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

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

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

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.)

193111-075

INSTALLATION

April 26, 2007 4-3

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 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 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.

Note: If this charger is equipped with certain

optional features, the connector attaching

procedure may be modified. Refer to

OPTIONS chapter of this manual for details.

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 program-

mable control settings may be desirable. The most

common changes are listed below:

TIME

Factory Setting for Time is Eastern Standard.