Installation & Operation Manual
High Performance
HF Opportunity Charger Systems
P24-750-R25
P36-750-R25
P36-1000-R25
P48-750-R25
IOOCRev.
Rev.01102012
10282013
IOOC
!
IOOCRev.
Rev.01102012
10282013
IOOC
!
A.C.T. HF Opportunity Charger System
Installation & Operation Manual
NOTES
Table Of Contents
Safety Instructions And Warnings
1.0
Installation
1.1
Location And Mounting
1.2
Floor Mounting
1.3
AC Power Connection
2.0
Operation
2.1
Start Charging
2.2
Stop Charging
2.3
LED And Stack Light Operational
Status Indicators
2.3.1
Front Panel Led Indicators
2.4
Front Panel Display And
Keypad Operation
2.4.1
Display Mode Overview
2.4.2
Real-Time Status Display
2.4.3
Charging History Display
2.4.4
Manual Operations Display
2.4.4.1 Manual Equalization
2.4.4.2 Manual Watering
2.4.4.3 Manual Operation Of External
Scavenging Fan
2.4.5
Fault History Display
3.0
Troubleshooting
4.0
Maintenance
4.1
Replacing Cables
4.2
Working Environment
Service Frequency
4.3
Recommended PM Inspection Items
5.0
Technical Specifications
IOOC Rev. 10282013
1-3
4
4
7
8
9
9
9
9
9
9
9
9
10
10
10
12
12
12
13
13
13
13
14
15
A.C.T. HF Opportunity Charger System
NOTES
Installation & Operation Manual
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS.
THIS MANUAL CONTAINS IMPORTANT SAFETY AND
OPERATING INSTRUCTIONS
WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS. BATTERIES
GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR
THIS REASON IT IS OF THE UTMOST IMPORTANCE THAT EACH TIME BEFORE
USING YOUR CHARGER, YOU READ AND FOLLOW THE INSTRUCTIONS PROVIDED
EXACTLY.
TO REDUCE RISK OF BATTERY EXPLOSION, FOLLOW THESE INSTRUCTIONS AND
THOSE MARKED ON THE BATTERY.
NEVER SMOKE OR ALLOW AN OPEN SPARK OR FLAME IN THE VICINITY OF THE
BATTERY.
USE CHARGER FOR CHARGING A LEAD-ACID BATTERY ONLY. IT IS NOT INTENDED
TO SUPPLY POWER TO AN EXTRA-LOW-VOLTAGE ELECTRICAL SYSTEM OR TO
CHARGE DRY-CELL BATTERIES. CHARGING DRY-CELL BATTERIES MAY CAUSE
THEM TO BURST AND CAUSE INJURY TO PERSONS AND DAMAGE TO PROPERTY.
NEVER CHARGE A FROZEN BATTERY.
STUDY ALL BATTERY MANUFACTURER’S SPECIFIC PRECAUTIONS SUCH AS
REMOVING OR NOT REMOVING CELL CAPS WHILE CHARGING AND RECOMMENDED
RATES OF CHARGE.
NEVER PLACE THE CHARGER DIRECTLY ABOVE OR BELOW THE BATTERY BEING
CHARGED; GASES OR FLUIDS FROM THE BATTERY WILL CORRODE AND DAMAGE
THE CHARGER.
LOCATE THE CHARGER AS FAR AWAY FROM THE BATTERY AS DC CABLES PERMIT.
DO NOT OPERATE CHARGER IN A CLOSED-IN AREA OR RESTRICT VENTILATION IN
ANY WAY.
BEFORE INSTALLING, USING OR MAINTAINING THE A.C.T.
CHARGER SYSTEM, READ AND UNDERSTAND THE ABOVE
AND THE FOLLOWING INSTRUCTIONS. ONLY QUALIFIED
PERSONNEL SHOULD INSTALL, OPERATE OR SERVICE
THIS EQUIPMENT.
IOOC Rev. 10282013
1
.1
.2
.3
Location And Mounting
Floor Mounting
A.C.T. A.C.T.
