Ametek POWER PRO FERRO 80 Series User manual

OWNER’S MANUAL 193111-050
Revised November 17, 2020
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
POWER PRO
FERRO 80 SERIES CHARGERS
Silicon Diode Ferroresonant
Transformer Type
Battery Charger
DO NOT DESTROY

NOTE: Information regarding obtaining additional copies of this manual is located in the Introduction
chapter of this manual.
A battery charger is identified by model number. Incorporated into the model number is the 8-hour
ampere-hour capacity, case size, input power phase, and number of cells in battery for which charger is
intended. The following example explains the basic model numbering arrangement.
Model 12 - 750 FR 80 T
1 Phase Input Power – S
3 Phase Input Power – T
80% Rated Suffix
Ferroresonant
Ampere-Hour Capacity in 8 Hours
Number of Cells
NOTE: This information is required for ordering certain replacement/service parts.

193111-050
TABLE OF CONTENTS
INTRODUCTION........................................................................................................................................ 1
How to use this Manual...................................................................................................................... 1-1
Equipment Identification..................................................................................................................... 1-1
Receipt of Equipment......................................................................................................................... 1-1
SAFETY INSTRUCTIONS AND WARNINGS ........................................................................................... 2
INITIAL SET-UP & DESCRIPTION ........................................................................................................... 3
INSTALLATION ......................................................................................................................................... 4
Location.............................................................................................................................................. 4-1
Environmental Characteristics ........................................................................................................... 4-1
Grounding .......................................................................................................................................... 4-1
Line Voltage Changeover Instructions ............................................................................................... 4-2
Line Connections to Battery Charger................................................................................................. 4-2
Charging Cable Connectors............................................................................................................... 4-3
Pre-operation Checks ........................................................................................................................ 4-3
OPERATION .............................................................................................................................................. 5
Preliminary ......................................................................................................................................... 5-1
Normal or Daily Charge .................................................................................................................... 5-1
Equalize or Weekend Charge ............................................................................................................ 5-2
Manual Stop ....................................................................................................................................... 5-2
Refresh Charge.................................................................................................................................. 5-2
Backup Timer Shutdown.................................................................................................................... 5-2
Battery Disconnect Shutdown............................................................................................................ 5-2
AC Power Fail .................................................................................................................................... 5-2
MAINTENANCE......................................................................................................................................... 6
Inspection and Cleaning .................................................................................................................... 6-1
Lubrication.......................................................................................................................................... 6-1
Fuse Replacement............................................................................................................................. 6-1
Silicon Diode Testing ......................................................................................................................... 6-1
Capacitor Testing ............................................................................................................................... 6-2
Troubleshooting ................................................................................................................................. 6-3
PARTS LIST .............................................................................................................................................. 7
DIAGRAMS
WARRANTY
November 17, 2020

November 17, 2020
193111-050
TABLE OF CONTENTS
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193111-050
INTRODUCTION
November 17, 2020 1-1
INTRODUCTION
How To Use This Manual
IMPORTANT: It is especially
important that all charger
internal components be kept
clean and dry, and all
electrical connections as
tightened as instructed in the
Maintenance chapter of this
manual. Replace any
precautionary or instruction
label that cannot be easily
read.
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. Warnings will be
enclosed in a box such as this.
CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.
NOTE offers helpful information concerning
certain operating procedures. Notes will be
shown in italics.
Equipment Identification
The unit's identification number (specification, model,
serial number) usually 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 possible 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 identification 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 may be purchased by
contacting Ametek/Prestolite Power Troy OH 45373,
include the Owner's Manual number and equipment
identification numbers.

193111-050
INTRODUCTION
1-2 November 17, 2020
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November 17, 2020 2-1
193111-050
SAFETY INSTRUCTIONS AND WARNINGS
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 past experi-
ence
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 dam-
age
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 equip-
ment.
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.

193111-050
SAFETY INSTRUCTIONS AND WARNINGS
2-2 November 17, 2020
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 on fingers to come in contact with
battery terminals or the cell connectors 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 ventilated.
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
To prevent arcing and burning of the connector
contacts, be sure the charger is OFF before connecting
or disconnecting the battery. (If the charger is
equipped with an ammeter, the ammeter should not
indicate
current flow.) Always connect battery before turning
charger ON.
F. Medical and First Aid Treatment
First aid facilities and a qualified first aid person should
be available for each shift for immediate treatment of
electrical shock victims.
EMERGENCY FIRST AID: Call
physician and ambulance
immediately. 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
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, flush very well
with clean water and obtain professional medical
attention immediately.
G. Equipment Warning Labels
Inspect all precautionary labels on the equipment.
Order and replace all labels that cannot be easily read.

