Ferroresonant Industrial Battery Chargers

Ferroresonant Industrial Battery Chargers
ACCU-CHARGER
Ferroresonant Industrial Battery Chargers
Setting the industry standard for maximum
performance
j A choice of 3 interchangeable controls for
added flexiblilty
j Quality-built for years of trouble-free service
j Fail-safe design protects batteries
j 100% rated to recharge fully discharged batteries
in 8 hours or less
j Ten-year transformer and diode warranty
j CDAC compatible–applied technology to control
material handling costs
j UL listed, CSA certified
®
Accu-Chargers for dependable an
Baked powdered
polyester finish
Prominently
displayed labels
• Voltage
change-over
• Fuse sizes
• Charging rate
adjustment
Modular designed
controls for
increased flexibility
Operating and
troubleshooting
manual
Quick connect
primary voltage
change-over
120/208/240 or
208/240/480, 575
Wide, hinged door
for easy access
Quick connect
output voltage tap
adjustments
UL listed,
CSA certified
Color coded
charging cables
Ferroresonant power
transformer(s) with
10-year warranty
jDesigned for maximum performance
jBattery/charger safeguards
jRating
The Accu-Charger sets the industry standard
for accuracy, efficiency, flexibility and
reliability. Designed to recharge any 100%
discharged lead-acid battery in its amperehour rating within 8 hours, the Accu-Charger
is engineered to provide the maximum in
charging performance. The charger uses
ferroresonant power conversion circuitry,
which is virtually maintenance-free, to provide
years of dependable service. The power
conversion circuitry maximizes battery life
by using a constantly tapering charge which
is automatically regulated by the “On Charge”
battery voltage. The output current of the
Accu-Charger is determined by the state
of discharge of the battery. The battery
is precisely charged, based on its depth
of discharge.
The Accu-Charger is internally protected
against overload, short circuit, incorrect
battery connection and voltage transients.
Shorting of the DC output will not damage
the charger or cause fuses to blow. Plus, in
the event of a component failure, the charging
rate will automatically go to “minimum,” thus
protecting the battery from damage.
The Accu-Charger is rated to recharge a
100% discharged battery in its ampere-hour
rating within eight hours.
jRegulation
jAdjustable DC output
jControl options
Depending on your charging requirements,
the Accu-Charger can be controlled by any
one of the following controls: AC500, AC1000
and AC2000.
Accu-Chargers will hold the finish rate of the
charge within ±1%, even with line voltage
variations as high as ±10%. This protects,
and properly charges the battery, even when
severe input voltage variations exist.
jSingle and three phase service
The Accu-Charger is available in a variety
of single and three phase models, providing
multiple AC input voltages as standard. Most
models are UL listed, CSA certified, and
meet BCI requirements.
jEasy to change AC input voltage
AC input voltage change-overs take just
minutes because of conveniently located
taps and quick-connect jumpers.
In rare instances where changes to the DC
output might be required, necessary
adjustments are made simple with
conveniently located quick-connect jumpers.
jWarranty
Minimize repair costs with ten-year original
purchaser warranty on power transformer
and silicon diodes, plus one-year warranty
on other components.
jConvection cooled, quiet
The Accu-Charger uses no fans to draw in
dirty air and has low sound levels for quiet
operation.
nd efficient charging every time!
jAutomatic operation
“A” Case
After the battery is connected and the
control is initiated, the Accu-Charger will
automatically start the charging operation.
It will continue to charge the battery until
the battery is fully charged at which time
the Accu-Charger will automatically
terminate the operation.
jInterchangeable control design
The Accu-Charger is designed to allow the
quick and easy installation or removal of
the controls. Unmatched in the industry, this
design allows controls to be interchanged
in minutes for greater control, flexibility
and automation of any battery charging
operation.
AC power
cable knockout
22-3/8"
(568.3 mm)
19-1/2"
(495.3 mm)
A
1"
(25.4 mm)
3/4"
(19.1 mm)
20-13/16"
(528.6 mm)
9"
(228.6 mm)
A
A denotes mounting pattern. Wall mounting dia. rear holes (4) 3/8"
jFunctional cabinet design
“B” Case
The cabinet is constructed with heavy-gauge
sheet metal and finished with a durable,
long-lasting powdered polyester baked finish.