HF Opportunity
ChargerSystem
System
AC Power Connection
HF Fast Charger
.0
.1
.2
.3
4
7
8
.3.1
.4
.4.1
Operation
9
DANGER
Start Charging
9
DANGER
Risk
of
High
Voltages
–
Lethal
voltages
are
present
within
Risk of High Voltages – Lethal voltages are present withinthe
Stop Charging
9 the
charger
chargerenclosure
enclosurewhenever
wheneverthe
theAC
ACmains
mainssupply
supplyisisenergized
energized
and/or
battery
or
isisconnected.
A.C.T.
HF
Fast
Charger
SystemThe
and/orthe
the
battery
orload
load
connected.
Thebus
busbars
barsand
and
LED And Stack
Light
Operational
9other
internal
components
present
the
risk
of
electric
shock.
other internal components present the risk of electric shock.
Status Indicators
9
WARNING
WARNING
DANGER
Front Panel
Led
Indicators
9
Risk
Gases
–
Working
in the
the
vicinity
lead
acid
Riskof
Explosive
Gases
– Working
in
vicinity
ofoflead
acid
Risk
ofofExplosive
High
Voltages
– Lethal
voltages
are
present
within
the
batteries
is
dangerous.
Batteries
generate
explosive
gases
batteries
is dangerous.
Batteries
charger
enclosure
whenever
the generate
AC
mainsexplosive
supply isgases
energized
Front Panel
Display
And
Keypad
Operation
9during
during
charging
and discharging.
To reduce
risk
battery
charging
and
discharging.
reduce
the The
risk the
of
battery
explosion,
and/or
the
battery
loadCharger
isToconnected.
bus
barsofand
other
A.C.T.
HFor
Fast
System
explosion,
ensure
adequate
ventilation
and
follow
these
instrucDisplay Mode
Overview
9 well
ensure components
adequate ventilation
instructions
internal
presentand
the follow
risk ofthese
electric
shock. as
.4.4
.4.4.1
an
mains
supply
incorporating
anmains
earth/ground.
groundcharger
enclosure
whenever
the AC
supply isThe
energized
to AC
an AC
mains
supply
incorporating
an earth/ground.
The
Manual Operations
Display
10
A.C.T.
HF
Fast
Charger
System
during
charging
and
discharging.
To reduce
the
risk
of
battery
ing
conductor
must
be
of
a
size
equal
or
larger
than
the
line
and/or
the
battery
or
load
is
connected.
The
bus
bars
and
other
grounding conductor must be of a size equal or larger than
the
explosion,
ensure adequate
ventilation
and
follow
these10
instruc(phase)
conductors.
internal
components
present
the
risk
of
electric
shock.
Manual Equalization
line (phase) conductors.
.0
cause
damage
or
result the
in personal
injury. shock.
internal
components
present
risk batteries.
oforelectric
or
working
in
the
vicinity
ing
conductor
must
be
ofofa lead-acid
size
equal
larger
than
the13
line
Technicalmay
Specifications
explosion,
ensure
adequate
ventilation
and
follow
these
instruc-
Installation & Operation Manual
5.0 TECHNICAL
TECHNICAL SPECIFICATIONS
SPECIFICATIONS
5.0
tions as well as those published by the battery manufacturer.
those published by the battery manufacturer.
Real-Time as
Status
Display
9
WARNING
WARNING
DANGER
WARNING
of Explosive
Gases
– Working
in the
vicinity
of connected
lead10
acid
Charging Risk
History
Display
Improper
Grounding
––The
must
Risk
Voltages
– Lethal
voltages
are
present
the to
RiskofofHigh
Improper
Grounding
Thecharger
charger
mustbe
bewithin
connected
.4.2
.4.3
batteries is dangerous. Batteries generate explosive gases
tions as well as those published by the battery manufacturer.
