OWNER’S MANUAL 193111-030

Revised October 23, 2002

IMPORTANT: Read these instructions before installing, operating, or

servicing this system.

AC1000
CHARGE CONTROL

DO NOT DESTROY

AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

 193111-030
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 .................................................................................................................................. 3

Cell Size Selection............................................................................................................ 3-1
Full Scale Digital Ammeter Selection ................................................................................ 3-1

STANDARD OPERATION ............................................................................................................... 4

AC1000 CONTROL FEATURES ................................................................................................... 5

Main Features................................................................................................................... 5-1
Description of Features..................................................................................................... 5-1

PROGRAMMING THE AC1000 ..................................................................................................... 6

Shunt Size ........................................................................................................................ 6-1
Adjusting the “80% Charged” Trip Point ........................................................................... 6-1
PT/DV/DT Disable ............................................................................................................ 6-1
Automatic Equalize ........................................................................................................... 6-1
Delayed Start .................................................................................................……………..6-2
Refresh Delay ................................................................................................................... 6-2
Push-to-Start or Fault Lockout Operation ......................................................................... 6-2
Cell Forming Cycles.......................................................................................................... 6-2
Cool Down Delay ...........................................................................................……………..6-2
Extra Run Time................................................................................................................. 6-2

TROUBLESHOOTING ...................................................................................................................... 7

PARTS LIST ......................................................................................................................................... 8

ELECTRONIC PRINTED CIRCUIT BOARD EXCHANGE

SERVICE POLICY

WARRANTY

October 30, 1998

 193111-030
INTRODUCTION

INTRODUCTION
How To Use This Manual CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.

NOTE offers helpful information concerning

IMPORTANT: It is especially certain operating procedures. Notes will be
important that all charger shown in italics.
internal components be kept
clean and dry, and all
Equipment Identification
electrical connections The unit's identification number (specification, model,
tightened. Replace any serial number) usually appears on a nameplate
precautionary or instruction attached to the front panel.
label that cannot be easily
read. 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
To ensure safe operation, read the entire manual, there is any damage, notify the carrier immediately to
including the chapter on Safety Instructions and file a claim. Furnish complete information concerning
Warnings. damage claims or shipping errors to the company
shown on the cover of this manual. Include all
Throughout this manual, the words WARNING, equipment identification numbers and group part
CAUTION, and NOTE may appear. Pay particular numbers (if any) as described above along with a full
attention to the information provided under these description of the parts in error.
headings. These special annotations are easily
recognized as follows: 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.
WARNING gives information
Additional copies of this manual may be purchased by
regarding possible personal contacting the company shown on the cover of this
injury. Warnings will be manual. Include the Owner's Manual number and
enclosed in a box such as this. equipment identification numbers.

October 30, 1998 1-1

 193111-030
SAFETY INSTRUCTIONS AND WARNINGS

SAFETY INSTRUCTIONS AND WARNINGS

1. Installation and Grounding of Electrically Powered
FOR OPERATION OF BATTERY Equipment – Electrical equipment must be installed
CHARGING EQUIPMENT and maintained in accordance with the National
Electrical Code, NFPA 70, and local codes. A
power disconnect switch must be located at the
IMPORTANT – READ AND equipment. Check nameplate for voltage and
phase requirements. If only 3-phase power is
UNDERSTAND THESE available, connect single-phase equipment to only
INSTRUCTIONS. DO NOT two wires of the 3-phase line. DO NOT CONNECT
LOSE THEM. ALSO READ the equipment grounding conductor (lead) to the
OPERATING/INSTRUCTION third live wire of the 3-phase line as this makes the
equipment frame electrically HOT, which can cause
MANUAL BEFORE a fatal shock.
INSTALLING, OPERATING,
OR SERVICING THIS If a grounding lead (conductor) is part of the power
EQUIPMENT. 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
A. General any plug. Use correct mating receptacles. Check
ground for electrical continuity before using
Battery charging products can cause serious equipment.
injury or death, or damage to other equipment or
property, if the operator does not strictly observe The grounding conductor must be of a size equal
all safety rules and take precautionary actions. to or larger than the size recommended by Code or
in this manual.
Safe practices have developed from past experience
in the use of charging equipment. These practices 2. Charging Leads – Inspect leads often for damage
must be learned through study and training before to the insulation. Replace or repair cracked or worn
using this equipment. Anyone not having leads immediately. Use leads having sufficient
extensive training in battery charging practices capacity to carry the operating current without
should be taught by experienced operators. overheating.

Only qualified personnel should install, use, or 3. Battery Terminals – Do not touch battery terminals
service this equipment. while equipment is operating.

B. Shock Prevention 4. Service and Maintenance – Shut OFF all power at

the disconnect switch or line breaker before
Bare conductors, or terminals in the output circuit, inspecting, adjusting, or servicing the equipment.
or ungrounded, electrically-live equipment can Lock switch OPEN (or remove line fuses) so that
fatally shock a person. To protect against shock, the power cannot be turned ON accidentally.
have competent electrician verify that the Disconnect power to equipment if it is to be left
equipment is adequately grounded and learn what unattended or out of service.
terminals and parts are electrically HOT.
Disconnect battery from charger.
The body’s electrical resistance is decreased when
wet, Keep inside parts clean and dry. Dirt and/or
permitting dangerous current to flow through the body. moisture can cause insulation failure. This failure
Do not work in damp area without being extremely can result in high voltage at the charger output.
careful. Stand on dry rubber mat or dry wood and use
insulating gloves when dampness or sweat cannot be
avoided. Keep clothing dry.