The cabinet is designed to provide direct
access to the AC power connection points
and conveniently facilitates any required
service.
jFlexible cabinet mounting
14-1/8"
(358.8 mm)
14-15/16"
(379.4 mm)
21-1/4"
(539.8 mm)
21-1/2"
(546.1 mm)
8-3/4"
(222.3 mm)
AC power cable
knockouts
26-1/8"
(663.6 mm)
23"
(584.2 mm)
All case styles can be wall, bench or floor
mounted and the B and C cases are
stackable to save floor space.
jEfficient, low cost operation
Dia. base mtg.
holes (4) 1/2"
17-3/4"
(450.9 mm)
19-3/8"
(492.1 mm)
1"
(25.4 mm)
The copper-wound, ferroresonant
transformer design of the Accu-Charger is
extremely efficient, converting AC input
power to useable DC output power.
“C” Case
jQuality-built for years of troublefree service
Quality is the driving force behind the AccuCharger. Its design allows it to meet the
many challenges associated with charging
batteries. Unmatched in construction,
reliability and value, each Accu-Charger is
subject to intensive quality control and test
procedures to ensure many years of troublefree service.
29-1/4"
(743.0 mm)
24-1/4"
8-3/4" (616.0 mm)
(222.3 mm)
AC power cable
knockouts
28-1/2"
(723.9 mm)
Dia. base mtg.
holes (4) 1/2"
25-1/2"
(647.7 mm)
27-1/8"
(689.0 mm)
19-1/16"
(484.2 mm)
1-3/4"
(44.5 mm)
jAccu-Charger charging
characteristics
The graph shows recharge data for a
complete charge cycle. Notice that as the
ampere-hours (A-H) returned to the battery
increase, the battery voltage increases and
the charging current gradually tapers to a
safe finish rate. The recharge rate starts at
approximately 20 amperes per 100 amperehours of battery capacity at 2.13 volts per
cell, then tapers to approximately 4.5
amperes per 100 ampere-hours at about
2.55 volts per cell. To assure complete
recharge of a fully discharged battery, the
total ampere-hours returned to the battery
is a minimum of 107%.
Battery
voltage
per cell
Charging current
amperes per 100 A-H
of battery capacity
Percentage of
ampere-hour capacity
returned to battery
22A
2.5V
110
20A
AMPE
18A
2.4V
80
12A
R
PE
AM
10A
2.2V
8A
2.0V
70
S
UR
HO
E-
60
50
40
VOLTS
6A
2.1V
90
16A
14A
2.3V
100
RE S
30
4A
20
2A
10
0A
0
1
2
3
4
5
CHARGING TIME (HOURS)
6
7
8
0
Accu-Charger options let you tailor a system to your exact requirements
j001 extra length charging cable:
j101 remote charger control box:
Permits the charger to be installed up to 20 ft. from the battery
location. See data sheet 1311.
Allows the control to be located up to 20 ft. from the charger, i.e.,
mezzanine or wall mounted. Note: Wiring connecting control and
charger not included.
j002 parallel charging cable with SBX connector:
For the simultaneous charging of two batteries, identical in cell
size but having different depths of discharge, with one charger.
j500 flange mounted fusible disconnect switch:
j003 series charging cable:
Disconnects power to the charger before door can be opened.
For B and C case chargers and 480 volt operation only.
Mounted beside door.
For the simultaneous charging of two batteries, identical in cell
size, ampere-hour rating, and depth of discharge, with one
charger.
j512 single point wiring, 2 circuit
j513 single point wiring, 3 circuit:
j010 wall mounting bracket:
Chargers are stacked two or three high, wired for single point
AC connection.
For B and C case chargers.
Accu-Charger accommodates interchangeable control design
No tools required! Change controls in minutes through two rivets that allow easy removal and
installation of any control. This flexibilty is unmatched in the industry!
jAC500
The AC500 is an automatic
start/stop control that uses the
patented PT/DV/DT charge
termination technique, or rate of
change of battery voltage with respect
to time. This technique provides an
efficient charge every time and
protects the battery from being over
or under charged. The AC500
features include 72 hour refresh,
manual and auto equalize, and
provides safety features such as
AC fail recovery, battery/charger
disconnect shutdown and backup timer protection. Available
with or without analog ammeter. See data sheet 1323 for
more information.
jAC1000 The AC1000 is an automatic
start/stop control utilizing the patented
PT/DV/DT charge termination
technique, or rate of change of battery
voltage with respect to time. This
proprietary technique used in
conjunction with the tapered curve of
the charger ensures that the battery
is precisely charged, never over or
under charged. The AC1000 stores 9
items of information for the most recent
charge cycle that can be reviewed at
the touch of a single button. Other
features include digital display,
battery/charger mismatch protection, dual back-up timers,
delayed start, cool down, refresh charge, forming cycles,
extended run time, auto equalize, selectable VT termination,
push-to-start and fault lockout operation. The AC1000 uses
the combination of the digital ammeter and 4 status LED’s
to indicate V/C, Amps and charge status of the charge cycle.