.4.4.2
.4.4.3
.4.5
.0
.0
.1
DANGER
Manual Watering
12
WARNING
WARNING
WARNING
Risk
of
High
Voltages
–
Lethal
voltages
are
present
within
the
Protect
Eyes
and
Skin
safety
and
protecRisk
of
Gases
–Wear
Working
ingoggles
the
vicinity
ofskin
lead12
acid
Protect
Eyes
and
Skin––Wear
safety
goggles
and
skin
Risk
of Explosive
Improper
Grounding
–the
The
charger
must
be
connected
to
Manual Operation
Of
External
Scavenging
Fan
charger
enclosure
whenever
AC
mains
supply
is
energized
tion
when
or Batteries
servicing
the
battery
charging
system
batteries
isinstalling
dangerous.
generate
gases
A.C.T.
HFinstalling
Fast
Charger
System
protection
when
or servicing
the explosive
battery
charging
an
AC
mains
supply
incorporating
an earth/ground.
The
groundand/or
the battery
or discharging.
loadofislead-acid
connected.
The the
busrisk
barsofand
other
Fault History
Display
12
or
working
the
vicinity
batteries.
during
charging
and
To
reduce
system
or in
working
in the
of lead-acid
ing
conductor
must
be
of avicinity
size
equal
orelectric
largerbatteries.
than
thebattery
line
internal
components
present
the
risk
of
shock.
explosion,
ensure adequate ventilation and follow these instruc(phase) conductors.
Troubleshooting
12
tions as well as those published
by the battery manufacturer.
DANGER
WARNING
WARNING
WARNING
Risk of High Voltages – Lethal
voltages are present within
the
WARNING
Maintenance
13
Toreduce
reduce
therisk
riskGases
ofinjury,
injury,
onlycharge
charge
rechargeable
lead-acid
Risk
of Explosive
–WARNING
Working
in the
vicinity of lead
acid
To
the
of
only
rechargeable
lead-acid
charger
enclosure
whenever
the
AC
mains
supply
is
energized
Protect
Eyes
and
Skin
–
Wear
safety
goggles
and
skin
protecRisk
of Improper
Grounding
–to
The
charger
must
be of
connected
to
batteries.
Charging
ortrying
trying
charge
other
types
batteries
isCharging
dangerous.
Batteries
generate
explosive
A.C.T.
HF
Fast
Charger
System
Replacingbatteries
Cables
13
batteries.
oror
to charge
other
types
of gases
batteries
and/or
the
battery
or
load
is connected.
The bus
bars
and
other
tion
when
installing
servicing
the
battery
charging
system
an AC
mains
supply
incorporating
an earth/ground.
The
groundmay cause
damage
or result in personal
injury.
during
charging
and discharging.
To reduce
the risk of battery
2
(phase)
tions as conductors.
well as those published
by the battery manufacturer.
DANGER
WARNING
WARNING
Risk of High Voltages – Lethal
voltages
are present within the
Risk
Gasesthe
–WARNING
Working
in the
vicinity
of lead
acid
WARNING
RiskofofExplosive
Fire - To reduce
risk
ofAC
fire,
install
battery
WARNING
charger
enclosure
whenever
the
mains
supply
ischarger
energized
Risk
offloor
Fire
- non-combustible
To
reduce
the only
risk
of
fire,
install
battery
charger
onto
Improper
Grounding
–
The
charger
must
be
connected
batteries
is
dangerous.
Batteries
generate
explosive
gases
To
reduce
the
risk
of
injury,
charge
rechargeable
lead-acid
on
a
of
material,
such
as
stone,
brick,
Protectthe
Eyes
and
Skin
–Charger
Wear
safety
goggles
and
skinand
protecand/or
battery
or
load
is
connected.
The
bus
bars
other
A.C.T.
HF
Fast
System
a
floor
of
non-combustible
material,
such
as
stone,
brick,
conan
AC
mains
supply
incorporating
an
earth/ground.
groundduring
charging
and
discharging.
To
the
riskofThe
ofbatteries
battery
batteries.
Charging
or
trying
to charge
other
types
conrete,
or
metal.
Do
not
install
on
orreduce
over
combustible
surfaces.
tion
when
installing
or
servicing
the
battery
charging
system
internal
present
the
risk
of
electric
shock.surfaces.
crete,
orcomponents
metal.