October 30, 1998 2-1

193111-030
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
with any metal conductor that is carrying this current. CAN BE FATAL. If person is
Do not permit rings on fingers to come in contact with unconscious and electric shock
battery terminals or the cell connectors on top of the is suspected, do not touch
battery. person if he or she is in contact
Battery acid is very corrosive. Always wear correct with charging leads, charging
eye and body protection when near batteries. equipment, or other live electrical
parts. Disconnect (open) power
D. Fire and Explosion Prevention at wall switch and then use
Batteries give off explosive flammable gases which First Aid. Dry wood, wooden
easily ignite when coming in contact with an open broom, and other insulating
flame or spark. Do not smoke, cause sparking, or material can be used to move
use open flame near batteries. Charge batteries only cables, if necessary, away from
in locations which are clean, dry, and well ventilated.
Do not lay tools or anything that is metallic on top of person. IF BREATHING IS
any battery. All repairs to a battery must be made DIFFICULT, give oxygen. IF NOT
only by experienced and qualified personnel. BREATHING, BEGIN ARTIFICIAL
BREATHING, such as mouth-to-
E. Arcing and Burning of Connector mouth. IF PULSE IS ABSENT,
To prevent arcing and burning of the connector BEGIN ARTIFICIAL CIRCULATION,
contacts, be sure the charger is OFF before connect- such as external heart massage.
ing 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 G. Equipment Warning Labels
electrical shock victims. 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 October 30, 1998

 193111-030
INITIAL SET-UP

INITIAL SET-UP
See Location Diagram of Selector Switches included in Full Scale Digital Ammeter Selection
this manual on page 6-1.
From the data plate on the charger, note the DC output
For proper operation, the AC1000 Control must be set per circuit – Max. Amps. Set S1-1 to the “on” position
to match the charger in which it is installed. and using the Equalize and Review Switches, set the
display for the proper value per the following chart.
Cell Size Selection
From the data plate on the charger, note the number of
cells. Place the corresponding DIP switch (S2) on the
AC1000 Control in the “closed” position.

S2-1 6 Cells
DC Output
S2-2 12 Cells per Cir- Full Scale
cuit Current
S2-3 18 Cells
0 – 76 100
S2-4 24 Cells
77 – 171 200
S2-5 36 Cells 172 – 320 400

S2-6 Unique Part Number

Only one of the above DIP switches should be in the

“closed” position at any one time.

March 8, 2000 3-1

 193111-030
STANDARD OPERATION

STANDARD OPERATION
1. Insure that battery size matches charger (Number of
WARNING: Do not disconnect cells and ampere hour capacity are within
a battery from this charger nameplate information).
while the charge in progress 2. Connect AC power to charger.
LED is lit; otherwise, a battery
explosion may result. 3. Connect the battery to the charger.
BATTERIES PRODUCE
4. After a five second downcount, the charger will turn
EXPLOSIVE GASES. Keep on and the “Charge in Progress” LED will light. The
sparks, flame, and cigarettes digital display will indicate output current.
away. Ventilate when charging
in an enclosed area. Always 5. The “80% Charged” LED will light when the battery
shield eyes when working voltage reaches the gassing point (Standard = 2.37
volts/cell).
near batteries.
6. When the charge termination point is reached, the
charger will turn off. The “Charge Complete” LED
will light and the “Equalize” LED will be lit if this was
an equalize charge.

October 30, 1998 4-1

193111-030
AC1000 CONTROL FEATURES

AC1000 CONTROL FEATURES

Main Features 16. 3 Programmable Start Modes
1. 30 Minute pT/dV/dT Charge Termination – Automatic Start (5 Second Delay)
2. Digital Display – Push-To-Start
3. Four LEDs for Status Display; LED lamp test – Delayed Start
provided

4. Manual Stop Capability

Description of Features
5. Review of Charge Cycle Information
Charge Termination — The standard AC1000 utilizes
- Amp hours returned during charge cycle a patented pT/dV/dT technique in order to determine
the charge termination point. This technique returns
- Start to 80% point timer approximately 107% of the amp hours removed from
a battery (regardless of the state of discharge) and
- 80% to pT/dV/dT point timer prevents variations in the incoming AC line voltage
- Open circuit voltage from affecting the amount of energy returned to the bat-
tery. The minimum time required for a pT/dV/dT charge
- Start current termination on the AC1000 Control is ten minutes. The
AC1000 Control can be programmed to utilize a
- Start voltage voltage-time charge termination technique. If the
pT/dV/dT charge termination is disabled, the control will
- Finish current terminate the charge cycle three hours after the battery
- Finish voltage reaches the “80% Charged” point.

- Charge termination code Digital Display — A seven segment, four digit display
is standard on the AC1000 Control. The characters are
6. Automatic, Push-to-Start, or Fault Lock-out a minimum of .56 inches tall, making the information on
Operation the digital display legible at distances exceeding ten
feet. The left hand decimal of the digital display is used
7. Manual or Automatic Equalize Operation to indicate when programmable features are selected.
The decimal will flash at a 25% duty cycle rate when
8. Dual Back-up Timer Shutdowns any programmable feature has been changed from
factory settings. A blank display is utilized for AC
9. One Part Number Control is User/Factory power fail indication.
programmable for 6-12-18-24-36 Cells
and 100-200-400 Amp Digital Ammeter Status Display LEDs — The “Charge In Progress”
LED (Amber) is illuminated whenever the charger is
10. 8-99 Hour Programmable Refresh Charge flowing current to the battery. There are four status
LEDs provided to indicate the present operating status
11. Voltage Time Feature (pT/dV/dT Disable) of the charger and battery (see Figure 5-1). A lamp test
feature is provided. See Review of Charge Cycle
12. “Cell Forming” Feature feature.

