OWNER’S MANUAL 193111-049

Revised December 10, 2008

IMPORTANT: Read these instructions before installing, operating, or

servicing this system.

POWER PRO
FERRO 100 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 100 T

3 Phase Input Power

100% Rated Suffix

Ferroresonant

Ampere-Hour Capacity in 8 Hours

Number of Cells

NOTE: This information is required for ordering certain replacement/service parts.

 193111-049
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

3 PHASE PARTS LIST .............................................................................................................................. 7

1 PHASE PARTS LIST .............................................................................................................................. 8

WARRANTY

August 9, 2002 Page 1

 193111-049
INTRODUCTION

INTRODUCTION
How To Use This Manual NOTE offers helpful information concerning
certain operating procedures. Notes will be
shown in italics.

IMPORTANT: It is especially Equipment Identification

important that all charger
internal components be kept The unit's identification number (specification, model,
clean and dry, and all serial number) usually appears on a nameplate
attached to the front panel.
electrical connections as
tightened as instructed in the
Maintenance chapter of this Receipt Of Equipment
manual. Replace any
precautionary or instruction When you receive the equipment, check it against the
label that cannot be easily invoice to make sure it is complete and inspect the
read. 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
Throughout this manual, the words WARNING, numbers (if any) as described above along with a full
CAUTION, and NOTE may appear. Pay particular description of the parts in error.
attention to the information provided under these
headings. These special annotations are easily Move the equipment to the site of installation before
recognized as follows: 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

WARNING gives information contacting Ametek/Prestolite Power Troy OH 45373,
regarding possible personal include the Owner's Manual number and equipment
injury. Warnings will be identification numbers.
enclosed in a box such as this.

CAUTION refers to possible equipment

damage. Cautions will be shown in bold
type.

August 9, 2002 1-1

 193111-049
SAFETY INSTRUCTIONS AND WARNINGS

SAFETY INSTRUCTIONS AND WARNINGS

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

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193111-049
SAFETY INSTRUCTIONS AND WARNINGS

C. Burn and Bodily Injury Prevention

The battery produces very high currents when short DANGER: ELECTRICAL SHOCK
circuited, and will burn the skin severely if in contact CAN BE FATAL. If person is
with any metal conductor that is carrying this current. unconscious and electric shock
Do not permit rings on fingers to come in contact with
battery terminals or the cell connectors on top of the is suspected, do not touch
battery. person if he or she is in contact
with charging leads, charging
Battery acid is very corrosive. Always wear correct eye equipment, or other live electrical
and body protection when near batteries. parts. Disconnect (open) power
at wall switch and then use
D. Fire and Explosion Prevention
First Aid. Dry wood, wooden
Batteries give off explosive flammable gases which broom, and other insulating
easily ignite when coming in contact with an open flame material can be used to move
or spark. Do not smoke, cause sparking, or use open cables, if necessary, away from
flame near batteries. Charge batteries only in person. IF BREATHING IS
locations which are clean, dry, and well ventilated.
Do not lay tools or anything that is metallic on top of DIFFICULT, give oxygen. IF NOT
any battery. All repairs to a battery must be made only BREATHING, BEGIN ARTIFICIAL
by experienced and qualified personnel. BREATHING, such as mouth-to-
mouth. IF PULSE IS ABSENT,
E. Arcing and Burning of Connector BEGIN ARTIFICIAL CIRCULATION,
such as external heart massage.
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. IN CASE OF ACID IN THE EYES, flush very well
with clean water and obtain professional medical
F. Medical and First Aid Treatment attention immediately.

First aid facilities and a qualified first aid person should

be available for each shift for immediate treatment of
electrical shock victims. G. Equipment Warning Labels
Inspect all precautionary labels on the equipment.
Order and replace all labels that cannot be easily read.
EMERGENCY FIRST AID: Call
physician and ambulance
immediately. Use First Aid
techniques recommended by the
American Red Cross.

2-2 August 9, 2002

 193111-049
INITIAL SET-UP & DESCRIPTION

INITIAL SET-UP & DESCRIPTION

Charger Cell Size Selection
The basic charging circuit is the silicon diode, From the data plate on the charger, note the voltage
rectifier-type with ferroresonant transformer (s). output. Place the corresponding DIP switch (S1) on
This ferroresonant transformer design regulates the Control in the “Closed” position.
charging current by allowing the battery to
determine its own charge cycle rate in accordance S1-1 12 Volts
with its state of discharge. It provides a constantly-
S1-2 24 Volts
tapering charge that eliminates the possibility of
overcharging, even with line voltage variations of S1-3 36 Volts
± 10%. Single-phase input chargers have one
S1-4 48 Volts
transformer, three-phase input chargers have two.
The charger is internally protected from overload S1-5 Optional
and short circuits.
Only one of the above DIP switches should be in the
When charging lead acid batteries, with the same “Closed” position at any one time.
number of cells and ampere-hour capacity as shown
on charger nameplate, the charging time will be Auto Equalize
approximately 8 hours. Batteries of smaller or
larger ampere-hour capacities can also be charged, Switch S1-6 can be used to select either Auto
but will require shorter or longer charging, Equalize or Manual Equalize.
respectively.