Doadequate
not
install
onpersonal
or
over
combustible
ing
conductor
must
be
of
a
size
equal
or
larger
than
the
line
explosion,
ensure
ventilation
and
follow
these
instrucmay
cause
damage
or
result
in
injury.
or working in the vicinity of lead-acid batteries.
(phase)
tions
as conductors.
well as those published by the battery manufacturer.
CAUTION
DANGER
IOOC Rev. 01102012WARNING
Risk
of
Fire
–
Use
only
on
circuits
provided
with
appropriate
WARNING
Explosive
Gases
–CAUTION
Working
in the
vicinity
of lead
Risk of High
Voltages
– Lethal
voltages
are
present
withinacid
the
WARNING
WARNING
branch
circuit
protection
in
accordance
with
the
National
Electrical
Risk
of
Improper
Grounding
–
The
charger
must
beisconnected
to
batteries
is
dangerous.
Batteries
generate
explosive
gases
charger
enclosure
whenever
the
AC
mains
supply
energized
Risk of
of Fire
Fire
Use
only –on
circuits
provided
with
appropriate
Protect
Eyes
and
Skin
Wear
goggles
and
skin
protecRisk
-–To
reduce
the
risksafety
of
fire,earth/ground.
install
battery
charger
on
To
reduce
the
risk
of
injury,
only
charge
rechargeable
lead-acid
Code,
NFPA
70.
The
appropriate
branch
circuit
protection
is:
an
AC
mains
supply
incorporating
an
The
groundduring
charging
and
To
reduce
risk
battery
and/or
the
battery
or discharging.
load
connected.
The the
bus
barsofand
other
branch
circuit
protection
inisaccordance
with
National
Electrition
when
installing
servicing
thesuch
battery
charging
system
a
floor
of
non-combustible
as the
stone,
brick,
conbatteries.
Charging
oror
trying
to
charge
other
types
of
batteries
Charger
model
P24-750-R25:10
Amperes
ing
conductor
must
be
of amaterial,
size
equal
or
larger
than
the
line
explosion,
ensure
adequate
ventilation
and
follow
these
instrucinternal
components
present
the
risk
of
electric
shock.
calworking
Code,
NFPA
70.
The
appropriate
branch
circuit protection
or
in
theDo
vicinity
of
lead-acid
batteries.
crete,
or metal.
not
install
on
or over
combustible
surfaces.is:
may
cause
damage
result
in
injury.manufacturer.
Charger
model
P36-750-R25:
15personal
Amperes
(phase)
tions
as conductors.
well
as STS-320:
thoseorpublished
by the battery
Charger
model
30 Amperes
Charger models P36-1000-R25:
20 Amperes
WARNING
Charger model STS-400: 35
Amperes
WARNING
Charger
model
P48-750-R25:
20
Amperes
Risk
Gases –WARNING
Working
in the vicinity
of connected
lead acid to
WARNING
Risk of
of Explosive
Improper Grounding
– The charger
must be
CAUTION
WARNING
Protect Eyes
and
Skin
–
Wear
safety
goggles
and
skin
protecbatteries
is
dangerous.
Batteries
generate
explosive
gases
IOOC
Rev.
10282013
To
reduce
risk
of
injury,
only
charge
rechargeable
lead-acid
an
AC
supply
incorporating
an
earth/ground.
The
groundRev.
Risk
ofmains
Firethe
Use
only
circuits
provided
with
appropriate
Risk
of
Fire
-–IOM320
To
reduce
the01102012
risk of
fire,
install
battery
charger
on
tion when
installing
or on
servicing
the
battery
charging
system
during
charging
and
discharging.
To
reduce
the
risk
of
battery
batteries.
Charging
or
trying
to
charge
other
types
of
batteries
ing
conductor
must
be
of
a
size
equal
or
larger
than
the
line
branch
circuit
protection
in
accordance
with
the
National
Electria
floor
of
non-combustible
material,
such
as
stone,
brick,
conor
working
in
the
vicinity
of
lead-acid
batteries.
explosion,
ensure
adequate
ventilation
and
follow these instrucmay
cause
damage
or install
result
in
injury.
