Ametek PRESTOLITE POWER EQUINOX User manual

OWNER’S MANUAL 193111-075
Revised October 20, 2008
IMPORTANT: Read these instructions before installing, operating, or
servicing this system.
Opportunity
Battery Charger
DO NOT DESTROY
AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.
EQUINOX

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 maximum
power rating, and maximum number of cells in battery for which charger is intended. The following
example explains the basic model numbering arrangement.
Model PAC 320 24
Maximum Number of Cells
DC Current Rating (Amps)
Prestolite Advanced Charger (Hi-Frequency SMPS)
NOTE: This information is required for ordering certain replacement/service parts.

193111-075
TABLE OF CONTENTS
January 2, 2008 Revised
INTRODUCTION .....................................................................................................................................1
How To Use This Manual ...................................................................................................................1-1
Equipment Identification .....................................................................................................................1-1
Receipt Of Equipment ........................................................................................................................1-1
SAFETY INSTRUCTIONS AND WARNINGS ........................................................................... 2
DESCRIPTION OF EQUIPMENT .............................................................................................. 3
Operating Modes ................................................................................................................................3-1
Opportunity Charging .........................................................................................................................3-1
EQUINOX Control ..............................................................................................................................3-2
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
Pre-Operation Changes to the Factory Control Settings....................................................................4-3
MAINTENANCE......................................................................................................................... 5
OPERATION .............................................................................................................................. 6
Preliminary..........................................................................................................................................6-1
Normal Or Daily Charge .....................................................................................................................6-1
Equalize Or Weekend Charge............................................................................................................6-2
Manual Stop .......................................................................................................................................6-2
AC Power Fail.....................................................................................................................................6-2
Abnormal Shutdowns .........................................................................................................................6-2
EQUINOX CONTROL FEATURES............................................................................................ 7
Main Features.....................................................................................................................................7-1
Description of Features ......................................................................................................................7-2
EQUINOX Charge Archive Function ..................................................................................................7-6
EQUINOX Charge Cycle Review Function ........................................................................................7-7
PROGRAMMING YOUR EQUINOX CONTROL ....................................................................... 8
Using Extended AH for Opportunity/Fast Charging ...........................................................................8-5
Multi Amp Hour Programming ............................................................................................................8-6
Timer Start Mode Programming .........................................................................................................8-7
OPTIONS ................................................................................................................................... 9
Series Charging..................................................................................................................................9-1
Remote Display Kit .............................................................................................................................9-1
Floor Mounting Stand .........................................................................................................................9-1
Archive Downloading Kit.....................................................................................................................9-2
Arcless Disconnect (Opt. 600)………………………...………….……………………………….………..9-2
Remote Stop Pushbutton Kit..…………………….…………...………………………………...…...…….9-2
PARTS LIST ............................................................................................................................ 10
DIAGRAMS
WARRANTY

1-1 April 26, 2007
193111-075
INTRODUCTION
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
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. 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 the company shown on the cover of this
manual. Include the Owner's Manual number and
equipment identification numbers.

April 26, 2007 2-1
193111-075
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 experience
in the use of charging equipment. These practices
must be learned through study and training before
using this equipment. Anyone not having
extensive training in battery charging practices
should be taught by experienced operators.
Only qualified personnel should install, use, or
service this equipment.
B. Shock Prevention
Bare conductors, or terminals in the output circuit,
or ungrounded, electrically-live equipment can
fatally shock a person. To protect against shock,
have competent electrician verify that the
equipment is adequately grounded and learn what
terminals and parts are electrically HOT.
Always wait one minute after de-energizing charger
before touching any interior components or connections.
The body’s electrical resistance is decreased when wet,
permitting dangerous current to flow through the body.
Do not work in damp area without being extremely
careful. Stand on dry rubber mat or dry wood and use
insulating gloves when dampness or sweat cannot be
avoided. Keep clothing dry.
1. Installation and Grounding of Electrically Powered
Equipment – Electrical equipment must be installed
and maintained in accordance with the National
Electrical Code, NFPA 70, and local codes. A
power disconnect switch must be located at the
equipment. Check nameplate for voltage and
phase requirements. If only 3-phase power is
available, connect single-phase equipment to only
two wires of the 3-phase line. DO NOT CONNECT
the equipment grounding conductor (lead) to the
third live wire of the 3-phase line as this makes the
equipment frame electrically HOT, which can cause
a fatal shock.
If a grounding lead (conductor) is part of the power
supply cable, be sure to connect it to a properly
grounded switch box or building ground. If not part
of the supply cable, use a separate grounding lead
(conductor). Do not remove a ground prong from
any plug. Use correct mating receptacles. Check
ground for electrical continuity before using
equipment.
The grounding conductor must be of a size equal
to or larger than the size recommended by Code or
in this manual.
2. Charging Leads – Inspect leads often for damage
to the insulation. Replace or repair cracked or worn
leads immediately. Use leads having sufficient
capacity to carry the operating current without
overheating.
3. Battery Terminals – Do not touch battery terminals
while equipment is operating.
4. Service and Maintenance – Shut OFF all power at
the disconnect switch or line breaker before
inspecting, adjusting, or servicing the equipment.
Lock switch OPEN (or remove line fuses) so that
the power cannot be turned ON accidentally.
Disconnect power to equipment if it is to be left
unattended or out of service.
Disconnect battery from charger.
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.

