Why does my AMETEK/PRESTOLITE POWER ULTRA CHARGE Battery Charger smell hot?
If your AMETEK/PRESTOLITE POWER Battery Charger smells hot, it could be due to several reasons: * Inadequate ventilation. * Ambient temperature being too high. * Lack of maintenance. * A bad transformer or control transformer. * A bad internal power connection. * A bad control board or inductor. * The wrong amp/hour jumper is installed. * A bad expansion board.
General| Category | Battery Charger |
|---|---|
| Manufacturer | AMETEK/PRESTOLITE POWER |
| Model | ULTRA CHARGE |
| Input Frequency | 50/60 Hz |
| Output Current | Up to 100A |
| Storage Temperature | -40°C to 85°C |
| Protection Features | Over Temperature |
| Input Voltage | 120/240 VAC |
Read these instructions before installing, operating, or servicing this system.
Explains how the model number indicates capacity, case size, input power phase, and cell count.
Provides guidance on how to effectively use the owner's manual for safe and proper operation.
Emphasizes keeping internal components clean and dry, and ensuring all electrical connections are tightened.
Details where to find the unit's identification number, such as model and serial number.
Instructions for checking the equipment upon receipt for completeness and potential shipping damage.
General safety rules for battery charging products, emphasizing training and qualified personnel.
Precautions against shock, burns, fire, explosion, and arcing during operation and maintenance.
Guidelines for grounding electrical equipment according to codes and safe practices.
Inspect charging leads for damage and avoid touching battery terminals during operation.
Procedure to shut off power before servicing and keeping internal parts clean and dry.
Information on first aid procedures for electrical shock victims and acid exposure.
Instructions to inspect and replace all precautionary labels on the equipment.
Describes the three operating modes: Multi-Cell, Fixed-Cell, and BID mode for automatic operation.
Explains preprogrammed and programmable output curves for different battery technologies.
Details the UC2000 control's components, user interface, and status LEDs.
Illustrates and presents typical I-E-I Volt Amp and Recharge Curves.
Crucial warning about connecting/disconnecting batteries during charging and battery safety.
Guidelines for selecting an installation site, emphasizing ventilation, surface, and clearance.
Warning about fire or explosion hazard from sparks or molten metal.
Specifies operating temperature, altitude, and humidity ranges for the charger.
Explains the importance of grounding for safety and static discharge, and how to properly ground the unit.
Warning about using an improperly sized grounding conductor.
Table detailing recommended AC input and branch fusing based on line amps.
Step-by-step instructions for changing the charger's line voltage connections.
Caution regarding incorrect connections and fuse sizes that can damage the equipment.
Instructions for connecting the AC power input cable to the charger.
Guidance on attaching charging cable connectors, ensuring correct polarity and secure connections.
Steps to inspect the charger and critical safety warnings before initial operation.
Details common factory control settings that may need adjustment before operation.
Safety warning before inspecting or cleaning the charger's interior.
Procedure for keeping the charger clean, dry, and well-ventilated for optimal service.
Guidance on replacing fuses, emphasizing correct type and potential damage from incorrect fuses.
Warning about electrical shock hazard from dirty or wet internal parts.
Initial steps before operating the charger: installation, grounding, and AC power.
Procedure for performing a normal or daily charge cycle for batteries.
Crucial warning about explosion hazards when connecting/disconnecting batteries during charging.
Explains when and how to perform an equalize or weekend charge cycle.
Procedure for manually stopping a charge cycle before completion.
Warning against connecting/disconnecting batteries while charge is in progress.
Describes AC power failure handling and associated electrical shock safety warnings.
Lists and explains various abnormal shutdown conditions for the charger.
Describes common shutdown faults like Low Current, Curve Error, Backup Timer, BID Read, etc.
Procedure for setting the charger's input phase to match the supply.
Chart showing battery capacity versus approximate charging time required.
Lists the primary features and capabilities of the UC2000 control system.
Covers Part Number, Refresh Charge, Cell Forming, Data Retention, Start Modes, Equalize, Cool Down, Max Temp, Voltage/AH Charging, BID Programming.
Covers Start Modes, Equalize Modes, Fault Lockout, Manual Voltage Adj, Max Temp Setting, Charge Termination.
Caution regarding maximum battery temperature recommendations from the manufacturer.
Manual voltage adjustment and max temperature setting procedures.
Charge termination techniques and alphanumeric display features.
Status LED functions and procedure for reviewing charge cycles.
Explains automatic/push-to-start modes and manual/automatic equalize modes.
Describes the fault lockout feature and its effect on charge cycle restarts.
Features for part number control and refresh charge cycles.
Warning for Finish Cell Forming and explanation of the 80% Charged Point.
Features for data retention and programming time-of-day start.