WARNING: Do not connect a S1-6 Equalize Type

battery to this charger if any LED
is lit. Do not disconnect a battery Open Auto Equalize every 5th Cycle
from this charger while a charge
Closed Manual Equalize
is in progress. Otherwise, arcing
and burning of connector parts or
a battery explosion may result.
Batteries produce explosive gases. Termination Type
Keep sparks, flame, and cigarettes
away. Ventilate when charging in Switch S1-7 can be used to select either 2.37 V/C or
an enclosed area. Always shield 2.45 V/C 80% Trip Point.
eyes when working near batteries.

S1-7 80% V/C

Open 2.37

Set-Up Closed 2.45

See Location Diagram of Selector Switches in-

cluded in this manual.

For proper operation, the Control must be set to

match the charger in which it is installed.

August 9, 2002 3-1

193111-049
INITIAL SET-UP & DESCRIPTION

Charger Control All front panel information (including operation

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

3-2 August 9, 2002

 193111-049
INSTALLATION

INSTALLATION
Location In addition to the usual function of protecting personnel
against the hazard of electrical shock due to fault in the
For best operating characteristics and longest unit life, equipment, grounding serves to discharge the static
take care in selecting an installation site. Avoid electrical charges which tend to build up on the
locations exposed to high humidity, dust, high ambient surfaces of equipment. These static charges can
temperature, or corrosive fumes. Moisture can cause painful shock to personnel, and can lead to the
condense on electrical components, causing corrosion erroneous conclusion that an electrical fault exists in
or shorting of circuits (especially when dirt is also the equipment.
present).
If a charger is to be connected to the AC power supply
Adequate air circulation is needed at all times in order with a flexible jacketed cable, one having a separate
to assure proper operation. Provide a minimum of 6 grounding conductor should be used. When included
inches of free air space at rear and sides of the unit. in cable assembly, grounding conductor will be green,
Make sure that ventilation openings are not obstructed. green with a yellow stripe, or bare. When connecting
Always remove the charger shipping skid from the unit input power to charger (as instructed in Line
before installation. The charger must be installed over Connection to Battery Charger section of this manual),
a noncombustible surface such as concrete or metal. connect grounding conductor to equipment grounding
Keep the charging area clear of all combustible terminal (stud with a green nut and a cup washer and
material such as wood, paper, and cloth. identified by symbol ), taking care to make a
good electrical connection. Connect other end of
WARNING: SPARKS OR MOLTEN METAL falling grounding conductor to the system ground.
through open bottom can cause fire or explosion. If, for any reason, an input cable which does not in-
• Install over noncombustible material such as clude a grounding conductor is used, the equipment
concrete or metal. must be grounded with separate conductor. Minimum
size and color coding requirements must be in accor-
dance with any applicable state or local code, or the
• Keep charging area clear of combustible
National Electrical Code.
material.
If metallic armored cable or conduit is used, the metal
Environmental Characteristics sheathing or conduit must be effectively grounded as
required by state or local code, or the National
Operating Characteristics 0°C to 40°C Electrical Code.
(32°F to 104°F)
If a system ground is not available, the charger frame
Operating Altitude To 2000 Meters must be connected to a driven ground rod (at least 8 ft
(6562 Feet) [2438 mm] long), or to a water pipe that enters the
Operating Humidity 80% up to 31°C, ground not more than 10 ft (3048 mm) from the
decreasing to 50% at charger. A grounding conductor must be connected to
40°C, non-condensing the rod or pipe in a manner that will assure a
permanent and effective ground. The conductor must
80% up to 88°F be sized in accordance with any applicable state or
decreasing to 50% at local code, or by the National Electrical Code. If in
104°F, non-condensing doubt, use the same size conductor as is used for the
conductors supplying power to the charger.
Grounding
The frame of the power source must be grounded for WARNING: ELECTRIC SHOCK Hazard -
personnel safety. Where grounding is mandatory Under no circumstance should you use
under state or local codes, it is the responsibility of the
user to comply with all applicable rules and regulations.
a grounding conductor with a current
Where no state or local codes exist, it is recommended carrying capacity less than the ampere
that the National Electrical Code be followed. rating shown in Table 4-1.