(phase)
cal Code,
NFPA
70.not
The
appropriate
branch
circuit protection
crete,
orconductors.
metal.
onpersonal
or over
combustible
surfaces.is:
tions as
well
as Do
those
published
by
the battery
manufacturer.
Charger model STS-320: 30 Amperes
13
IOOC Rev. 01102012
IOOC Rev. 10282013
15
A.C.T. HF Opportunity Charger System
Installation
& Operation
A.C.T. HF Fast
ChargerManual
System
A.C.T. HF Fast Charger System
4.3 Recommended PM Inspection items
DANGER
DANGER
Risk
Voltages
Lethal
voltages
are present
RiskofofHigh
Electric
Shock– from
Stored
Energy
– Wait atwithin
least the
charger
enclosure
whenever
the
AC
mains
supply
is
energized
five minutes after de-energizing the AC power supply and
and/or
the battery
load isorconnected.
bus bars
other
disconnecting
theorbattery
load beforeThe
opening
the and
charger
internal
components
present
the
risk
of
electric
shock.
A.C.T.
HF
Fast
Charger
System
enclosure or touching any of the de-energized AC supply parts.
DANGER
DANGER
Risk of High Voltages – Lethal
voltages are present within the
RISK
OF
ELECTRIC
SHOCK
turning
off AC
for
charger enclosure whenever the- After
AC mains
supply
is power
energized
servicing,
allow
5
minutes
for
the
system
to
bleed
down
before
and/or the battery or load is connected. The bus bars and other
touching
the AC connections.
internal
components
present the risk of electric shock.
WARNING
DANGER
Risk of Explosive Gases – DANGER
Working in the vicinity of lead acid
Risk of Electric Shock and/or Electric Energy from High Current
batteries
is
dangerous.
Batteries
generate
gasesthe
Risk
of High
Lethal voltages
areexplosive
present within
Levels
– DoVoltages
not touch–un-insulated
battery,
connectors,
bus
during
charging
and
discharging.
To
reduce
the
risk
of
battery
charger
whenever
theshould
AC mains
supply is energized
bars or enclosure
terminals. All
tools used
be adequately
insulated
explosion,
ensure
adequate
ventilation and
these
instrucand/or
thethe
battery
or load
is connected.
Thefollow
busInspect
bars
and
other
to avoid
possibility
of shorting
connections.
cables
tions
as
well
as
those
published
by
the
battery
manufacturer.
internal
components
present
the
risk
of
electric
shock.
A.C.T.
HF
Fast
Charger
System
often for damage to the insulation. Replace cracked, worn or
a) AC Input Voltages, connections
and fuses.
WARNING
Risk of
Explosive
– Working
the vicinity with
of lead
b) Cleaning
out
chargerGases
cabinet
must beinperformed
theacid
air
batteries
is
dangerous.
Batteries
generate
explosive
gases
filter removed. Using dry compressed air not exceeding 20psi.
during
charging
and
discharging.
To reduce
the not
risk to
of battery
Or an
electric
blower
(A.C.T.
preferred
method)
exceed
explosion, ensure adequate ventilation and follow these instruc30cfm.
otherwise damaged cables
immediately.
WARNING
WARNING
Risk of Improper Grounding
– The charger must be connected to
Risk
ofmains
Explosive
Gases
– DANGER
Workinganinearth/ground.
the vicinity of The
leadgroundacid
an AC
supply
incorporating
CAUTION
batteries
is
dangerous.
Batteries
generate
explosive
gases
Risk
of
High
Voltages
–
Lethal
voltages
are
present
within
the
ing
conductor
be of afrom
sizeGases
equal Vented
or larger
the line
Risk
of Fire ormust
Explosion
bythan
Batteries
–
during
charging
and
discharging.
To
reduce
the
risk
of
battery
charger
enclosure
whenever
the
AC
mains
supply
is
energized
(phase)
conductors.
Discharge
static electricity from tools and technician by touching
explosion,
ensure
ventilation
and
these
instrucand/or
the
battery
or
loadCharger
is connected.
Thefollow
bus bars
and
other
A.C.T.
