September 30, 2011 9-7
193111-095
TROUBLESHOOTING
Action Steps
1. Reference the INSTALLATION chapter (pg. 4-1).
2. Disconnect AC power to the charger and replace the AC fuse. Reapply AC power to the charger. If the fuse (s) blows
instantly, the primary PCB is probably bad. Contact the factory for replacement.
3. A bad wire harness connection can cause many different problems. Check the ribbon cable connections, make sure
they are properly seated in their housings. Check the wire bundles and connectors, make sure they are connected
well and crimped properly. Inspect all wiring crimp connected to the primary board. They should all be fully inserted
and tight.
4. To check the board for proper operation, first check the S1 dip switch selections. They should match the charger
maximum cell size, check the nameplate. Check DC voltages (+/- 5%) between J1-4 and the following: E34 = 4.85,
E33 13.00, J1-1 = 5.00. If the charger still does not operate properly even though the above checks are correct, the
control may need to be replaced.
5. The primary board is the large PCB that is on the lower left (both for dual engine units) side of the unit. It has several
functions that include providing power to the control. Check that the 2 green LEDs are lit when AC power is applied.
If they are not, remove power and check fuses FS1 and FS2. Contact the factory for any further details.
6. Open the charger door and check the keypad connection at J3 (right side of pcb). Make sure that the cable is not
twisted and is fully engaged.
7. Once step 6 has been checked, with no battery connected to the charger, press any of the number keys. The display
should display data represented by that key. If it does not, the keypad is bad.
8. Temporarily shut down any equipment on the same voltage supply line and see if the charger starts to respond
normally. If the charger 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 Ametek representative.
9. Measure the AC supply voltage coming into the charger to confirm that it matches the charger input voltage
requirements. Also see Action #1.
10. On the left side of the display, a 16 pin header connector should be mated with a 16 position receptacle on the main
control pcb. Check for full insertion and proper alignment.
11. 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 Ametek representative.
12. Remove the charger side cover(s) to expose where the output cables connect to the charger. The black (Negative)
output cable goes into the charger and connects to bus bar adjacent to the DC output fuse. The red (Positive) output
cable goes into the charger and connects to the bus bar that is mounted to the top of the output transformer.
13. 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 them 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.
14. For 6 through 24 cell chargers, a jumper loop should be between pins 3 and 4 at the J8 connector on the left side of
the control. For 36 and 40 cell units, the jumper should be from J8-2 to J8-4.
15. Refer to the INSTALLATION chapter and go to the paragraph labeled ―LOCATION‖. This will define the guide lines.
If a charger has inadequate ventilation, many different problems can occur. If a charger runs under extreme
temperatures, any component inside the charger could fail prematurely.
16. An extremely high ambient temperature can cause many different problems. If a charger runs under extreme
Temperatures, any component inside the charger could fail prematurely.
17. If the AH jumper is incorrect for the charger, it will cause the unit to charge at rates either higher or lower than
Nameplate rating.
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