August 9, 2002 4-1

193111-049
INSTALLATION

DISCONNECT BRANCH FUSE SIZE COPPER CABLE SIZE AWG * *

LINE AMPS SWITCH * (AMPERES)
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
18.1-22 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).

Line Voltage Changeover CAUTION: INCORRECT CONNECTIONS

AND INCORRECT FUSE SIZE can damage
Instructions this equipment. Follow voltage changeover
instructions carefully.
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
Line Connections to Battery Charger
is factory connected.
Follow local code requirements if different than
2. If charger is not connected correctly, check serial instructions in this manual.
nameplate to determine that charger is equipped
to be connected for available line voltage. If 1. Turn charger OFF.
charger is suitably equipped, make voltage change-
over connections by following instructions on AC 2. Be sure charger is connected correctly for available
INPUT label inside charger. line voltage as instructed above.

3. If charger is reconnected, check input fuse (s) 3. On charger nameplate, note the AC input amperes
ratings with ratings specified on label and replace corresponding to the line voltage to which charger
if necessary. is to be connected. Use that ampere value to select
the proper disconnect switch, fuse, and power cable
sizes from Table 4-1.

4-2 August 9, 2002

 193111-049
INSTALLATION

4. Route AC power input cable in through knock-out Pre-operation Checks

provided in side panel of charger cabinet. Securely
fasten cable wires to a power input terminal inside 1. Inspect charger thoroughly for damage; loose
charger. Refer to Grounding section of this manual screws, nuts, or electrical connections.
for proper connection of grounding conductor.
(Charger cabinet top or side panel, or both, may
have to be removed to provide access to terminal WARNING: ELECTRICAL SHOCK
block.) HAZARD – Before inspecting or
cleaning inside cabinet, turn OFF
5. With disconnect switch (on AC input power line) in and remove fuses of disconnect
“OPEN” or “OFF” position, connect power cable switch (supplying AC power to
coming from charger, to the switch. Install fuses in
switch. charger), disconnect battery, and
check for voltage on capacitors.
Charging Cable Connectors Discharge through insulated
screwdriver if there is any reading.
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. 2. Remove all special tags that are tied to charger.
Keep tags with this manual for future reference.
If connectors must be attached to charging cables, Leave all precautionary and instruction labels in
follow instructions supplied with connectors. place on charger. Carefully read and follow
instructions on all tags and labels. Make sure all
CAUTION: Make sure connectors are labels remain visible to anyone operating charger.
securely attached to cables (good
solder joint or well tightened set screws, 3. Make sure all charger cabinet panels are fastened
whichever is applicable). Be certain in place, to assure proper flow of ventilating air
that positive charger cable will connect through cabinet.
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.

August 9, 2002 4-3

 193111-049
OPERATION

OPERATION
A. Preliminary B. Normal or Daily Charge
Make sure the charger is installed and grounded as WARNING: DO NOT connect a battery to
instructed in the INSTALLATION chapter of this this charger if the “Charge in Progress”
manual. LED is lit. Do not disconnect a battery from
this charger while a charge is in progress;
Maintain electrolyte level in the batteries to be otherwise, arcing and burning of connector
charged, as instructed by the battery manufacturer. parts or a battery explosion may result.
Because the volume of electrolyte expands during Batteries produce explosive gases. Keep
the charging process, only add water when the sparks, flame, and cigarettes away.
battery is at least 80% charged. An amber light will Ventilate when charging in an enclosed
be illuminated on the charger control panel when area. Always shield eyes when working
the battery is at or above 80% charge. near batteries.

Insure the battery size matches the charger.

1. Insure the battery size matches the charger
Battery number of cells must equal the number of (Battery voltage and ampere hour capacity are
cells stated on the charger data plate. within nameplate information).

Battery ampere-hour capacity must be within the 2. Securely engage the battery and charger
ampere-hour range stated on the charger data connectors.
plate.
3. After a five second delay (all LED‘s will be lit),
the charger will turn on. The “Charge in
WARNING: EXPLOSION HAZARD – Do not Progress” LED will indicate charging current.
connect a battery to this charger if the
“Charge in Progress” LED is illuminated on 4. The “80% CHARGED” LED will light when the
the charger. Do not disconnect a battery battery on charge reaches the 80% charged
from this charger if the “Charge in Progress” voltage.
LED is illuminated or ammeter is indicating
charging current; otherwise, arcing and 5. The charger will automatically turn off and the
burning of connector parts can occur or a “Charge Complete” LED will light when the
battery explosion may result. Batteries charge has finished. reaching 80% charge.
produce explosive gases. Keep sparks, The light will remain on until the battery is
flames, and cigarettes away. Ventilate when disconnected from the charger.
charging in an enclosed area. Always
shield eyes using face shield and goggles
when working near batteries. NOTE: To disconnect battery from charger before
charge is complete, first press the “Manual
Stop” key, then disconnect the battery
from the charger.
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.