HFadequate
Fast
System
a grounded
surface
when
working
in the vicinity of batteries.
tions as components
well as thosepresent
published
by
the
battery
manufacturer.
internal
the
risk
of
electric
shock.
WARNING
tions as well as those published by the battery manufacturer.
c) Buss bar bolts are tight along with DC fuse.
WARNING
d) Visually
DC Grounding
Cables, connectors
andmust
tips be
for connected
tightness to
Riskinspect
of Improper
– The charger
and damage.
an AC mains supply incorporating an earth/ground. The groundingall
conductor
must
be of a size
equal
or larger than the line
e) Check
plugs and
harnesses
are
secure.
f)
(phase) conductors.
Check communication cable when BFD installed.
(BF displayed in bottom rightWARNING
hand corner of display).
Protect
Eyes and
Skin –
Wear
safety
goggles
and skinbattery
protecg) Check
for correct
charge
start
rate.
Check
for correct
tion
when
installing
or
servicing
the
battery
charging
system
type loaded.
or working in the vicinity of lead-acid batteries.
h) Check Finish and EQ windows for settings that match
customer idle times.
WARNING
To reduce the risk of injury, only charge rechargeable lead-acid
batteries. Charging or trying to charge other types of batteries
may cause damage or result in personal injury.
WARNING
Risk of Fire - To reduce the risk of fire, install battery charger on
a floor of non-combustible material, such as stone, brick, concrete, or metal. Do not install on or over combustible surfaces.
CAUTION
14
2
Risk of Fire – Use only on circuits provided with appropriate
branch circuit protection in accordance with the National Electrical Code, NFPA 70. The appropriate branch circuit protection is:
Charger model STS-320: 30 Amperes
Charger modelIOOC
STS-400:
35 Amperes
Rev. 10282013
IOM320 Rev. 01102012
2
Protect Eyes and Skin – Wear
safety goggles and skin protecWARNING
WARNING
DANGER
tion when
installing
or servicing
the
battery
charging
system to
Risk
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is
dangerous.
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charger
enclosure
whenever
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energized
ing
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during
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and
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its output devices. Always
explosion,
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observe local safety codes and standards.
tions
as well
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WARNING
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batteries.
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or
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to
charge
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types
of
batteries
DANGER
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– CAUTION
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vicinity
of connected
lead
acid
may
cause
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asFire
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WARNING
a floor
of non-combustible
material,
such
as
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conTo
reduce
the risk of injury,WARNING
only
charge
rechargeable
lead-acid
DANGER
WARNING
CAUTION
crete,of
metal.
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not
install
on
or
over
combustible
surfaces.
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oforHigh
Explosive
Gases
–
Working
in
the
vicinity
of
lead
acid
batteries.
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or
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to
charge
other
types
of
batteries
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and
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–
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safety
goggles
and
skin
protecRisk
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–
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voltages
are
present
within
the to
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The charger
must
beoverheating
connected
Air Filter
Maintenance
– To –prevent
damage
from
batteries
is
dangerous.
Batteries
generate
explosive
gases
may
cause
damage
or
result
in
personal
injury.
tion
when
installing
or
servicing
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battery
charging
system
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enclosure
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accordance
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risk
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charger
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WARNING
cal
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NFPA
70.
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appropriate
branch
circuit
protection
a
floor
of
non-combustible
material,
such
as
stone,
brick,
conTo
reduce
the
risk
of
injury,
only
charge
rechargeable
lead-acid
Risk of
of Improper
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Gases
– Working
ingoggles
the vicinity
ofskin
leadprotecacid is:to
Protect
Eyes andGrounding
Skin – Wear
safety
and
Risk
– The
charger
must
be
connected
Charger
model
STS-320:
30
Amperes
crete,
or
metal.
Do
not
install
on
or
over
combustible
surfaces.
batteries.
Charging
or
trying
to
charge
other
types
of
batteries
batteries
isinstalling
dangerous.
explosive
gases
tionAC
when
or Batteries
servicing generate
the
battery
charging
system
an
mains
supply incorporating
an earth/ground.
The
groundCharger
model
STS-400:
Amperes
may
cause
damage
or
result
in personal
injury.
during
charging
and
discharging.