13. Low Current Shutdown Disable

14. Digitally Adjustable 80% Point

15. Programmed Features maintained for a minimum

of 10 Years

5-1 October 30, 1998

 193111-030
AC1000 CONTROL FEATURES

Automatic , Push-to-Start Operation, or Fault Lock-

out — In the automatic start mode, the charger will
start five seconds after the battery is connected. The
digital display will count down during this five second
period (i.e., 5-4-3-2-1). In the push-to-start mode, the
charger will not start the charge cycle until the “Push to
Stop/Review” key is pressed. When fault lockout is se-
lected, the charger will not start until the “Stop/Review”
key has been pressed.
Manual or Automatic Equalize — An equalize charge
is a prolonged charge cycle (by 3 hours) used to cor-
rect any inequalities of voltage and specific gravity
which may have developed between the cells during
service. AC1000 Controls are shipped from the factory
with the automatic equalize feature set to every fifth cy-
cle.
After an abnormal shutdown, the Equalize function can
be programmable to equalize from every 1–30 cycles.
When the automatic equalize feature is active, the
“Equalize” key on the front panel is disabled. When
automatic equalize is disabled, an equalize charge is
requested by pressing the “Equalize” key on the front
panel of the AC1000 Control after a battery is con-
nected to the charger. If this key is pressed again dur-
ing the charge cycle, the equalize request will be can-
celed.
Back-Up Timer Shutdown — The standard AC1000
Control has two back-up timers. The charger will
Figure 5-1 Status LEDs and Trouble Chart shutdown and the display will show 0-80% and all leds
will flash if ten hours has passed since the start of a
Review of Charge Cycle — When the charge has charge cycle and the battery has not reached gassing
been terminated, either by the AC1000 Control, the voltage (80% charged), or if five hours has passed
operator, or the removal of battery, the charge cycle since the battery has reached gassing voltage and a
history can be automatically read out by pressing the pT/dV/dT charge termination has not occurred. The
“Stop/Review” key. After displaying the information display will show 80-E and all leds will flash. If the
from memory, the unit will return to the normal (AC1) pT/dV/dT feature has been disabled, only the 10-hour
display. Nine functions are displayed during the charge back-up timer is active.
cycle review. This feature can greatly aid in the One Part Number Control — The standard AC1000
analyzing of charge data and in situations where Control is user/factory programmable for 6, 12, 18, 24,
troubleshooting is required. See the Troubleshooting and 36 cell Accu-Chargers with 100, 200, and 400 amp
chapter in this manual. shunts. Any combination of the above cell sizes and
current shunt sizes can be selected by DIP switches on
Function Description the P.C. boards and programming the control. This
feature reduces the quantity of spare parts inventory.
1 Amp-Hours Returned
See the Initial Set-Up chapter for further information.
2 Start to 80% Time
3 80% to Termination Time
4 Battery Open Circuit Voltage Refresh Charge Feature — A refresh charge of a
5 Start Current storage battery is a charge given to charged and wet
6 Start Volts/Cell batteries which are in storage or inactive periods to
7 Finish Current replace losses due to local action and to insure that
8 Finish Volts/Cell every cell is brought periodically to a full state of
9 Charge Termination Code charge.

Figure 5-2 List of Functions 1-9

October 30, 1998 5-2

193111-030
AC1000 CONTROL FEATURES

The AC1000 Control has an 8 to 99 hour programma-

ble refresh charge timer which starts with a normal 80% Charged Point — A standard AC1000 Control
charge complete, either pT/dV/dT or voltage time. If a will light the “80% Charged” LED and enable the
battery is left connected to the charger for the pro- charge termination routine when the battery voltage
grammed number of hours after a charge complete, reaches 2.37 volts/cell. The 80% charged point can
the control will automatically begin a refresh charge be programmed 2.31 to 2.59 V/C, in 0.02 V/C steps.
cycle. This allows the user to alter the battery’s time on
charge when utilizing the voltage-time charge
The control will start automatically even if programmed termination method.
for delayed start or push-to-start operation. The refresh
charge cycle will not count as a charge cycle if the Battery Voltage Discrimination —– An AC1000
control is programmed to provide an equalize charge Control will not initiate a charge cycle if the open
by number of cycles. Charge cycle data (Functions #1- circuit voltage of the battery is less than 1.75 volts/cell
9) is not affected by a refresh charge. The charge or greater than 2.30 volts/cell. The low battery
termination technique for a refresh charge will be discrimination feature can be overridden by
pT/dV/dT regardless of how the control is user simultaneously pressing the “Push to Stop/Reset/
programmed, and the 0-80% back-up timer will be four Review” and the “Push to Equalize” pushbuttons for
hours and fifteen minutes during a refresh charge. This two seconds while the “Lo B” status is displayed.
feature will insure that any battery left connected to the This feature aids in the prevention of charger
charger for extended periods of time will not be operation on mismatched batteries and chargers.
damaged due to self-discharge, and will be kept in a
fully charged state. CAUTION: Care should be exercised
when overriding the low battery
Finish Cell Forming Feature — The AC1000 discrimination feature as the charger
Control can be programmed to provide voltage-time will run for nine hours if a battery is
charge termination and disable the low current connected to the charger with a
shutdown feature for a limited number of charge cycles. lower number of cells than the charger
The number of cycles programmed in the control will is rated for.
be decremented each time a charge complete
condition is reached. The number of forming cycles Data Retention — The AC1000 Control uses
selected can be from 0 to 30 charge cycles. EEPROM for all data retention. User programmed
information and charge cycle data are stored in
WARNING: Enabling the Finish Cell EEPROM for a minimum data retention time of ten
Forming feature will cause the years.
charger to continue to run for a
period of time if the battery has been Delayed Start — The AC1000 Control can be
disconnected before Charge Complete programmed to delay the start of a charge cycle for a
or pressing the Manual Stop switch. specific period of time. Any time period from 0 minutes
This condition will continue until the to 23 hours and 45 minutes, in 15 minute increments,
programmed number of cycles have can be used for the delayed start period. When a
been completed. The battery should AC1000 is programmed for delayed start, and a
never be disconnected while a charge battery is connected to the charger, the display
is in progress. alternates between ds and —. This feature can be
used to save on energy costs, provide a battery cool
down period, or to prevent opportunity charging.
WARNING: Care should be exercised
when disabling the low current shut- A standard AC1000 Control, when programmed for
down feature as the charger will delayed start can be manually overridden by pressing
continue to run if a battery is the “Push to Stop/Review” pushbutton while the start
disconnected without first pressing the of the charge cycle is being automatically delayed by
stop switch when the low current the control. The manual override feature allows the
shutdown is disabled. operator to start a charge cycle immediately if a
battery is needed sooner than the delayed start time
would allow.