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193111-049
OPERATION

C. Equalize Or Weekend Charge D. Manual Stop

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

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 193111-049
MAINTENANCE

MAINTENANCE
Lubrication
WARNING: ELECTRICAL SHOCK
HAZARD — Before inspecting or None required.
cleaning inside cabinet, turn OFF
and remove fuses of disconnect
switch (supplying AC power to Fuse Replacement
charger), disconnect battery, and
check for voltage on capacitors. The silicon diodes in this charger are protected by a
Discharge through insulated “fast-clearing” type fuse.
screwdriver if there is any reading.
CAUTION: The use of any other type
fuse besides the “fast-clearing” type
may cause damage to silicon diodes.
Inspection And Cleaning
Silicon Diode Testing
For uninterrupted, satisfactory service from this
charger, it's necessary to keep unit clean, dry, and well WARNING: ELECTRICAL SHOCK
ventilated. At least every three months, or more often HAZARD — Before checking electrical
as necessary, wipe and blow out all dirt from unit's components, turn OFF and remove
interior components, with clean, dry air of not over fuses of disconnect switch (supplying
25 psi (172 kPa) pressure. Use a hand bellows if AC power to charger), disconnect
compressed air isn't available. battery, and check for voltage on
capacitors. Discharge through insulated
Check and tighten all electrical connections as screwdriver if there is any reading.
necessary to eliminate unnecessary losses and to
avoid subsequent trouble from overheating or open
circuits. Check for broken wiring or damaged insulation 1. Disconnect one diode lead to isolate diode from
on wiring. electrical circuitry.

2. Use a good quality ohmmeter (preferably one

WARNING: ELECTRICAL SHOCK having a mid-scale value of approximately
HAZARD — Failure to keep internal 50 ohms) to measure resistance values.
parts clean and dry may allow
transformer (s) to short out, 3. Zero ohmmeter on R x 1 scale.
causing secondary circuits to
carry dangerously high voltage. 4. Record indicated resistance while placing either
ohmmeter lead on threaded end of diode and
other ohmmeter lead on diode lead.

Be sure to replace all charger cabinet panels after any 5. Reverse ohmmeter leads on diode and record
servicing, to assure proper flow of cooling air through indicated resistance.
unit and to protect internal components.
6. Consider diode good if one resistance reading is
infinitely (or very) high and the other is extremely
WARNING: ELECTRICAL SHOCK low.
HAZARD — All cabinet panels must
be replaced to protect personnel from NOTE: An acceptable low resistance value
contact with hazardous voltages. or range of values can't be given because of
different readings from different ohmmeters,
and differences in diodes of the same rating.

August 9, 2002 6-1

193111-049
MAINTENANCE

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.

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.

6-2 August 9, 2002

 193111-049
MAINTENANCE

Troubleshooting

DANGER: 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.

CAUTION: HIGH VOLTAGE FROM TEST EQUIPMENT can damage silicon diodes and other
parts. Short silicon diodes with extremely short leads, or disconnect, before applying voltage
from a "megger" or other high voltage test equipment.

The following chart contains information which can be used to diagnose and correct unsatisfactory operation
or failure of various components of the unit. Each malfunction is followed by a suggested checking or inspection
procedure. Refer to Connection/Schematic Diagram in the Diagrams chapter included in this manual.

Troubleshooting Guide

No charging current (Ammeter reads zero)

Check line voltage.

Close fused disconnect switch or repair open circuit.

Check for proper line voltage.

Refer to Line Voltage Changeover instructions in Installation chapter.

Check for blown fuses.

Replace blown fuses. See Table 4-1 for proper fuse sizes.

Check for internal short circuit (diode, winding, wiring).

Repair short circuit, or replace faulty component.

Check for "open" battery circuit.

Clean and tighten connections, especially battery cable connections.

Check Charge Control.

Connect a jumper from the red-white lead of Control Transformer T1 to the red
lead of Contactor K1 coil. If charger starts and ammeter shows charging current
when a battery is connected, check further for faulty printed circuit card on control
and replace as necessary.

