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Ametek Deka PowerForce User Manual

Ametek Deka PowerForce
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OWNER MANUAL – MOTIVE POWER CHARGER
IMPORTANT: Read these instructions before installing, operating, or servicing this system.
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Ametek Deka PowerForce Specifications

General IconGeneral
Input Frequency50/60 Hz
DimensionsVaries by model
WeightVaries by model
Battery TypeLead-acid
Charging StagesBulk, Absorption, Float
Protection FeaturesOver Voltage, Over Current, Over Temperature, Short Circuit
Operating Temperature-20°C to 50°C

Summary

Introduction to the Motive Power Charger

How to Use This Manual

Guidance on effectively using the manual, including understanding special annotations.

Equipment Identification

Details on locating unit identification numbers like model and serial numbers on the front panel.

Receipt of Equipment

Instructions for checking equipment upon receipt, reporting damage, and handling shipping errors.

Description of Equipment

Operating Modes

Explains the different operating modes available for the charger, such as conventional and opportunity charging.

PowerForce Control System

Details the standard charge control system and its features, including termination methods and data archiving.

Conventional Charging

Describes conventional charging methods for batteries, noting limitations for lithium batteries.

Opportunity Charging

Explains opportunity charging for high current output during short breaks, suitable for up to 25% charging.

Fast Charging

Details fast charging capabilities up to 50%, ideal for opportunity charging and lithium batteries.

Safety Instructions and Warnings

General Safety Practices

Outlines general safety rules, burn prevention, and fire/explosion hazards for charging equipment.

Electrical Safety Precautions

Covers preventing electrical shock, arcing, and burning from connectors and improper grounding.

Emergency Response

Details emergency first aid procedures for electrical shock and acid exposure.

Installation Guidelines

Location and Environmental Considerations

Guidance on selecting an optimal installation site, considering environmental factors and airflow.

Grounding Procedures

Explains the importance of proper grounding for safety and static discharge, referencing electrical codes.

Line Connections and AC Supply

Instructions for connecting AC power input cables and specifies acceptable supply input conditions.

Mounting Pattern

Provides dimensions for the mounting pattern and details on fastener specifications.

Pre-Operation Checks and Maintenance

Generators and Backup Power Systems

Discusses special considerations for on-site power generation and backup systems.

Charging Cable Connector Safety

Guidance on correctly connecting charging cables, ensuring proper polarity and secure connections.

Pre-Operation Inspection

Instructions to inspect the charger for damage, loose connections, and ensure all labels are visible.

Factory Control Settings Adjustment

Details common pre-operation changes to factory settings like time, voltage, capacity, and curve.

Inspection and Cleaning Procedures

Procedures for inspecting and cleaning the charger interior, including safety precautions.

Charger Operation

Preliminary Setup Steps

Steps to ensure the charger is installed, grounded, and connected to AC power before operation.

Normal or Daily Charging

Step-by-step guide for performing a normal or daily charge cycle on a battery.

Equalize or Weekend Charging

Explains when and how to perform an equalize or weekend charge to correct cell inequalities.

Manual Charge Stop

Instructions on how to manually stop a charge cycle before completion.

AC Power Failure Recovery

Describes how the charger resumes charging after an AC power interruption.

PowerForce Control Features and Shutdowns

Abnormal Shutdowns: Battery Voltage Errors

Shutdowns due to high or low battery voltage conditions or cell count mismatches.

Abnormal Shutdowns: Current and Timing Errors

Shutdowns related to low/high current, backup timer timeouts, or over max AH returned.

Abnormal Shutdowns: Battery and System Temperature

Shutdowns due to battery or charger over-temperature conditions.

Abnormal Shutdowns: System and BID Errors

Shutdowns for charge engine errors or incompatible BID battery data.

Main Features Overview

Lists the primary capabilities and functions of the PowerForce Control system.

Advanced Features and Settings

Review of Archived Charge Cycle Data

Details how to review archived charge cycle data, including various parameters.

Programmable Start Modes

Outlines the various programmable start modes available for the charger.

Failure Mode Diagnostics

Lists various failure modes that can cause the charger to shut down.

Multi-Voltage Charging Capability

Explains the charger's capability to charge batteries of different voltage sizes.

Temperature Compensation

Details how the charger modifies output voltage for battery temperature variations.

Maximum Battery Temperature Control

Describes monitoring and controlling maximum battery temperature during charging.

Charge Termination and Start Modes

Charge Termination Methods

Explains VT, Voltage Time termination and the patented DV/DT technique.

80% Charged Point

Details the point at which the charger identifies 80% charge completion.

Touch Screen Display Features

Highlights the user-friendly interface of the touch screen display with plain English.

Review of Charge Cycle History

Explains how the Statistics App can be used to review charge cycle history.

Start Mode Options

Covers automatic start, time-of-day start, delayed start, and time-of-day blockout modes.

Manual Override of Start Modes

Explains how to manually override programmed start modes for immediate charging.

Navigating the PowerForce Control Interface

Automatic Equalize Modes

Details the three types of automatic equalize: by cycle, BID cycle, or day of week.

Programmable Cool Down Time

Explains the feature to set a cool down period for the battery after charging.

No Gassing Time Setting

Describes setting a timer to prevent gassing above 80% capacity.

Maximum Battery Temperature Limit

Explains setting a maximum battery temperature limit to prevent overheating.