5-3 October 30, 1998

 193111-030
AC1000 CONTROL FEATURES

Programmable Cool Down Time — A programmable Extra Run Time —– The charge time can be
cool down feature allows the battery to cool down for extended past the normal charge termination point
0 to 8 hours before the charger signals charge com- (pT/dV/dT or VT) from 0 to 60 minutes. If equalize has
plete. During the cool down period the alphanumeric been selected, any extra run time programmed will not
display reads “Cool” . This feature allows the battery to be added. This feature may be useful in some
cool down before being returned to use and can be abnormal charging situations such as cold storage.
used to minimize the battery maximum temperature
during operation.

October 30, 1998 5-4

193111-030
Programming Your AC1000 Control

Figure 6-1

6-1 October 30, 1998

 193111-030
Programming Your AC1000 Control

Programming Your AC1000 Control

The AC1000 programming function allows 10 functions Shunt size – The shunt size must be programmed
to be programmed to customize your AC1000 Control to match one of 3 possible charger shunt sizes (100,
to your particular charging application. Programming is 200, or 400 amp). The parameter is adjusted by
not available during an active charge cycle, and can closing DIP switch S1-1 with no battery connected to
only be accessed when no battery is connected to the the charger, and using the “Equalize” and “Stop” keys
charger. With no battery connected, the display will to set the proper shunt size. Closing the DIP switch
read “AC1” and DIP switches S1-1 thru S1-10 can be to the original “off” position will store the setting in the
independently closed to program a particular charge control memory. Any control that has been factory
parameter. The display will indicate the initial value of installed in a charger is set to match that charger at
the parameter that is selected. The user can then press the factory. Controls shipped separately are factory
the “Equalize” or “Manual Stop” keys to increment or set for a 200 amp shunt.
decrement the parameter to the desired value. The DIP
switch is then returned to it’s original position and the 80% Voltage (volts/cell) — The 80% voltage is
new parameter value is stored in the control. adjustable from 2.31 to 2.59 volts/cell by 0.02 volts/cell
steps. The setting is adjusted by closing DIP switch
Table 6-2 contains the programming steps required to S1-2 with no battery connected to the charger, and
change the number of automatic equalize cycles from using the “Equalize” and “Stop” keys to set the desired
the factory setting of 05 to 00 (automatic equalize volt/cell setting. Closing the DIP switch to the original
Disabled). Descriptions of the programmable functions “off” position will store the setting in the control
are listed after Table 6-1. If a programmable feature is memory. The factory setting is 2.37 volts/cell.
modified by the user to a value other than the factory
setting, then the left-most decimal point on the pT/dV/dT — To disable the factory pT/dV/dT charge
display will blink on and off indicating the change. termination setting, close DIP switch S1-3 to the “on”
The factory settings for all of the features are also position with no battery connected to the charger, and
included below. using the “Equalize” and “Stop” keys to select
pT/dV/dT or VT (Voltage time Termination). The
current setting will be displayed as listed below.

STEP CONTROL DISPLAY

READING
1.) Make sure that the “AC1” pT/dV/dT =
battery is VT =
disconnected from
Closing the DIP switch to the original “off” position
2.) Close DIP switch “05” will store the setting in the control memory. The
control is factory set to pT/dV/dT Termination.
3.) Press the “00”
Auto-Equalize Cycles — The number of complete
“Stop/Review”
charge cycles between equalize charges. This setting
button until the
is programmed by closing DIP switch S1-4 with no
display reading is
battery connected to the charger. Setting this
parameter to 0 disables the auto-equalize feature and
4.) Open DIP switch “AC1” - Left-most equalize charge requests are performed by pressing
S1-4 decimal point the “Equalize” push-button on the control front panel.
When the auto-equalize function is enabled
(programmed to a value other than 0), then the
5.) Operation complete “AC1” - Left-most “Equalize” push-button cannot be used to request an
decimal point equalize charge. The AC1000 Control is shipped
from the factory with the auto-equalize feature set for
every five cycles.
Table 6-2
AC1000 Control Programming Example