Features for delayed start and input kilowatt-hour usage calculation.
Features for time-of-day blockout and manual override of start modes.
Automatic equalize types and programmable cool down time feature.
Maximum battery temperature control and user programmable password.
Retrieves and displays charge cycle information for the last 99 cycles.
Details various data items related to charge cycle: Amp Hours, Charge Time, Battery OCV, etc.
Lists codes indicating the reason for charge cycle termination.
Data items for equalize time, start time, and end time of the charge cycle.
Data items for Truck ID and Battery ID, requiring Prestolite modules.
Data items related to BID: Start Temp, End Temp, Amp Hours, Cell Size, Battery Type.
Data items for the present month and date the charge cycle occurred.
Allows retrieval and display of charge cycle information and data.
Data items from Termination Reason to Auto Equalize settings.
Data items for the current time and day of the week.
Programming functions for Time-of-Day Start and Delayed Start.
Functions for selecting and overriding charger start modes.
Programming functions for Forming Cycles and Special Options.
Programming functions for Fixed Cell Size and Fixed Amp Hours.
Warning about the Finish Cell Forming feature causing continuous run if battery is disconnected.
Programming functions for Fixed Amp Hours and Fixed Battery Temperature.
Caution regarding maximum battery temperature limits.
Selects battery type for proper output voltage and current characteristics with BID.
Settings for custom output curve: Start Amps, Finish Amps, Gassing V/C, Lid V/C.
Programming functions for Charger ID and Refresh Delay.
Disables DV/DT termination, enables Voltage Time termination.
Programming functions for Present Month, Date, and Year.
Enables automatic cell selection; OFF uses Fixed Cell Size.
Sets hours for battery cool down after charge complete.
Conditions and steps required to program or reprogram a Prestolite BID.
Sets max battery temp for charging; requires BID.
Number of kilowatt hours used during last cycle; not programmable.
Programs Max Cell Size for 40-cell chargers in multi-cell mode.
Explains programming process and menu navigation.
Functions for setting time, day, and equalize parameters.
Functions for setting start modes, blockout times, and start override.
Programming functions for Forming Cycles and Special Options.
Programming functions for Fixed Cell Size and Fixed Amp Hours.
Warning about the Finish Cell Forming feature causing continuous run if battery is disconnected.
Programming functions for Fixed Amp Hours and Fixed Battery Temperature.
Caution regarding maximum battery temperature limits.
Selects battery type for proper output voltage and current characteristics with BID.
Settings for custom output curve: Start Amps, Finish Amps, Gassing V/C, Lid V/C.
Programming functions for Charger ID and Refresh Delay.
Disables DV/DT termination, enables Voltage Time termination.
Programming functions for Present Month, Date, and Year.
Enables automatic cell selection; OFF uses Fixed Cell Size.
Sets hours for battery cool down after charge complete.
Conditions and steps required to program or reprogram a Prestolite BID.
Sets max battery temp for charging; requires BID.
Number of kilowatt hours used during last cycle; not programmable.
Programs Max Cell Size for 40-cell chargers in multi-cell mode.
Explains customizing Ultra Charge for multi-battery applications using Multi AH feature.
Example application demonstrating Multi AH programming for 6, 12, and 18 cell batteries.
Shows key entry sequences and display outputs for Multi AH programming.
Explains using Timer Start Mode to override auto start/stop for manual charge time selection.
Example application for programming Timer Start Mode for a 24-Cell 935AH Battery.
Shows key entry sequences and display outputs for Timer Start Mode programming.
Provides cables to charge two batteries simultaneously in parallel.
Provides cables to charge two batteries simultaneously in series.
Meets 'JIC' requirements for disconnecting AC power for safety.
Caution for making correct positive-to-positive and negative-to-negative connections.
Provides emergency or service disconnect of AC power.
Required for communications with Prestolite CDAC system.
Allows remote control of functions and status indicators.
Facilitates wall mounting of T Case Chargers.
Facilitates lifting of T Case Chargers.
Allows downloading Ultra Charge archive data to a laptop PC.
Provides an emergency stop pushbutton for remote operation.
Table listing symptoms, probable causes, and recommended action steps.
Troubleshooting for display, LED, keypad, and control response problems.
Steps to diagnose why the charger does not respond when a battery is connected.
Probable causes and actions for a unit that smells hot.
Causes and actions for batteries exhibiting low specific gravity.
Causes and actions for batteries not lasting a full shift.
Causes and actions for excessive battery water usage.
Causes and actions for a low number of Amp Hours returned to the battery.
Causes and actions for excessive battery temperature during or after charging.
Causes and actions for an incorrect charge rate.
Causes and actions for delays in CDAC approval.