Check output circuit fuses. If fuse has blown, check for problem causing fuse to blow.

a. Reverse battery connections, if polarity is wrong.

b. Determine whether a diode is shorted. Refer to Silicon Diode Testing in Maintenance

chapter.

August 9, 2002 6-3

193111-049
MAINTENANCE

Low charging current at beginning of cycle (battery fully discharged)

Check for failed capacitor (s) (one or more).

Replace capacitor if can is ruptured or fails test. Refer to Capacitor Testing in Maintenance chapter.

Check line voltage for connection to proper input voltage.

Refer to Line Voltage Changeover instructions in Installation chapter.

Check battery for one or more defective cells.

Less than rated output on fully discharged battery (approximately 1/2 rated output) (3-phase
chargers only)

Check for either a shorted transformer, or wiring short circuit.

Replace as necessary.

Charger does not shut OFF automatically or start automatically

Check Charge Control.

1. If charger does not start automatically, check for 24 volts AC between the red-white lead and
the red-black wire of control transformer T1. If 24V AC is present, connect a jumper from the
red-white lead of control transformer T1 to the red lead of contactor K1 coil. If charger
starts, check further for faulty printed circuit card on control and replace as necessary.

2. If charger does not stop automatically when equipped with pt/dv/dt control,
check to be sure charging voltage rises above 2.37 volts/cell during the cycle. If not, see low
charging current or less than rated output above. If battery on-charge voltage rises above
2.37 volts/cell during the cycle, check for defective control printed circuit card.

6-4 August 9, 2002

 193111-049
MAINTENANCE

DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and
remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for
voltage on capacitors. Discharge through insulated screwdriver if there is any reading.

August 9, 2002 6-5

193111-049
MAINTENANCE

DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and
remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for
voltage on capacitors. Discharge through insulated screwdriver if there is any reading.

6-6 August 9, 2002

 193111-049
MAINTENANCE

DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and
remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for
voltage on capacitors. Discharge through insulated screwdriver if there is any reading.

August 9, 2002 6-7

193111-049
PARTS LIST (3 PHASE)

Figure 7-1 (3 PHASE)

7-1 August 9, 2002

 193111-049
PARTS LIST (3 PHASE)

ITEM NO. PART NO. DESCRIPTION

1 195534 Base, Charger

2 195535 Panel, Rear

3 195537 Panel, Side, Left

4 195536 Panel, Side, Right

5 195540-002 Meter, DC Amps

6 195538 Panel, Top

7 195539 Panel, Front

8 195251 Overlay, Charger

9 195531 Label, DC Output

10 194002 Heat Sink, Flat

11 194122 Heat Sink, Formed, 45

12 404033 Insulator, Standoff

13 See Table Diode, Silicon

14 195529-001 Control, Charger

15 See Table Transformer, Power, Teaser

16 See Table Transformer, Power, Main

17 See Table Transformer, Control

18 357205-060 Jumper, Orange

19 357205-061 Jumper, White

20 See Table Capacitor, Trans.

21 See Table Contactor, AC Input, Line

22 See Table Fuse, Output

23 392458 Bus Bar

24 W10080-005 Connector, Output Cable

25 See Table Cable, Output

26 378234-013 Covering, Flex Cable

August 9, 2002 7-2

193111-049
PARTS LIST (3 PHASE)