October 23, 2002 6-2

193111-030
Programming Your AC1000 Control

Delayed Start — The time from battery connection to Forming Cycles — To select any number of forming
the start of a charge sequence is programmable from cycles from 0 to 30, close DIP switch S1-8 to the “on”
0 minutes to 23 hours and 45 minutes in fifteen minute position, and using the “Equalize” and “Stop” keys to
increments. The delay time is programmed by closing select the number of forming cycles desired. Closing
DIP switch S1-5 with no battery connected to the the DIP switch to the original “off” position will store the
charger. The control is shipped from the factory with setting in the control memory.
the delayed start time set to 0.
Cool Down Delay — The battery cool down delay time
Refresh Delay — The time from a normal charge is adjustable from 0 to 8 hours in 1 hour increments.
Termination to the start of a refresh charge is The parameter is adjusted by closing DIP switch S1-9
adjustable from 8 to 99 hours in 1 hour increments. with no battery connected to the charger. The factory
The refresh delay time is programmed by closing DIP setting is 0 hours.
switch S1-6 with no battery connected to the charger.
The control is shipped from the factory with the refresh Extra Run Time — 0 to 60 minutes of extra charger
delay time set to 72 hours. run time after normal charge complete can be selected
by closing DIP switch S1-10 to the “on” position, and
Start mode — “Push to Start” or “Fault Lockout” using the “Equalize” and “Stop” keys to select the
modes of operation can be selected by closing DIP desired number of minutes. Closing the DIP switch to
switch S1-7 to the “on” position, and using the the original “off” position will store the setting in the
“Equalize” and “Stop” keys to select either mode of control memory. The control is factory set to 0 minutes
operation. The current setting will be displayed as of extra runtime after charge complete.
listed below:

Normal (Auto Start) = AS

Push to Start = PS
Fault Lockout = FL

Closing the DIP switch to the original “off” position will

store the setting in the control memory. The control is
factory set to “Normal” start mode.

6-3 October 23, 2002

193111-030
TROUBLESHOOTING

TROUBLESHOOTING
Troubleshooting Table

ACTION
SYMPTOM PROBABLE CAUSES
PARAGRAPH PAGE

No Display And (1) No AC Voltage To Charger 7.01 7-5

No LED’s (2) Input Fuse (s) Blown 7.02 7-5
(3) Control Trans. Breaker Tripped 7.03 7-5
(4) Bad Control Transformer 7.04 7-5
(5) Wrong Control Trans. Connection 7.05 7-5
(6) Bad Harness/Connection – Loose or Incorrect 7.06 7-5
(7) Bad Control Board 7.07 7-5

Bad Lamp Test (1) Bad Control Board 7.07 7-5

Display (1) Noisy Environment 7.08 7-5

Illegible (2) Low Input Voltage 7.09 7-5
(3) Bad Control Transformer 7.04 7-5
(4) Bad Control Board 7.07 7-5

Charger Doesn’t (1) Output Fuse Bad 7.10 7-5

Respond To (2) Bad Harness/Connections – Loose Or Incorrect 7.06 7-5
Battery Being (3) Bad Control Board 7.07 7-5
Connected (4) Output Cables Reversed 7.11 7-6
(5) Bad Output Connector 7.12 7-6

Control Not (1) Noisy Environment 7.08 7-5

Responding (2) Low Input Voltage 7.09 7-5
(Locked Up) (3) Power Interruption 7.08 7-5

Battery has Low (1) Reading Not Temperature Corrected 7.13 7-6
S.G.’s (2) Bad Battery 7.14 7-6
(3) Bad Equalize Schedule 7.15 7-6

Battery Doesn’t (1) Faulty Lift Interrupt 7.16 7-6

Last Full Shift (2) Manual Disconnect 7.17 7-7
(3) A.H. Required > Battery Nameplate 7.18 7-6
(4) Battery Not Providing Nameplate Rating 7.14 7-6
(5) Bad Equalize Schedule 7.15 7-6

7-1 October 30, 1998

 193111-030
TROUBLESHOOTING

ACTION
SYMPTOM PROBABLE CAUSES
PARAGRAPH PAGE

Battery Water (1) Charger Too Large For Battery 7.22 7-6
Usage Is Too (2) Bad Equalize Schedule 7.15 7-6
High (3) Control Set For Voltage/Time 7.19 7-6

Low Number Of (1) Faulty Lift Interrupt 7.16 7-6

A.H.’s Returned (2) Battery Not Fully Discharged 7.20 7-6
To Battery (3) Manual Disconnect 7.17 7-6
(4) Battery Not Providing Nameplate Rating 7.14 7-6
(5) Bad Control Board 7.07 7-5

Battery (1) Insufficient Cool Down Before And/Or After

Temperature Charging 7.21 7-6
Too High (2) Battery Power Demand Too Great 7.18 7-6
(3) Charger Too Large For Battery 7.22 7-6
(4) Bad Equalize Schedule 7.15 7-6
(5) Control Set For Voltage/Time 7.19 7-6

Incorrect Charge (1) Battery A.H. Not Equal To Charger A.H. 7.22 7-6
Rate (2) Bad Control Board 7.07 7-5

Charger Doesn’t (1) Bad Control Board 7.07 7-5

Shutdown When
Battery Is
Disconnected

Noisy Unit (1) Loose Sheet Metal 7.23 7-6

(2) Bad Contactor 7.24 7-6
(3) Loose Transformer Mounting 7.25 7-7
(4) Noisy Transformer 7.26 7-7
(5) Placed On Rack That Makes Noise 7.27 7-7

Meter Reading (1) Bad Output Connector 7.12 7-6

Wrong (V/C) (2) Bad Harness/Connections – Loose or Incorrect 7.06 7-5
(3) Internal Power Connection 7.28 7-7
(4) Bad Control Board 7.07 7-5

October 30, 1998 7-2

193111-030
TROUBLESHOOTING

ACTION
SYMPTOM PROBABLE CAUSES
PARAGRAPH PAGE

Meter Reading (1) Bad Output Connector 7.12 7-6

Wrong (V/C) (2) Bad Harness/Connections – Loose Or Incorrect 7.06 7-5
(3) Internal Power Connection 7.28 7-7
(4) Bad Control Board 7.07 7-5