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thethan
risk of
or working
in
the
vicinity
ofa35lead-acid
batteries.
ing
conductor
must
be
of
size
equal
or larger
thebattery
line
explosion,
ensure adequate ventilation and follow these instruc(phase) conductors.
IOOC
Rev.
10282013
3
CAUTION
Rev.
01102012
tions as wellIOM320
as
those
published
by the battery manufacturer.
Risk of Fire – Use only onWARNING
circuits
provided
with
appropriate
WARNING
WARNING
branch
protection
in
accordance
with
the
National
ElectriRisk
of circuit
Fire
- To
reduce
the
risksafety
of
fire,goggles
install
battery
charger
on
To
reduce
the
risk
of
injury,
only
charge
rechargeable
lead-acid
Protect
Eyes
and
Skin
–
Wear
and
protecRisk
of
Improper
Grounding
– The
charger
must
beskin
connected
to
cal
Code,
NFPA
70.
The
appropriate
branch
circuit
protection
a floor of non-combustible material, such as stone, brick, con-is:
A.C.T. HF Opportunity Charger System
Installation & Operation Manual
1.0 INSTALLATION
3.0 TROUBLESHOOTING
1.1 Location and Mounting
The Charging System does not contain user serviceable parts. Please
contact A.C.T. at 877-228(ACT)-5922 in case of malfunction.
The charging area should be well ventilated, dry and adequately clean
before the charger is mounted.
4.0 MAINTENANCE
The A.C.T. opportunity chargers offer a wide variety of mounting options
such as floor mount, wall mount, or stacked on top of each other.
The charger has four air vent openings around its top, and air inlet
openings at its front and back bottom. To allow proper cooling of the
charger, at least the following should have unobstructed airflow:
• The air inlet at the bottom of the front.
AND
• Two of the four air outlet vents at the top of the charger.
This means that two of the four air outlets at the top, and the air inlet at
the bottom back is allowed to be covered by a wall, other charger or other
obstruction, which allows great installation flexibility.
Three chargers stacked on top of each other in a corner of two walls is an
example of an acceptable installation:
NOTE:
THE MAXIMUM NUMBER OF OPPORTUNITY CHARGERS THAT
CAN BE PLACED ON TOP OF EACH OTHER IS THREE. WHEN
STACKING CHARGERS, THE MAXIMUM ALLOWED AMBIENT
OPERATING TEMPERATURE IS REDUCED TO 43ºC (109ºF)
WHEN TWO CHARGERS ARE STACKED ON TOP OF EACH
OTHER, AND TO 38ºC (100ºF) WHEN THREE CHARGERS ARE
STACKED ON TOP OF EACH OTHER.
Regularly inspect air filter at the bottom of the charger and clean
or replace as necessary. Inspect DC cables for wear.
4.1 Replacing Cables
If The DC output cables or Euro connectors become worn or are
damaged, they should be immediately replaced.
4.2 Working Environment Service Frequency
Location and environmental conditions must be taken into to account
when determining the frequency that the Air Filter is cleaned or replaced.
A.C.T. guidelines are as follows:
Normal
A normal daily operation Conventional Charging basic material
handling of clean product in dry environments.
Clean or replace Filter annually
Severe
Extended operating hours or constant use when Fast or Opportunity
charging in dusty hot but dry environments.
Clean or replace Filter Semi-annually
Extreme
All dusty or sandy conditions such as in cement plants, lumber or flour
mills, coal dust or stone-crushing areas.
Exposure wet to cool or cold air in enclosed applications.
Corrosive atmosphere such as in chlorine or salt-sea air environments.
Clean or replace Filter Quarterly
Air Filter can be blown out or washed in warm soapy water
(Filter must be completely dried prior to re- install)
4
IOOC Rev. 10282013
IOOC Rev. 10282013
13
Installation&OperationManual
A.C.T. HF Opportunity Charger System
Installation & Operation Manual
A.C.T. HF Opportunity Charger System
2.4.4.2 Manual Watering
The second window down in the Manual Operation menu is the manual
1.3 AC window.
Power Connection
watering
This window allows the user to manually operate
AC
power
connections
should
bewindow
made by
licenseddown
electrician
watering valves.