ITEM NO. PART NO. DESCRIPTION

27 Call Factory Block, Terminal

28 406434 Label, Warning, Sparks

29 405548 Label, Supply Connections

30 See Table Label, AC Input

31 404099 Label, Danger

32 195532 Label, Caution, Input Service

33 406518 Label, Warning

34 402037-027 Grommet, Rubber

35 406593 Label, Input Service

7-3 August 9, 2002

 3 PHASE
208/240/480 VOLT
UNITS
AC

August 9, 2002
MODEL OUTPUT T2 T3 DIODE CAPS INPUT CONTROL OUTPUT
NUMBER SPEC FUSE TRANS TRANS CONTACTOR (4 Required) /TRANS LABEL TRANS CABLE
12-510FR100T 500522-1 409023-4 195082 195083 406243-1 193143-1 TRY-154-4 191457 406247-2 396143-2
12-600FR100T 500523-1 409023-4 195091 195092 406243-1 193143-1 TRY-154-4 191457 406247-2 396143-2
12-750FR100T 500524-1 409023-5 195100 195101 406243-1 402832-3 TRY-154-6 191457 406247-2 396143-4
12-880FR100T 500525-1 409023-6 195109 195110 406243-1 402832-3 TRY-154-4 191457 406247-2 396143-4
TRY-154-1
12-1050FR100T 500526-1 409023-7 195118 195119 406243-1 402832-3 TRY-154-4 191457 406247-2 396143-5
TRY-154-1
18-510FR100T 500527-1 409023-4 195127 195128 406243-1 193143-1 TRY-154-4 191457 406247-2 396143-2
18-600FR100T 500528-1 409023-4 195136 195137 406243-1 193143-1 TRY-154-4 191457 406247-2 396143-2
TRY-154-2
18-750FR100T 500529-1 409023-5 195145 195146 406243-1 402832-3 TRY-154-4 191457 406247-2 396143-4
TRY-154-2
18-880FR100T 500530-1 409023-6 195154 195155 406243-1 402832-3 TRY-154-6 191457 406247-2 396143-4
18-965FR100T 500531-1 409023-7 195163 195164 406244-1 402832-3 TRY-154-4 191457 406247-2 396143-5
TRY154-2
18-1050FR100T 500532-1 409023-7 195172 195173 406244-1 402832-3 TRY-154-4 191457 406247-2 396143-5
TRY-154-2
18-1100FR100T 500533-1 409023-8 195181 195182 406244-1 402832-3 TRY-154-4 191457 406247-2 396143-5
TRY-154-2
18-1200FR100T 500534-1 409023-8 195190 195191 406244-1 402832-3 TRY-154-4 191457 406247-2 396143-5
TRY-154-3
24-450FR100T 500535-1 409023-4 195199 195200 406243-1 193143-1 TRY-154-6 191457 406247-2 396143-2
24-600FR100T 500536-1 409023-4 195208 195209 406243-1 193143-1 TRY-154-6 191457 406247-2 396143-2
24-750FR100T 500537-1 409023-5 195217 195218 406244-1 402832-3 TRY-154-4 191457 406247-2 396143-4
TRY-154-2
24-880FR100T 500538-1 409023-6 195226 195227 406244-1 402832-3 TRY-154-6 191457 406247-2 396143-4
24-965FR100T 500539-1 409023-7 195235 195236 406244-1 402832-3 TRY-154-6 191457 406247-2 396143-5

7-4
PARTS LIST (3 PHASE)
193111-049
 3 PHASE

7-5
480/575 VOLT
UNITS
193111-049

AC
MODEL OUTPUT T2 T3 DIODE CAPS INPUT CONTROL OUTPUT
NUMBER SPEC FUSE TRANS TRANS CONTACTOR (4 Required) /TRANS LABEL TRANS CABLE
12-510FR100T 500522-2 409023-4 195086 195087 406243-1 193143-1 TRY-154-4 191252 406247-4 396143-2
PARTS LIST (3 PHASE)

12-600FR100T 500523-2 409023-4 195095 195096 406243-1 193143-1 TRY-154-4 191252 406247-4 396143-2
12-750FR100T 500524-2 409023-5 195104 195105 406243-1 402832-3 TRY-154-6 191252 406247-4 396143-4
12-880FR100T 500525-2 409023-6 195113 195114 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-4
TRY-154-1
12-1050FR100T 500526-2 409023-7 195122 195123 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-5
TRY-154-1
18-510FR100T 500527-2 409023-4 195131 195132 406243-1 193143-1 TRY-154-4 191252 406247-4 396143-2
18-600FR100T 500528-2 409023-4 195140 195141 406243-1 193143-1 TRY-154-4 191252 406247-4 396143-2
TRY-154-2
18-750FR100T 500529-2 409023-5 195149 195150 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-4
TRY-154-2
18-880FR100T 500530-2 409023-6 195158 195159 406243-1 402832-3 TRY-154-6 191252 406247-4 396143-4
18-965FR100T 500531-2 409023-7 195167 195168 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-5
TRY154-2
18-1050FR100T 500532-2 409023-7 195176 195177 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-5
TRY-154-2
18-1100FR100T 500533-2 409023-8 195185 195186 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-5
TRY-154-2
18-1200FR100T 500534-2 409023-8 195194 195195 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-5
TRY-154-3
24-450FR100T 500535-2 409023-4 195203 195204 406243-1 193143-1 TRY-154-6 191252 406247-4 396143-2
24-600FR100T 500536-1 409023-4 195212 195213 406243-1 193143-1 TRY-154-6 191252 406247-4 396143-2
24-750FR100T 500537-1 409023-5 195221 195222 406243-1 402832-3 TRY-154-4 191252 406247-4 396143-4
TRY-154-2
24-880FR100T 500538-1 409023-6 195230 195231 406243-1 402832-3 TRY-154-6 191252 406247-4 396143-4
24-965FR100T 500539-1 409023-7 195239 195240 406243-1 402832-3 TRY-154-6 191252 406247-4 396143-5

August 9, 2002
 193111-049
DIAGRAMS (3 PHASE)

DIAGRAMS - 3 PHASE

DIAGRAM DIAGRAM
MODEL NO. OUTPUT SCHEMATIC OUTPUT SCHEMATIC DIMENSIONAL
INFORMATION 208/240/480 VOLTS 480/575V OUTLINE

3 PHASE
195432 195541 195542
(2 TRANSFORMERS)

See model number description inside front cover.