Meter Reading (1) Control Board Shunt DIP Switch Set Incorrectly 7.29 7-7
Wrong (Amps) (2) Bad Output Connector 7.12 7-6
(3) Bad Harness/Connections – Loose or Incorrect 7.06 7-5
(4) Internal Power Connection 7.28 7-7
(5) Bad Control Board 7.07 7-5
(6) Bad/Incorrect Shunt 7.30 7-7

Unbalanced (1) Incorrect Wiring To Primary Of Transformer 7.31 7-7

Input Current (2) Incorrect Cabling To Transformer Secondary 7.32 7-7
(3) Bad Diode 7.33 7-7
(4) Bad Control Board 7.07 7-5
(5) AC Supply 7.01 7-5
(6) Bad Transformer 7.34 7-7

High Input (1) Incorrect Wiring To Primary Of Transformer 7.31 7-7

Current (2) Incorrect Cabling To Transformer Secondary 7.32 7-7
(3) Incorrect AC Input Jumper Setting 7.35 7-7
(4) Bad Diode 7.36 7-7
(5) Bad Control Board 7.07 7-5
(6) AC Supply 7.01 7-5
(7) Bad Transformer 7.34 7-7

LEDs Flashing, (1) Battery A.H.> Charger A.H. 7.36 7-7

Display Reads (2) Bad Output Connector 7.12 7-6
“0-80” OR “80-E” (3) Bad Battery 7.14 7-6
(Back-up Timer
Timeout)

7-3 October 30, 1998

 193111-030
TROUBLESHOOTING

ACTION
SYMPTOM PROBABLE CAUSES
PARAGRAPH PAGE

LEDs Flashing, (1) Someone Pressed Manual Stop Button 7.17 7-6
Display Reads (2) Bad Control Board 7.07 7-5
“OFF”
(Manual Stop)

LEDs Flashing, (1) Bad Harness/Connections – Loose or Incorrect 7.06 7-5

Display Reads (2) Bad Battery 7.15 7-6
“Lo-A” (3) Bad Internal Power Connections 7.28 7-7
(Low Current (4) AC Supply 7.01 7-5
Shutdown) (5) Bad AC Fuse 7.02 7-5
(6) Bad Contactor 7.24 7-6
(7) Output Fuse Bad 7.10 7-5
(8) Bad Control Board 7.07 7-5
(9) Bad Transformer 7.34 7-7

LEDs Flashing, (1) Battery Over Discharged 7.37 7-7

Display Reads (2) Bad Harness/Connections – Loose Or Incorrect 7.06 7-5
“Lo-b” (3) Bad Battery 7.14 7-6
(4) Bad Control Board 7.07 7-5
(5) Bad Output Cables/Connector 7.12 7-6

LEDs Flashing, (1) Wrong Cell Size Battery 7.38 7-7

Display Reads (2) Bad Control Board 7.07 7-5
“HI-b”

Display Reads (1) Intermittent AC Fail (Supply) 7.01 7-5

“ACLo” (2) Control Transformer Connection 7.05 7-5
(3) Bad Harness/Connection – Loose or Incorrect 7.06 7-5
(4) Bad Control Transformer 7.04 7-5
(5) Bad Control Board 7.07 7-5

October 30, 1998 7-4

193111-030
TROUBLESHOOTING

Action
7.01 Refer to the INSTALLATION chapter in the charger manual.

7.02 Disconnect AC power and replace the bad AC fuse. Reapply AC power to the charger. If the fuse (s) blows instantly,
check the connections on the input side of the contactor to make sure there are no shorts between any of the input
wires . If that’s okay, then check or change the control transformer. If the fuse (s) blow after the contactor closes,
then check the input wiring from the contactor to the main transformer (s). Refer to the charger manual and
locate the diagram for your charger to confirm that the charger is wired correctly. Also check the wires going up to
the terminal block on the transformer, the wires will have numbers that correspond to the number on the terminal
block. If they are incorrect, change them and start over. If it still blows fuse (s), the transformer will have to be
replaced.

7.03 Disconnect AC power and reset the breaker. Disconnect the control and reapply AC power to the charger. Measure
to see if 24VAC is on the output side of the control transformer. If there is, the control has failed. If there isn’t 24VAC,
then replace the control transformer. It is still possible that the control has failed; so once the control transformer is
replaced, measure to see if the 24VAC drops once the control is connected.

7.04 Check and see if any input fuses are blown. Visually inspect the control transformer for discoloration on the casing
of the input side of the control transformer. Disconnect the control before applying AC power. Once AC power is
reapplied, measure the input voltage to the control transformer, it should be the AC supply voltage (208/240/480)
(240/480/575). If not, check the control transformer input wiring. If you did read the supply voltage, then measure the
output side and you should read 24VAC. If not, replace the control transformer.

7.05 Look at the casing of the control transformer on the input side. Reference the charger manual to determine the
input. There will be four pins and each one will be labeled as follows: COM (common), 208 (208VAC), 240 (240VAC),
and 480 (480VAC). Some chargers are equipped with higher input voltage control transformers labeled as follows:
COM (common), 240 (240VAC), 480 (480VAC), and 575 (575VAC). There should always be a wire on the common
terminal no matter what voltage is applied to the charger, and the second wire will go to the pin labeled as the voltage
that is applied to operate the charger. Measure the voltage on the output side of the control transformer, it should
read approximately 24VAC.