Password Protection

Details how to enable a 4-number password for programming functions.

Home Screen Navigation

Describes the default Home screen and its navigation options.

Dashboard Application

Explains the Dashboard app for displaying real-time charge cycle information.

Statistics Application

Details accessing charge data from the current cycle via the Statistics app.

Archive Application

Explains the Archive app for saving and tracking charging records and battery data.

Settings Application

Describes the Settings app for customizing charger output and parameters.

PowerForce Dashboard Interface

Dashboard Navigation Icons

Covers Home, Clock, Battery, Info, and Charge Time icons for interface navigation.

Charge Status Indicators

Displays State of Charge, Temperature, Status, VPC, Amps, Date/Time, and Wireless connection.

PowerForce Charge Archive Details

Key Charge Metrics

Includes Returned Amp Hours and total Charge Time for the cycle.

Cycle Timing and Voltage Data

Covers 80% to End time, Battery OCV, Start/Finish Volts, and Equalize Time.

Start and End Charge Parameters

Includes Start Amps, Start Time, End Time, and Finish Amps.

Battery Identification and Configuration

Details Battery ID, BID temps, AH capacity, cell count, and battery type.

Module Performance Data

Displays maximum current and temperature for each charger module.

Charge Status and Fault Codes

Basic Operational States

Indicates common states like Session Start, Gassing, and Charge Complete.

Battery Condition Errors

Errors related to battery voltage, temperature, and rejection.

Current and Timing Faults

Faults related to current limits, backup timers, and AH returned.

System and Communication Faults

Errors for charge curve, DIDT, engine, communication, and warnings.

Module Specific Faults

Errors reported by individual charger modules (e.g., Over Temp, IGBT Err).

PowerForce Statistics App Views

Statistics View 1: Battery and Cycle Basics

Shows battery ID, AH returned, time, and start/end voltage and current.

Statistics View 2: Temperature and Timing

Displays battery/ambient temperatures and start/end times.

Statistics View 3: Charge Curve and Errors

Details charge curve type, cycle parameters, and error counts.

Statistics View 4: Faults and BID Status

Indicates subsystem faults, rectifier warning, and BID installed status.

Battery Lifetime Performance Data

Presents charge return ratio and average temperature over battery lifetime.

PowerForce Control Settings Menu

Settings Menu Access

Opens the settings menu with eight access icons for various configurations.

General Settings Configuration

Location for changing default settings like time, date, and battery parameters.

Start Mode Configuration

Configuration for automatic, time-of-day, or delayed start modes.

Charge Curve and Parameters

Selection of battery type and charge curve parameters, including custom settings.

BID / BMS Settings

Configuration of BID/BMS settings for connected batteries and communication.

Equalize Mode Settings

Setting the equalize type and frequency for batteries.

Refresh Charge Settings

Configuration of refresh charge cycles, including timing and voltage per cell.

No Gassing Time Setting

Setting the no gassing time to prevent charging above 80% capacity.

Battery Watering Indicator

Setting up a battery watering indicator to alert users.

Programming Settings Details

General Settings - Part 1

Contains parameters like Control SN, Cool Down Hours, Fixed Temperature, and Display Backlight.

General Settings - Part 2

Includes settings for Temperature Compensated Voltage, Password, and Multi-Volt Mode.

Password Protection Setup

Enables password protection to secure control settings modification.

Multi-Volt Mode Operation

Enables automatic cell selection for multi-cell batteries or fixed voltage settings.

Power Saver Mode

Configures the display to go blank after a period of inactivity to save power.

Network Settings Configuration

Configuration for EPID and Wireless Access for network connectivity.

Time and Date Settings

Setting the charger's internal clock and date.

Start Mode and Charge Curve Configuration

Date and Time Settings

Screen for setting the charger's current time and date.

Touch Screen Calibration

Process for calibrating the touch screen display by pressing indicated points.

Start Mode Options

Covers automatic, TODS, delayed, and TODB start modes.

Start Mode Control Override

Enables manual override of programmed start modes.

Battery Voltage and Charge Curve Selection

Allows selection of supported battery voltage and modification of charge curve.

Charge Termination and Time Settings

Explains termination types and settings for fixed AH and additional charge time.

BID and Equalize Mode Settings

BID Settings Configuration

Programs battery ID, AH capacity, cell count, and charge curve into the BID.

BMS Mode Settings

Configures BMS mode, including CAN communication and optional/required settings.

Equalize Mode Options

Sets equalize type and frequency: Off, Cycle, Day of Week, BID Cycles, or Manual.

Refresh Charge Settings

Sets the number of hours or VPC level before a refresh charge starts.

No Gassing and Battery Watering

No Gassing Time Configuration

Timer to prevent gassing above 80% capacity by setting time or blockout periods.

1x/day Full Charge Feature

Prevents more than one full charge per day, regardless of programming.

Battery Watering Indicator

Enables a battery watering indicator to alert users when watering is needed.

Warranty Information

Product and Parts Warranty Coverage

Details the warranty coverage period for chargers and parts, including exceptions.

Commencement of Warranty Periods

Specifies warranty periods start from the date of shipment by the manufacturer.

Limitation of Remedy

Outlines the manufacturer's liability limited to repair or replacement of defective products.

Warranty Alteration and Use Clause

States that unauthorized alterations or use of defective product voids all warranties.

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