August 9, 2002
193111-049
PARTS LIST (1 PHASE)

Figure 8-1 SINGLE PHASE

8-1 December 10, 2008

 193111-049
PARTS LIST (1 PHASE)

ITEM NO. PART NO. DESCRIPTION

1 191578 Panel, Rear

2 191580 Panel, Side, Right

3 191580 Panel, Side, Left

4 191581 Top

5 192983 Panel, Front

6 See Table Meter DC Amps

7 191574 Base

8 195251 Overlay, Charger

9 195532 Label, Caution AC Input

10 195529-001 Board, PC, Ay

11 357205-060 Jumper, Orange (2 Required)

12 357205-061 Jumper, White (2 Required)

13 See Table Capacitor, AC Oil

14 TRY174-003 Bracket, Capacitor

15 See Table Transformer, Control

16 406434 Label, Warning, Input

17 See Table Transformer, T2

18 Contact Factory Terminal Block

19 392458 Bus Bar (2 Required)

20 See Table Fuse, Output.

21 See Table Contactor, Line

22 See Table Rectifier Ay

23 378234-013 Cover, Outer Neoprene

24 W10080-005 Connector, Strain Relief

25 See Table Cable, Output

26 See Table Label, AC Input

December 10, 2008 8-2

193111-049
PARTS LIST (1 PHASE)

ITEM NO. PART NO. DESCRIPTION

27 404099 Label, Danger

28 406518 Label, Warning

29 195531 Label, DC Fuse

30 406593 Label, AC Input

31 405548 Label, Frame Ground

32 406748 Label, AC Line Connections, 120V

33 195856 Harness, Wire (Not Shown)

8-3 December 10, 2008

 1 PHASE
208/240/480 VOLT UNITS
AC
MODEL OUTPUT DC T2 CAPS RECTIFIER INPUT CONTROL OUTPUT
NUMBER SPEC FUSE METER TRANS CONTACTOR /TRANS ASSEMBLY LABEL TRANS CABLE

December 10, 2008

6-450FR100S 500708-1 409023-4 195540-2 196678 406240-1 TRY-154-4 196699-1 406461 406247-2 396143-2
12-450FR100S 500709-1 409023-4 195540-2 196679 406240-1 TRY-154-6 196699-1 406461 406247-2 396143-2
12-510FR100S 500710-1 409023-4 195540-2 196680 406240-1 TRY-154-6 196699-1 406461 406247-2 396143-2
12-600FR100S 500711-1 409023-4 195540-2 196682 406240-1 TRY-154-6 196699-2 406461 406247-2 396143-2
12-750FR100S 500712-1 409023-5 195540-2 196683 406240-1 TRY-154-6 196699-2 406461 406247-2 396143-4
12-880FR100S 500713-1 409023-6 195540-2 196685 406240-1 TRY-154-6 196699-3 406461 406247-2 396143-4
TRY-154-6
18-450FR100S 500714-1 409023-4 195540-2 196687 406240-1 TRY-154-6 196699-1 406461 406247-2 396143-2
TRY-154-2
18-510FR100S 500715-1 409023-4 195540-2 196689 406240-1 TRY-154-6 196699-1 406461 406247-2 396143-2
TRY-154-1
18-600FR100S 500716-1 409023-4 195540-2 196691 406240-1 TRY-154-6 196699-2 406461 406247-2 396143-2
TRY-154-4
24-380FR100S 500717-1 409023-3 195540-1 196693 406240-1 TRY-154-6 196699-1 406461 406247-2 396143-1
TRY-154-1

8-4
PARTS LIST (1 PHASE)
193111-049
8-5
1 PHASE
480/575 VOLT UNITS
193111-049

AC
MODEL OUTPUT DC T2 CAPS RECTIFIER INPUT CONTROL OUTPUT
NUMBER SPEC FUSE METER TRANS CONTACTOR /TRANS ASSEMBLY LABEL TRANS CABLE
12-510FR100S 500710-2 409023-4 195540-2 197873 406240-1 TRY-154-6 196699-1 191655 406247-4 396143-2
PARTS LIST (1 PHASE)

December 10, 2008

 193111-049
DIAGRAMS (1 PHASE)

DIAGRAMS - 1 PHASE

DIAGRAM DIAGRAM
MODEL NO. OUTPUT SCHEMATIC OUTPUT SCHEMATIC DIMENSIONAL
INFORMATION 208/240/480 VOLTS 480/575V OUTLINE

1 PHASE
195433 197871 195859
(1 TRANSFORMER)

See model number description inside front cover.