7.06 A bad harness/connection can cause many different problems. The best way to confirm a bad harness/connection
problem is to take measurements where the harness is connected to the charger and then follow the wire (s) up the
harness to the PC boards and measure there also. The measurement should match what was measured at the
charger connection. If it doesn’t, check the following: Check the connectors at the square plugs where the control
harness connects to the charger harness, the connectors could be pressed out of the plugs. Make sure the
connectors look okay inside the edge mount connector at the PC board (s). Make sure the harness connections are
tight where they connect to the charger. Make sure the wires are crimped to the terminals tightly and also check to
make sure that they are crimped to the bare wire and not to the insulation only.

7.07 To check the Control Board for proper operation, first check the DIP Switch settings of S2. Make sure the proper cell
size is set to match the charger. Also make sure the shunt size setting matches the shunt in the charger ( See
Programming Your AC1000 Control page 6-2). If the control still does not operate properly even though the above
settings are correct, the Control Board still may need to be replaced. However, this is unlikely and all other
possibilities should be taken before this step.

7.08 Temporarily shut down any equipment on the same voltage supply line and see if the control starts to respond
normally. If the control does, then check all grounds going to the equipment that is shut down. If the problems still
exist, then return power to all the other equipment and call your local Prestolite Power Representative.

7.09 Measure the AC supply voltage coming into the charger to confirm that it matches the charger input tap settings.

7.10 Use an Ohmmeter and measure directly across the DC Fuse. A good fuse will measure almost (0) Ohms and a bad
one will measure a very high resistance, in the megohm range or greater. If for some reason a DC fuse measures
somewhere in between, replace the DC fuse and send it in to your local Prestolite Power Representative.

7-5 October 30, 1998

 193111-030
TROUBLESHOOTING

7.11 Refer to the DIAGRAM chapter in the owners manual and locate where the output cables connect to the charger. The
black (Negative) output cable goes into the charger and connects to a bus bar on the end of the DC fuse which is
located on the left portion of the interior panel. The red (Positive) output cable goes into the charger and connects to
the flat heat sink plate at the rear of the charger. The output connector will have a (+) and (-) symbol on it.
The (+) terminal should have the red output cable connected to it, and the (-) should have the black
output cable connected to it.

7.12 Make sure the output connector does not have any cracks on its casing that could result in a short. Make sure the
output cable lugs are making a good connection with the battery connector. You will see traces of pitting on the lug
surface from arcing if there isn’t a good connection. This could be the result of a weak retainer clip in the connector
or lugs that were soldered on incorrectly. If the lugs had too much heat applied to tem when the cables were soldered
on, the solder will wick up the cable and make it very stiff. When they are inserted into the connector, the stiff cable
forces the retainer clip down and creates poor connection between the battery connector and the charger connector.

7.13 Specific Gravity readings vary with the temperature of the electrolyte. To temperature correct the readings to match
the nameplate ratings of the battery, use the following rule of thumb: +1 S.G. point per 3 degrees F. increase of the
electrolyte temperature from 77 degrees F.

7.14 Take “Specific Gravity” readings and measure “Cell Voltages”. If acid has been spilled or the battery has been
extremely heated, it is possible that a battery’s capacity could be greatly reduced, and the acid is not capable of
increasing to the battery nameplate rating.

7.15 The proper equalize schedule is one that is tailored to the specific battery and charger operation. The AC1000
auto equalize feature can be used to automate the equalize schedule (see the “AC1000 Control Features” chapter
of this manual).

7.16 A faulty lift interrupt on a lift truck can cause the battery to be over or under discharged. Check the interrupt voltage
of the interrupt following the procedures found in your truck and/or lift interrupt operators’ manual (s).

7.17 Repeated manual disconnecting of the battery from the charger before complete can cause long term battery damage
and lead to inefficient truck/battery operations. When it is necessary to stop the charge cycle before charge
complete, always terminate the charge cycle by pressing the STOP button before disconnecting the battery from the
charger.

7.18 If the application requires a larger AH battery than is presently in use, the only long term solution is to replace the
battery with one of the proper AH rating.

7.19 Set the control to PDV/DT termination (see the “Initial Set-Up” chapter of this manual).

7.20 If fully discharged batteries are desired for efficient operations, lift interrupts can be installed on the trucks to allow
the operators to recognize a fully discharged battery.

7.21 A cool down can be programmed into the AC1000 control to add a specified cool down time between charge
termination and the signaling of charge complete (see the “Programming Your AC1000 Control” chapter of this
manual). A delayed start can be programmed into the AC1000 control to add a specified delay time between battery
connection and the start on the charge (see the “Programming Your AC1000 Control” chapter of this manual).

7.22 Check the charger A.H. rating. If it does not match the battery nameplate A.H. rating ( it should be within 20% of the
battery nameplate rating), then the battery should be charged using a charger with the correct output rating to match
the battery rating within 20%.

7.23 Check and tighten all sheet metal fasteners (screws and bolts).

7.24 If the contactor is not functioning properly, then check the voltage across the contactor coil. If the voltage is
24VAC +/- 10%, replace the contactor with a properly functioning part.

March 8, 2000 7-6

193111-030
TROUBLESHOOTING

7.25 Check and tighten all transformer mounting screws.

7.26 Check transformer for visible damage. Coat the transformer coil with a Prestolite approved (contact Prestolite
Service) air dry varnish. If that fails to reduce the noise level, drive a shim of the proper material (contact
Prestolite Service) between coil and core.

7.27 Check for and tighten any loose fasteners on the rack. Remove any lightweight loose objects that are on the rack
near the charger.

7.28 Check charger internal connection points that visually appear to be poorly connected or heat damaged. Any
connections that appear loose or overheated must be re-lugged. Recheck any repaired connections by performing
a continuity test.

7.29 Check the shunt size DIP switch setting (see the “Initial Set-Up” chapter in this manual) and ensure that it matches
the shunt in the charger.