See data sheet 1322 for more information.
DISTRIBUTED BY:
Because we continually improve our products,
specifications are subject to change without notice.
©2000, AMETEK, Inc. Prestolite Power, Troy, Ohio
Data Sheet: 1305 11/00 5M Printed in U.S.A.
Replaces: 11/99
jAC2000 Unparalleled in the industry,
AC2000 control offers outstanding
features and options to take you into
the 21st century. The AC2000 utilizes
the latest engineering and electronic
technology to provide the ultimate in
charge cycle information. Up to 30
cycles of charge information is
automatically stored for retrieval. Plus,
the control allows the review of charge
cycle data anytime without affecting the
charging operation. The AC2000 offers
five different start modes and many
features including a sealed-membrane keypad, refresh
charge, extended run time, high-current shutdown,
battery/charger mismatch discrimination, new battery
recognition after AC fail, automatic or manual equalize
operation, and cool down. It uses a PT/DV/DT charge
termination technique to ensure that the rate of change for
both battery voltage and current always provides an efficient
and accurate termination of charge. See data sheet 1320
for more information.
With the addition of an optional expansion board, the AC2000
is capable of interfacing with the Charger Data Acquisition
and Control system, CDAC. This system turns your battery
chargers into a fleet maintenance system with the ability to
monitor your fleet operation, maximizing equipment utilization
and extending battery life. See data sheet 1317 for more
information.
Accu-Charger models
Application
Output
No.
battery
cells
Recommended battery
ampere-hour range for
8 hour charge
DC output
amperes
2.13 v/cell
6
6
6
6
6
6
6
6
6
0-180
181-250
251-380
381-450
451-510
511-600
601-750
751-880
881-1050
36
50
76
90
102
120
150
176
210
Model Number
A case
B case
AC Input, Amperes
C case
180A1-6
250A1-6
380A1-6
450A1-6
510B1-6
600B1-6
750B1-6
880B1-6
1-phase
120/208/240
volts
1-phase
208/240/480, 575
volts (see notes)
6.0/3.5/3.0
8.1/4.7/4.1
13.2/7.6/6.6
15.0/8.7/7.6
3.5/3.0/1.5, 1.0
4.7/4.1/2.0, 1.5
7.6/6.6/3.3, 2.8
8.7/7.6/3.8, 3.1
10.6/9.2/4.6, 3.8
11.5/10.0/5.0, 4.2
15.2/13.2/6.6, 5.5
17.0/15.0/7.5, 6.5
600C3-6
750C3-6
880C3-6
1050C3-6
9
381-450
90
12
12
12
12
12
12
12
12
12
12
0-250
251-380
381-450
451-510
511-600
601-750
751-880
881-1050
1051-1200
1201-1400
50
76
90
102
120
150
176
210
240
280
16
751-880
176
18
18
18
18
18
18
18
18
18
18
18
18
18
0-250
251-380
381-450
451-510
511-600
601-750
751-880
881-965
661-1020
966-1050
1051-1200
1201-1400
1401-1600
50
76
90
102
120
150
176
193
204
210
240
280
320
24
24
24
24
24
24
24
24
24
24
24
181-250
0-380
181-250
381-450
451-600
601-750
751-880
881-965
881-1050
1051-1200
1201-1400
50
76
50
90
120
150
176
193
210
240
280
36
36
36
36
36
36
36
0-250
251-380
381-450
451-600
601-750
751-880
881-965
50
76
90
120
150
176
193
250C3-36
380C3-36
450C3-36
600C3-36
750C3-36
880C3-36
965C3-36
40
40
40
40
451-550
511-600
601-725
751-880
110
120
750
176
550C1-40
600C3-40
725C3-40
880C3-40
450C3-9
16.7/9.6/8.4
250A1-12
380A1-12
450B1-12
510B1-12
600B1-12
750B1-12
880B1-12
450C3-12
510C3-12
600C3-12
750C3-12
880C3-12
1050C3-12
1200C3-12
1400C3-12
9.6/8.4/4.2, 3.5
14.5/12.6/6.3, 5.2
16.8/14.6/7.3, 6.1
18.5/16.1/8.1, 6.7
22.7/19.8/9.9, 8.2
29.1/25.3/12.7, 10.5
34.3/29.9/14.9, 12.4
880C3-16
250A1-18
380B1-18
450B1-18
510B1-18
600B1-18
*750B1-18
380C3-18
450C3-18
510C3-18
600C3-18
750C3-18
880C3-18
965C3-18
1020C1-18
1050C3-18
1200C3-18
1400C3-18
1600C3-18
250B1-24
380B1-24
450B1-24
250C3-24
450C3-24
600C3-24
750C3-24
880C3-24
965C3-24
1050C3-24
1200C3-24
1400C3-24
12.8/11.1/5.6, 4.6
20.0/17.4/8.7, 7.2
24.5/21.4/10.7, 8.9
26.7/23.3/11.6, 9.7
31.1/27.1/13.5, 11.3
42.9/37.4/18.7, 15.5
Weight, lbs.