December 10, 2008

 WARRANTY
AMETEK/PRESTOLITE POWER “POWER PRO” BATTERY CHARGERS

AMETEK/Prestolite Power (hereinafter called “Prestolite”) warrants that each new and unused Power Pro Battery Charger manufactured
and supplied by it is of good workmanship and is free from any inherent mechanical defects, provided that (1) the product is installed and
operated in accordance with generally accepted industrial standards and in accordance with the printed instructions of Prestolite, (2) the
product is used under normal conditions for which designed, (3) the product is not subjected to misuse, negligence or accident, and (4) the
product receives proper care, protection and maintenance under supervision of competent personnel. This warranty is subject to the
following provisions:

1.PRODUCTS AND PARTS WARRANTED. Subject to the exceptions listed below each Power Pro Battery Charger is warranted for
a period of one (1) year from the date of its shipment by Prestolite, provided the charger is used in accordance with Prestolite’s published
performance rating for the unit involved. The exceptions to this warranty are as follows:
a) Power transformers and diodes on unit(s) are warranted for ten (10) years after Prestolite’s shipment of the unit(s) of which they
are a part, provided, however, that during the last nine (9) years of this ten (10) year period the warranty covers parts
replacement only-no labor or other services are provided by Prestolite, nor shall Prestolite be obligated to reimburse the owner
or any other person for any work performed.
b) Primary switch contacts, fuses, bulbs, and filters are not warranted unless found to be defective prior to use.

2.COMMENCEMENT OF WARRANTY TIME PERIODS. The warranty periods indicated in the Warranty Schedule shall
commence on the date of shipment by Prestolite.

3.PERSONS COVERED BY WARRANTY. This warranty is extended by Prestolite only to the purchaser of new equipment from
Prestolite or one of its authorized distributors. The products purchased under this agreement shall be used exclusively by the buyer and
its employees and by no other persons, and therefore there shall be no third party beneficiary to this warranty.

4.LIMITATION OF REMEDY. The existence of claimed defects in any product covered by this warranty is subject to Prestolite’s
factory inspection and judgment. Prestolite’s liability is limited to repair of any defects found by Prestolite to exist or, at Prestolite’s
option, the replacement of the defective product. F.O.B. factory after the defective product has been returned by the purchaser at its
expense to Prestolite’s shipping place. Replacement parts will be warranted for the remainder of the original Power Pro Battery Charger
Warranty or for a period of ninety (90) days, whichever is greater.

PRESTOLITE and its authorized distributors or dealers shall not be liable for direct or indirect, special or consequential damages in
excess of such repair or replacement. In no event shall the purchaser be entitled to recover for contingent expenses resulting from, but not
limited to, telephone calls, telegrams, travel expenses, lodging, duties and taxes, labor, rental or replacement equipment, loss of business
or profits or other commercial losses.

5.USE OF DEFECTIVE PRODUCT. Continued use of a Power Pro Battery Charger after discovery of a defect VOIDS ALL
WARRANTIES.

6.ALTERED EQUIPMENT. Except as authorized in writing, the warranty specified does not cover any equipment that has been
altered by any party other that Prestolite.

EXCEPT AS STATED ABOVE, ALL OTHER WARRANTIES AND CONDITIONS, EITHER EXPRESSED OR IMPLIED,
INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE
EXCLUDED AND BUYER ASSUMES ALL RISK AND LIABILITY RESULTING FROM USE OF THE GOODS.
AMETEK/PRESTOLITE POWER NEITHER ASSUMES NOR AUTHORIZES ANY PERSONS TO ASSUME FOR
AMETEK/PRESTOLITE POWER ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OR USE OF THE GOODS
SOLD, AND THERE ARE NO ORAL AGREEMENTS OR WARRANTIES COLLATERAL TO OR AFFECTING THIS WRITTEN
WARRANTY.

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.

AMETEK/PRESTOLITE POWER
TROY, OHIO, U.S.A.

Data Sheet: 1150

Index: 080102
Replaces: Original