temp Err – Charger overtemp error
DIDT Shutdown – DiDt Shutdown error
Engine Error – Charge Engine Error
Over Temp Warn – Charger Cabinet is overheating, (charging power
may be reduced in this state)
Output Limited – The charger is unable to meet the required output
Low Batt Reject – Low Battery Volts Reject Warning
SM Inhibit – Charging temporarily halted due to Start Mode
Batt Cycle Delay – Multi-Cell charging delay active. This delay oc-
curs to avoid issues with the user disconnecting and reconnecting a
battery quickly when the charger is set for Multi-Cell Mode
No Gas Inhibit – Charging is delayed due to No Gassing being active
Equalize – Charger is currently equalizing
Refresh Started – Charger is in a 60 second countdown to begin a
refresh.
Battery Watering – Charger is running the battery watering routine.
Addition Charge – Charger is running additional Finish Current
charge as specified by the customer.
BID Comm Failed – Communication with the BID device has ended
and failed.

17
Batt Cool Down – Battery is cooling down.
Arcless Error – Arcless subsystem fault, charging disabled.
PowerForce Statistics App

18
This is where the battery type and charge curve parameters are
chosen. If set to custom curve, the start rate, finish rate, gassing
voltage, and lid voltage can be changed to meet the needs of the
application.
BID / BMS (Opportunity or Fast) Settings
Is the page where BID settings can be set for a connected battery.
BID or BMS communication can be configured.
NOTE: To program a BID module with a charger, the battery must
be plugged into the charger and the charger must be in manual
stop.
Equalize Mode
This is where the equalize type and frequency is set. Batteries can
be equalized by cycle, BID cycle or by day-of-the-week.
Refresh
Refresh charge cycles can be set in this screen. It can be turned
on or off, and be set by hours or voltage per cell.
No Gassing
No Gassing time is set on this screen. It can be set to a total of
connected hours or by a daily schedule.
The Statistics App can be accessed during or after a charge cycle.
The same information that is available in the archive records are
available here, but it is updating in real time.
NAVIGATING THE POWERFORCE CONTROL
SETTINGS
The Settings app opens the settings menu. There are eight icons
that can be accessed from this page. The next chapter will have
details about each icon.
NOTE: If the Password is turned on, there will be a red lock in the
bottom right corner. Press this icon to enter the password to ac-
cess the settings.
General
This is the location where the default settings can be changed to
match a specific battery. Time and date are also entered in this
menu.
Start Mode
The default start mode is automatic. If the start mode needs to
be changed to time-of-day start, time-of-day blockout or delayed
start. There is also a timer mode that will prompt the user to input
the amount of time a charger will charge.
Charge Curve and Parameters

19
Display Temperature Compensated Voltage - Select to display
voltages after temperature compensation. Values reported on the
Dashboard will show actual voltage of the battery when you ad-
just for it’s temperature.
Password – Select to enable password protection. A lock icon
will be shown in the bottom right corner. If it is red, click the icon
to input the password in order to modify control settings. If it is
green, it is not locked.
Multi-Volt Mode - Select to enable the automatic cell selection
mode of operation for the charger. When multi-cell mode is
selected, the charger cannot automatically recognize the
difference between 72 and 80 volt sizes. Therefore, in Multi-
Volt Mode, the charger must be programmed to 72 or 80 volts.
Regardless of this setting 72 or 80 volt batteries with properly
programmed PowerForce BID modules will be charged correctly.
Power Saver – Display will go blank after 3 minutes in order to
save power. Touch the display to wake the control.
NETWORK SETTINGS
EPID – Extended PAN ID. This is the network ID utilized in
IntelliFleet downloads and Insight Cloud communications. The de-
fault is network 00.
Wireless Access – Enable or disable wireless connectivity
TIME/DATE
Battery Watering
This setting is used to indicate to the user when to water the bat-
teries.
Programming Settings
SETTINGS APP
The Settings app has eight icons that grant the user access to
different programming parameters. Each icon is selected using
the touch screen and each will open a series of screens that set-
tings can be inputted.
General
The first screen in the General Settings menu contains the
following parameters. The interface uses the touchscreen to
navigate and input boxes, dropdown menus, and toggle switches
are used to program parameters.
Fixed Temperature – This is the setting for the average battery
temperature. If no BID’s or WBID’s are present, this is the value
the charger will use to compensate gassing voltage. This setting
does not affect BID’s.
Max Battery Temperature – The maximum battery temperature
for the battery while charging is in progress. If BID or WBID mod-
ules reach this temperature, the charger will wait for the battery
to cool 5 degrees Fahrenheit below this threshold to continue
charging.
Fixed Volts – This is the programmed voltage size for the char-
ger. Multi-volt mode and BID/WBID modules will override this
setting.
NOTE: A charger will not be able to output a higher voltage or
current than what it is rated. It will electronically protect itself from
overheating by pulling the output back or ending the charge cycle.
Display Backlight – The backlight of the control board can be set
to three levels of light intensity. Low, medium, and high.
Control SN – The Control SN is the number designation for the
charger. This is how the charger will be identified on IntelliFleet or
the Insight Cloud.
Cool Down Hours – The charger can be set to display cool down
hours after a charge cycle. This indicates to the user that the
battery needs to cool before use. It can be set from 0 hours to 24.
The default is 0.

20
5. Timer Mode– The charger will prompt the user to input the
desired charge time.
Override– This toggle switch can enable a manual override if the
start mode is set to anything but Auto.
CHARGE CURVE AND PARAMETERS
Battery Voltage Selection
The bottom arrows allow selection of the battery voltage sup-
ported by the charger. The user should select the proper voltage
and modify the charge curve and other settings as needed.
Charge Curve
The curve setting is the battery type the charger uses to select
proper output voltage & current characteristics, if the charger
does not detect a PowerForce BID.
The values on the right are the rates for the chosen charge curve.
The custom curve allows the user to modify these values.
Termination Type
VT-4 – The charger will continue to charge for 4 hours after the
80% SOC point is reached.
VT-6 – The charger will charge for 6 hours after 80% SOC point is
reached
For VT-4 and VT-6 If 80% SOC in less than 5 minutes the charger
will automatically select DvDt to limit extra time at finish current.
If FLD or MAX curve is selected the charger will automatically select
DvDt upon reaching 2.65VPC (temperature corrected) to limit extra
time at finish current. For DSG the DvDt changeover is at 2.45 (tem-
perature corrected).
DVDT – When the charger reaches 80% SOC, battery voltage is
monitored and the charge stopped when the voltage rise slows to a
point to indicate a fully charged battery.
FIXED BATTERY AH - configures the battery capacity
Additional Charge Time - Extra run time, starts at the Charge
Complete point (00:00 to 02:00 hours) default 00.
Time/Date– This is the screen that the controls time and date is
programmed. The clock is a 24 hour clock.
Press the Save Date button to save these settings.
Screen Calibration
Screen Calibration– Calibrate the touch screen display by press-
ing the screen where the little + symbols appear.
START MODE
The start mode can be set to:
1. Auto– Charge cycles begins when battery is detected
2. TODS– Time of Day Start can start the charge cycle at a desired
time every day.
3. Delay– Delays the start of a charge cycle for the programmed hours.
4. TODB– Time of Day Blockout can prevent charging during a spec-
ified time period.