Causes and actions for the charger not shutting down when the battery is disconnected.
Causes and actions for a noisy unit.
Causes and actions for erratic operation of the charger.
Causes and actions for incorrect meter readings of voltage/cell and amps.
Causes and actions for an 'Unbalance Line Fault' display.
Causes and actions for high input current.
Causes and actions for a 'Curve Error Fault' display.
Causes and actions for a 'Backup Timer Fault' display.
Causes and actions for a 'Manual Stop Fault' display.
Causes and actions for a 'Low Current Fault' display.
Causes and actions for a 'Low Battery Fault' display.
Causes and actions for a 'Hi Battery Fault' display.
Causes and actions for a 'Setup Error Fault' display.
Causes and actions for a 'Check AC Power' display.
Causes and actions for various control error displays (COP, Clock Monitor, Illegal Opcode).
Causes and actions for a 'DIDT Fault' display.
Causes and actions for a 'High Amp Hour Fault' display.
Causes and actions for a 'Low Voltage Fault' display.
Causes and actions for a 'Bad BID Fault' display.
Detailed steps for troubleshooting specific issues, referencing other manual sections.
Step 1: Refer to the INSTALLATION chapter for initial troubleshooting.
Step 2: Check AC fuse, input connections, and control transformer for faults.
Step 3: Reset breaker, check control transformer output, and replace if necessary.
Step 4: Inspect input fuses, check control transformer casing, measure voltages.
Step 5: Check control transformer input wiring and output voltage.
Step 6: Troubleshoot bad harness/connections by checking connectors and crimps.
Step 7: Check DIP switch settings, voltages, and connections for the Control Board.
Troubleshoot no alphanumeric display by checking display to Control Board connection.
Consider replacing the Control Board if other steps fail.
Step 8: Check keypad connection to the Control Board.
Step 9: Test keypad function by pressing keys; check LEDs with '0' key.
Steps 10-12, 19: Check line voltage, fuses, and transformer for issues.
Steps 13-15, 20-21: Inspect connectors, cables, suppressor cores, and connections.
Steps 16-18: Review installation location and ambient temperature guidelines.
Steps 22-23: Check inductor condition and AH jumper settings.
Steps 24: Test expansion board and check CDAC system for issues.
Notes on temperature correction for specific gravity readings.
Notes on battery performance and optimizing equalize schedules.
Steps 28-29: Review and reprogram charge curve and Fixed AH settings.
Step 30: Confirm correct Fixed Temperature Setting in the Program chapter.
Note on charging limitations at low electrolyte temperatures.
Step 32: Check BID module communication and programming; replace if faulty.
Steps 33-34: Check lift interrupts and proper charge cycle termination.
Steps 35-36: Adjust battery AH rating and forming cycles settings.
Steps 37-40: Address insufficient charging time and opportunity charging conditions.
Steps 38-39: Program DV/DT termination and check lift interrupts.
Steps 40-52: Check various components and perform noise reduction measures.
Steps 53 & 58: Test SCR and diodes using VOM/DVM and replace if faulty.
Steps 54 & 55: Clean charger and replace damaged or incorrect shunts.
Steps 56-59: Reconnect transformer wiring and input jumpers.
Steps 60-61: Program UC2000 for battery formation and AH rating.
Steps 62-64: Program UC2000 modes and set DIP switches.
Step 65: Replace ampere hour jumper to match charger nameplate AH rating.
Diagram showing the parts breakdown for three-phase models.
Table listing part numbers and descriptions for three-phase models.
Table listing part numbers and descriptions for three-phase models.
Table listing part numbers and descriptions for three-phase models.
List of AC input fuses for various three-phase Ultra Charge models.
Note regarding parts used for weather-resistant enclosures.
Diagram showing the parts breakdown for single-phase models.
Table listing part numbers and descriptions for single-phase models.
Policy for exchanging solid-state control components and modules.
Caution regarding static electricity affecting printed circuits and devices.
Index listing diagrams and dimensional outlines by input voltage.
Key to symbols and component abbreviations used in the schematic diagrams.
Schematic diagram for the single control PCB.
Schematic showing the overall Ultra Charge connection diagram.
Key to symbols and component abbreviations used in the schematic diagrams.
Diagram showing alternate configuration with a disconnect switch.
Key to symbols and component abbreviations used in the schematic diagrams.
Diagram showing alternate configuration with a disconnect switch.
Specifies dimensions in inches and millimeters.
Table detailing cabinet dimensions (A through G).
Details warranty periods for SCR products, PCBs, transformers, inductors, etc.
Covers warranty start dates, eligible persons, remedy limits, and altered equipment clauses.
Disclaimer of other warranties, express or implied, and limitation of liability.
Emphasizes safety and the use of skilled technical assistance.
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