193111-050
INITIAL SET-UP & DESCRIPTION
November 17, 2020 3-1
INITIAL SET-UP & DESCRIPTION
Charger
The basic charging circuit is the silicon diode, rectifi-
er-type with ferroresonant transformer (s). This fer-
roresonant transformer design regulates charging
current by allowing the battery to determine its own
charge cycle rate in accordance with its state of dis-
charge. It provides a constantly-tapering charge
that eliminates the possibility of overcharging, even
with line voltage variations of ± 10%. Single-phase
input chargers have one transformer, three-phase
input chargers have two. The charger is internally
protected from overload and short circuits.
When charging lead acid batteries, with the same
number of cells and ampere-hour capacity as shown
on charger nameplate, the charging time will be
approximately 8 hours. Batteries of smaller or larg-
er ampere-hour capacities can also be charged, but
will require shorter or longer charging, respectively.
WARNING: Do not connect a
battery to this charger if any LED
is lit. Do not disconnect a battery
from this charger while a charge
is in progress. Otherwise, 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.
Set-Up
See Location Diagram of Selector Switches includ-
ed in this manual.
For proper operation, the Control must be set to
match the charger in which it is installed.
Cell Size Selection
From the data plate on the charger, note the voltage
output. Place the corresponding DIP switch (S1) on
the Control in the “Closed” position.
S1-1 12 Volts
S1-224 Volts
S1-3 36 Volts
S1-448 Volts
S1-5Optional
Only one of the above DIP switches should be in the
“Closed” position at any one time.
Auto Equalize
Switch S1-6 can be used to select either Auto
Equalize or Manual Equalize.
Termination Type
Switch S1-7 can be used to select either 2.37 V/C or
2.45 V/C 80% Trip Point.
S1-6Equalize Type
Open Auto Equalize every 5th Cycle
Closed Manual Equalize
S1-780% V/C
Open 2.37
Closed 2.45

193111-050
INITIAL SET-UP & DESCRIPTION
3-2 November 17, 2020
Charger Control
The Control has an on board microcontroller to
monitor and control the charging process. The up
-to-date status of the charge cycle can be easily
monitored by watching the status of the four LED’s,
charge in progress, 80% charged, charge complete,
and equalize. The Control utilizes a patented
pt/dv/dt charge termination technique which elimi-
nates excessive gassing by returning approximately
107% of the amp-hours removed from the battery.
All front panel information (including operation
instructions) is back printed on a polycarbonate
overlay which is resistant to damage from oils, gas-
oline, and frequent operator handling. The Control
is “matched” to the output voltage of the charger by
means of a printed circuit board mounted DIP
switch. Features of the Control include Auto Start/
Stop, Auto/Manual Equalize, Manual Stop, Backup
Timer Protection, pt/dv/dt Termination Method,
2.37 V/C & 2.45 V/C 80% Point, 48 Hour Refresh,
and AC Power Fail Recovery.

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 corrosion
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 6
inches of free air space at rear and sides 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.
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.
Environmental Characteristics
Operating Characteristics 0°C to 40°C
(32°F to 104°F)
Operating Altitude To 2000 Meters
(6562 Feet)
Operating Humidity 80% up to 31°c,
decreasing to 50% at
40°C, non-condensing
80% up to 88°F
decreasing to 50% at
104°F, non-condensing
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 conclusion 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 conductor 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 (stud with a green nut and a cup washer and
identified by symbol ), 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 grounding 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.
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.
WARNING: ELECTRIC SHOCK HAZARD -
Under no circumstance should you use a
grounding conductor with a current
carrying capacity less than the ampere
rating shown in Table 4-1.
November 17, 2020 4-1
193111-050
INSTALLATION
INSTALLATION

193111-050
INSTALLATION
4-2 November 17, 2020
Table 4-1 Recommended AC Input and Branch Fusing
LINE AMPS DISCONNECT
SWITCH * COPPER CABLE SIZE AWG * *BRANCH FUSE SIZE (AMPERES) 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
The above table (Table 4-1) is based on 75°C (167°F) rated conductors and 40°C (104°F) ambient tempera-
tures.
Refer to National Electrical Code (1999) 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 1999 – Table 250-
Line Voltage Changeover
Instructions
1. Determine if the charger is connected for available
line voltage. A label located near AC input terminals
is marked with the AC voltage for which the charger
is factory connected.
2. If charger is not connected correctly, check serial
nameplate to determine that charger is equipped
to be connected for available line voltage. If
charger is suitably equipped, make voltage change-
over connections by following instructions on AC
INPUT label inside charger.
3. If charger is reconnected, check input fuse (s)
ratings with ratings specified on label and replace
if necessary.
CAUTION: INCORRECT CONNECTIONS
AND INCORRECT FUSE SIZE can damage
this equipment. Follow voltage changeover
instructions carefully.
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.