3-phase
208/240/480, 575
volts (see notes)
Approx.
shipping
weight
6.1/5.3/2.6, 2.2
9.0/8.0/4.0, 3.3
10.5/9.0/4.5, 3.7
10.7/9.2/4.6, 3.8
75
85
95
110
120
185/225
190/290
205/285
290
6.7/6/3, 2.5
220
8.2/7.1/3.6, 3.0
9.4/8.2/4.1, 3.4
11.2/9.7/4.9, 4.1
14.7/12.9/6.4, 5.3
17.7/15.5/7.7, 6.4
21.3/18.6/9.3, 7.7
23.2/20.1/10.0, 8.5
28.0/25.0/12.5, 10.5
95
105
190/280
195/283
205/285
230/295
235/310
330
370
410
23.3/20.3/10.2, 8.5
320
29.0/25.2/12.6, 10.5
33.6/29.3/14.7, 12.2
37.2/32.4/16.2, 13.5
48.6/42.4/21.2, 17.6
110
190/290
205/295
215/300
225/310
290/320
370
380
335
385
425
450
550
8.9/7.7/3.9, 3.2
17.0/14.8/7.4, 6.2
22.5/19.6/9.8, 8.2
28.1/24.5/12.2, 10.2
35.3/30.8/15.4, 12.8
36.6/31.9/15.9, 13.2
41.1/35.8/17.9, 14.9
43.4/37.8/18.9, 15.7
55.5/48.4/24.2, 20.1
195
219
285
225/290
320
380
375
380
450
470
510
12.5/11.0/5.5, 4.5
20.5/18.0/9.0, 7.5
27.5/24.0/12.0, 10.0
32.2/28.1/14.0, 11.7
43.6/38.0/19.0, 15.8
NA/43.0/21.5, 17.9
NA/48/24, 20
310
325
365
390
415
485
490
36.6/31.9/16, 13.3
41.4/36/18, 15
NA/47/23.5, 19.6
375
465
490
515
11.0/10.0/5.0, 4.0
13.3/11.6/5.8, 4.8
15.7/13.7/6.9, 5.7
17.3/15.1/7.6, 6.3
22.9/19.9/10.0, 8.3
24.2/21.1/10.5, 8.8
25.8/22.5/11.2, 9.3
53.4/46.6/23.3, 19.4
17.4/15.2/7.6, 6.3
25.1/21.9/10.9, 9.1
31.5/27.5/13.7, 11.4
62.2/54.2/27.1, 22.6
*Not UL or CSA listed and not available in 50 Hz.
NOTE 1: Single phase chargers can be connected to one phase of a three-phase power system.
NOTE 2: Contact factory for availability on non-standard voltages, non-standard cell sizes, 50 Hertz
chargers, or special applications.
NOTE 3: All chargers are furnished with standard nonexplosive-proof battery charging connector and
8 ft. (A case) or 10 ft. (B and C case) output cable.
NOTE 4: Standard voltages for single and three phase models are 208/240/480. Alternate voltage
configuration 240/480/575.
NOTE 5: Not all options are available for models listed, contact factory for availability.
2220 Corporate Drive j Troy, Ohio j 45373-1099 j 800 367 2002
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