7.30 Replace damaged and/or incorrect shunt with one of correct size.

7.31 Reconnect transformer primary wiring to match the schematic in the charger manual.

7.32 Reconnect transformer secondary wiring to match the schematic in the charger manual.

7.33 Check the diode as described below. If it tests faulty, replace with a diode of the proper type.

Connect a VOM set on the 1k Ohms scale; positive to diode anode, negative to diode cathode . The VOM should
read a low impedance (near short circuit). Reverse the meter leads; in this direction, the meter should read a high
impedance (> 1K Ohms). (A DVM may be used if it is set to the diode scale.) A high impedance will be indicated
by an over range indication (usually OL); a low impedance will be indicated by a low reading of about 1.00 .

7.34 AC fuses are most likely to have failed. Visually inspect the transformer. If a winding has failed, the winding will
appear to be burnt or look black. The varnish might be flaking off. Refer to the “Diagram” chapter in the charger
manual and locate the diagram for your charger. On the diagram, there will be a winding configuration for the
transformer . With power removed, disconnect the diodes from the transformer. Reapply AC to the charger.
Measure the transformer secondary voltage. If less than 25 VAC is present, replace the transformer.

7.35 Refer to the “Installation” chapter in the charger manual and reconnect the input primary jumpers to match the input
voltage. Be sure to connect the control transformer primary properly.

7.36 Check the charger A.H. rating. If the battery A.H. rating exceeds the charger nameplate rating by more than 20%,
then the battery should be charged using a charger with a higher A.H. capacity.

7.37 If the battery has been over discharged and the open cell voltage is less than 1.75 volts/cell, then the low battery
reject feature is enabled. The control will not start the charge until the battery voltage rises or the user overrides
the low battery reject mode. See the “AC1000 Control Features” chapter of this manual for details concerning the
low battery reject feature. An over discharged battery could be indicative of a faulty lift interrupt.

7.38 The battery connected to the charger may be the wrong cell size for the charger. Check the nameplate on the battery
and verify that it matches the cell size of the charger.

7.39 Hold in the “Manual Stop” and “Equalize” buttons simultaneously for two seconds until the display reads “EEEE”.
Release the two buttons. The control should now function properly.

7.40 Measure the DC voltage between connector pins J3-5 and J3-1 on the control PC board: positive of DMM to J1-5,
negative of DMM to J1-3. The measured voltage should be between 1.00 and 1.86 VDC. If the measured voltage is
out of range, remove the jumper from the connector and inspect it for loose or damaged connections.

7-7 March 8, 2000

193111-030
PARTS LIST

PARTS LIST

ITEM NO. ITEM DESCRIPTION PART NUMBER

1 CONTROL PC BOARD 193868-001

2 CONTROL HARNESS 191303

3 PLASTIC PRESS RIVET 193101-001

8-1 October 30, 1998

193111-030
ELECTRONIC PRINTED CIRCUIT BOARD EXCHANGE SERVICE POLICY

ELECTRONIC PRINTED CIRCUIT

BOARD EXCHANGE SERVICE POLICY
Because of the definite superiority of certain solid- A standard exchange price has been established for
state control components over conventional electro- each printed circuit board without regard to the amount
mechanical relays and regulators, the company prod- of repair required to the original turned in, which is
uct lines now incorporate solid-state controls for appli- applied against the cost of the replacement. Exchange
cations in which they may be used to advantage. To prices for a specific printed circuit board may be
facilitate testing and servicing, these control compo- determined by contacting an authorized company
nents and circuits have been assembled as modules distributor or by writing to the factory, giving the
on printed circuit boards, mounted in such a manner SPECIFICATION or ASSEMBLY, MODEL, and
as to be quickly and easily removed. Electrical con- SERIAL numbers of the unit in which the printed circuit
nections to other components of the unit are by means board is installed.
of plug-in, screw type, or “Faston” connectors.
This Exchange Plan applies only to the specified solid-
In recognition of the fact that most users of this state control components circuitry which have failed
equipment lack the facilities and specially trained due to electrical fault or normal deterioration resulting
personnel necessary to service and repair electronic from use and age. The plan does not cover parts
equipment, the company has established an electronic which have been physically damaged through accident
printed circuit board exchange service plan. or abuse, or to which unauthorized repairs have been
made or attempted.
Under the Printed Circuit Board Exchange Plan, the
owner of the equipment may exchange the printed
circuit board (s) in which fault has developed for a
replacement.

CAUTION: Printed circuits and

other devices may be affected
by static electricity. Handling
precautions required.

October 30, 1998

 WARRANTY
AMETEK/PRESTOLITE POWER INDUSTRIAL BATTERY CHARGERS

Ametek/Prestolite Power (hereinafter called “Prestolite”) warrants that each new and unused Industrial 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 Industrial Battery Charger is warranted for a period of
one (1) year from the date of it’s 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 silicon diodes on unit (s) shipped after January 1, 1997 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 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 in-
spection and judgement. Prestolite’s liability is limited to repair of any defects found by Prestolite to exist or, at Prestolite’s option, the re-
placement of the defective product. F.O.B. factory after the defective product has been returned by the purchaser at its expense to Presto-
lite’s shipping place. Replacement and exchange parts will be warranted for the remainder of the original Industrial 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, tele-
phone 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 an Industrial 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 than Prestolite.

EXCEPT AS STATED ABOVE, ALL OTHER WARRANTIES AND CONDITIONS, EITHER EXPRESSED OR IMPLIED, INCLUDING IMPLIED WAR-
RANTIES 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 PER-
SONS 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, quali-
fied technical assistance should be utilized.

AMETEK/PRESTOLITE POWER
TROY, OHIO USA

Data Sheet: 1140

Index: 110100
Replaces: 082499