193111-050
INSTALLATION
November 17, 2020 4-3
4. Route AC power input cable in through knock-out
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.
(Charger cabinet top or side panel, or both, may
have to be removed to provide access to terminal
block.)
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.
Charging Cable Connectors
If connectors are already attached to charging cables,
make sure that they’re 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 connectors are
securely attached to cables (good
solder joint or well tightened set screws,
whichever is applicable). Be certain
that positive charger cable will connect
to positive battery terminal. If necessary,
trace cables into charger and use
supplied connection diagram 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), disconnect battery, and
check for voltage on capacitors.
Discharge through insulated
screwdriver if there is any reading.
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.

4-4 November 17, 2020
193111-050
INSTALLATION
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November 17, 2020 5-1
193111-050
OPERATION
OPERATION
A. Preliminary
Make sure the charger is installed and grounded as
instructed in the INSTALLATION chapter of this
manual.
Maintain electrolyte level in the batteries to be
charged, as instructed by the battery manufacturer.
Because the volume of electrolyte expands during
the charging process, only add water when the
battery is at least 80% charged. An amber light will
be illuminated on the charger control panel when
the battery is at or above 80% charge.
Insure the battery size matches the charger.
Battery number of cells must equal the number of
cells stated on the charger data plate.
Battery ampere-hour capacity must be within the
ampere-hour range stated on the charger data
plate.
WARNING: EXPLOSION HAZARD – Do not
connect a battery to this charger if the
“Charge in Progress” LED is illuminated on
the charger. Do not disconnect a battery
from this charger if the “Charge in Progress”
LED is illuminated or ammeter is indicating
charging current; otherwise, arcing and
burning of connector parts can occur or a
battery explosion may result. Batteries
produce explosive gases. Keep sparks,
flames, and cigarettes away. Ventilate when
charging in an enclosed area. Always shield
eyes using face shield and goggles when
working near batteries.
CAUTION: The charging of a battery with
the incorrect number of cells or an ampere-
hour capacity outside the range stated on
the charger data plate will result in severe
over or under charging of the battery,
resulting in reduced battery performance
and life.
B. Normal or Daily Charge
WARNING: DO NOT connect a battery to
this charger if the “Charge in Progress”
LED is lit. Do not disconnect a battery from
this charger while a charge is in progress;
otherwise, 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.
1. Insure the battery size matches the charger
(Battery voltage and ampere hour capacity are
within nameplate information).
2. Securely engage the battery and charger
connectors.
3. After a five second delay (all LED‘s will be lit),
the charger will turn on. The “Charge in
Progress” LED will indicate charging current.
4. The “80% CHARGED” LED will light when the
battery on charge reaches the 80% charged
voltage.
5. The charger will automatically turn off and the
“Charge Complete” LED will light when the
charge has finished. reaching 80% charge.
The light will remain on until the battery is
disconnected from the charger.
NOTE: To disconnect battery from charger before
charge is complete, first press the “Manual
Stop” key, then disconnect the battery
from the charger.