193111-075
SAFETY INSTRUCTIONS AND WARNINGS
2-2 April 26, 2007
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 make sure charger output if off
before connecting battery.
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.

193111-075
DESCRIPTION OF EQUIPMENT
April 26, 2007 3-1
DESCRIPTION OF EQUIPMENT
Figure 3-1
The basic charging circuit is the IGBT switchmode
converter with an isolating transformer. This IGBT
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
constant 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 EQUINOX provides opportunity battery
charging over a wide range of environmental
conditions. The charger will precisely charge your
battery based on battery temperature, type, and size;
by automatically adjusting its own output charge
characteristic within the power limits of the chargers
power circuit.
When applied with the Prestolite Power optional Battery
Identification Module (BID), the EQUINOX identifies
a battery selected for opportunity charging at the time
of connection and adjusts its output for that specific
battery. During the charge cycle, or duration of
connection if used as an opportunity charger the
EQUINOX continuously monitors the battery’s
temperature via the BID and adjusts its output to match
the battery temperature as it changes throughout the
charge cycle.
Upon connection of the battery, the EQUINOX 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 start rate, and adjusts its output curve
based on this information.
The EQUINOX is internally protected against
overload and short circuits by both input and output
fusing, plus Prestolite’s unique curve monitoring circuit
periodically measures the output curve to ensure that
the voltage and current are within the limits set at the
factory.
Operating Modes
The EQUINOX reads the information that was
programmed into the BID Module during installation and
charges the battery based on an opportunity charging
profile with start rates programmable from 20 to 50
amps per 100AH, or a profile designed to recharge a
fully discharged battery in 8 hrs. Valve regulated
batteries of several types can also be recharged at the 8
hour rates when equipped with a properly programmed
BID Module.
The EQUINOX always defaults to the BID mode when
an installed BID Module is detected. 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 mismatching batteries and chargers. In
applications where some batteries are to be opportunity
charged, while others require 8 hour charge profiles the
BID and EQUINOX provide the most flexible solution.
Opportunity Charging
In applications utilizing opportunity charging, the high
current output of the EQUINOX 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.
FIGURE 3-1

3-2 April 26, 2007
193111-075
DESCRIPTION OF EQUIPMENT
EQUINOX Control
The extreme flexibility of the EQUINOX lies in the state
of the art micro controller used in the EQUINOX charger
control.
The EQUINOX control is made up of three main
components: the Control and Regulator Boards, and
the Keypad/Display. The Control portion provides the
basic operating features of the charger, such as auto
start/stop, auto equalize, charge cycle review, real time
clock, communications, etc. The Regulator portion
actually controls the firing or switching of the IGBTs,
thus controlling the chargers DC output.
The Keypad/Display provides the user interface with the
charger. The durable membrane keypad is impervious
to moisture and mechanical shock. The bright, 2 line,
20 character, alphanumeric, vacuum fluorescent display
constantly shows the charger’s output volts, amps, and
amp hours returned during the charge cycle. The
display also provides the user with plain English
messages concerning charge cycle status.
Four bright LEDs molded into the keypad keep the user
informed of charge status at a glance, even from long
distances. LEDs notify you that a charge is in progress,
that the battery is 80% charged, equalize cycle, charge
complete, and fault indication.
WARNING: Do not connect a
battery to this charger if any LED
lamp is lit. 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 cigarettes
away. Ventilate when charging
in an enclosed area. Always shield
eyes when working near batteries.

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 the 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. 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.
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 errone-
ous 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.
April 26, 2007 4-1
193111-075
INSTALLATION
INSTALLATION

193111-075
INSTALLATION
4-2 Revised October 20, 2008
Table 4-1 Recommended AC Input and Branch Fusing
LINE AMPS DISCONNECT
SWITCH *
BRANCH FUSE SIZE
(AMPERES)
COPPER CABLE SIZE AWG * *
POWER GROUND
0-2.5 30A 5 No. 14 No. 14
2.6-4.5 30A 7 No. 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
18.1-24 30A 30 No. 10 No. 10
24.1-32.5 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 temperatures.
Refer to National Electrical Code (2005) 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 2005 – Table 250-95).
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 changeover
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. A “WARNING” label inside
charger also lists fuse sizes for each line voltage
(circled fuse rating is required for internal line
voltage connections made at factory).
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.
(Charger cabinet top or side panel, or both, may
have to be removed to provide access to terminal
block.)