5-2 November 17, 2020
193111-050
OPERATION
C. Equalize Or Weekend Charge
The Control features Auto Equalize on every 5th
charge cycle. Closing S1-6 can disable the feature.
When the Auto Equalize feature is disabled, an
Equalize charge can be selected or de-selected for
any charge cycle
using the sequence below.
1. Insure the battery size matches the charger.
(Number of cells and ampere-hour capacity are
within charger nameplate rating.)
2. Securely engage the battery and charger
connectors.
3. After a 5 second delay (all LED’s will be lit), the
charger will turn on. The “Charge in Progress”
LED will indicate charging current.
4. Press the “EQUALIZE” key. The “Equalize” LED
will light solid. Press the key again to cancel the
equalize charge.
NOTE: The equalize charge cannot be can-
celled
once the battery reaches the equalize charging
period. Press the STOP key to terminate the
charge.
5. The “80% CHARGED” LED will light when the
battery on charge reaches the 80% charged
voltage.
6. The battery reaches the normal termination
point.
However, the battery is charged another 3 hours.
The “Equalize” LED will flash during this equalize
period.
7. The charger will automatically turn off, and the
“Charge Complete” and the “Equalize” LED will
light when the equalized charge has finished.
The LEDs will remain on until the battery is
disconnected from the charger.
WARNING: DO NOT connect a battery to
this charger if the “Charge in Progress” LED
is lit. Do not disconnect a battery from this
charger while a charge is in progress;
otherwise, 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.
D. Manual Stop
1. To turn the charger OFF during any part of a
charge cycle, press the STOP key. All four
LEDs will flash.
2. To restart the charger, disconnect and
reconnect the battery. A new charge cycle will
begin.
E. Refresh Charge
In order to guarantee that a fully charged battery
is
always ready for use, a “Refresh” feature has
been incorporated into the Control. If a battery
is left connected to the charger for 72 hours after
a
“Charge Complete” has been reached, the Control
will start a charge sequence. The running time of
this “Refresh” charge will depend on the depth of
self-discharge of the battery.
F. Back-up Timer Shutdown
A back-up timer will shut down the charger and all
4 LEDs will flash then the “Charge Complete” LED
will flash if the battery on charge does not reach
the 80% voltage during the first 10 hours of
charging.
Likewise, if the charger does not reach the
termination point within 5 hours after reaching the
80% charged voltage, all 4 LEDs will flash then
the
“Charge Complete” LED will flash.
G. Battery Disconnect Shutdown
If the battery is disconnected from the charger
during a charge cycle, the charger will be shut
down. All LEDs will be off.
H. AC Power Failure
During an AC power failure, the Control stores
key information about the charge cycle. The
information is retained by powering some of the
control’s key components with a battery derived
power supply. This causes the control to resume
the charge where it left off when the AC power is
returned, unaffecting timers and equalize
requests.

193111-050
MAINTENANCE
November 17, 2020 6-1
WARNING: ELECTRICAL SHOCK
HAZARD — Before inspecting or
cleaning inside cabinet, turn OFF
and remove fuses of disconnect
switch (supplying AC power to
charger), disconnect battery, and
check for voltage on capacitors.
Discharge through insulated
screwdriver if there is any reading.
Inspection And Cleaning
For uninterrupted, satisfactory service from this
charger, it's necessary 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
compressed air isn't available.
Check and tighten all electrical connections as
necessary to eliminate 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 internal
parts clean and dry may allow
transformer (s) to short out,
causing secondary circuits to
carry dangerously high voltage.
Be sure to replace 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 replaced to protect personnel from
contact with hazardous voltages.
Lubrication
None required.
Fuse Replacement
The silicon diodes in this charger are protected by a
“fast-clearing” type fuse.
CAUTION: The use of any other type
fuse besides the “fast-clearing” type
may cause damage to silicon diodes.
Silicon Diode Testing
WARNING: ELECTRICAL SHOCK
HAZARD — Before checking electrical
components, turn OFF and remove
fuses of disconnect switch (supplying
AC power to charger), disconnect
battery, and check for voltage on
capacitors. Discharge through insulated
screwdriver if there is any reading.
1. Disconnect one diode lead to isolate diode from
electrical circuitry.
2. Use a good quality ohmmeter (preferably one
having a mid-scale value of approximately
50 ohms) to measure resistance values.
3. Zero ohmmeter on R x 1 scale.
4. Record indicated resistance while placing either
ohmmeter lead on threaded end of diode and
other ohmmeter lead on diode lead.
5. Reverse ohmmeter leads on diode and record
indicated resistance.
6. Consider diode good if one resistance reading is
infinitely (or very) high and the other is extremely
low.
NOTE: An acceptable low resistance value
or range of values can't be given because of
different readings from different ohmmeters,
and differences in diodes of the same rating.
Capacitor Testing
1. Heed WARNING in Silicon Diode Testing section.
2. Disconnect capacitor and connect leads of
ohmmeter (set to highest scale) to capacitor
terminals.
MAINTENANCE

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MAINTENANCE
6-2 November 17, 2020
3. If capacitor is good, pointer will deflect, indicating
capacitor is being charged, followed by a
deflection in the opposite direction indicating
partial discharge.
If there is no deflection, capacitor is “open” and
must be replaced. Also, if meter needle moves and
stops at one value, replace capacitor.
Replacement capacitors must be ordered from
factory. When ordering, supply serial number of
charger and microfarad (MFD) or (µF) value printed
on capacitor.