One reaches
this
byascrolling
from the
only.
Verify
if
the
charger’s
ratings
match
the
available
manual equalization window with the down arrow. Once utility
in the manual
voltage.
The
charger
should
be
connected
to
meet
local
electrical
watering window, the left and right arrow keys increase and decrease the
or National
Electrical
Code
duration
setting.
Once
requirements.
duration
has
been selected,
watering
the desired
the• A
selection
is accepted
initiated
bycharger
pressingforthe
knock out
is providedand
on watering
the right side
of the
AC“ENTER”
key.installation.
Watering can be immediately stopped by pressing the “BACK” key.
can
stopped
This
immediately
terminates
watering
be
immediately
by
•
The
ground
connection
should
be
made
to
the
compression
lug
pressing the “BACK” key. This immediately terminates watering and
provided
on
the
side
wall
of
the
charger.
returns the display to the Real Time Status display.
• Use
Manual
Operation
2.4.4.3
copper
conductors
only. of External
Scavenging
Fan
The
window
must
down
ingrounded
Manual
in accordance
• The
be
with the
Facilities
thirdcharger
the
Operation menu
is the
manual fan
window.
windowmethod.
the user to manually operate an external
Utility
grounding
This
allows
scavenging
fan for removal
of fumes.
One
reaches
by
• All connections
must comply
with all
local
codesthis
andwindow
ordinances.
down
window with the
arrow.
scrolling
from the manual watering
down
Once in the manual
watering window, the left and right arrow keys turn
the fan on or off. Pressing the “BACK” key returns the display to the Real
Time Status display.
2.4.5 Fault History Display
BACK OF CHARGERS
AGAINST WALL
ONE SIDE OF
CHARGERS
AGAINST WALL
NO AIRFLOW
OBSTRUCTION
ALLOWED ON
THIS SIDE
The Fault History Display enables theDANGER
user to view a summary of recent
fault events on
the Charging
Station.
The summary information
is:
,*,-*&"&
'('/*'*
$$'/%"&-,+'*,!+1+,%,'$'/&'*
• Type of +*.""&
fault
,'-!"& ,!'&&,"'&+
• Time and date of fault
• If fault is an HPE fault, HPE number
CAUTION
The up and down
keys allow
the user3-*&!*
to scroll through
the history
arrow
*''*(
of recent events.
($1"& ('/*+0,*&$"*-",*#*,',-*&'&
('/*
NO AIRFLOW
OBSTRUCTION
ALLOWED ON
FRONT SIDE
12
8
IOOC Rev. 10282013
IOOC Rev. 01102012
5
IOOC Rev. 10282013
IOOC Rev. 01102012
5
A.C.T. HF Opportunity Charger System
Installation
& Operation
Manual
Installation
& Operation
Manual
For wall mounting, only use mounting brackets especially designed for the
STS series chargers, available from your local A.C.T. dealer:
For installations in Canada: Regardless of the installation surface, the
metal STS charger mounting plate (available from your local A.C.T. dealer)
should be installed between the charger and the installation surface:
STEEL PLATE
REQUIRED FOR
INSTALLATIONS IN
CANADA
6
IOOC Rev. 10282013
IOOCMVHP
Rev. 01102012
IOOC Rev. 10282013
11
11
A.C.T. HF Opportunity Charger System
Installation & Operation Manual
2.4.3 Charging History Display
1.2 Floor Mounting
The Charging History Display enables the user to view a summary
of recent charging events on the Charging Station. The summary
information is:
If the charger is mounted on the floor, make sure the charger is mounted
on non-combustible material, such as concrete. The four mounting holes
in the bottom of the charger are 3/8” (10mm) diameter. Use 5/16” x 4”
bolts or larger bolts that are suitable for use with the installation surface.
Hole can be predrilled following the bolt pattern below:
• Type of event (Fast Charge, Finish, Equalization) and whether it was completed or aborted by a disconnection
• Amp-Hours returned during the charging event
• Battery state of charge (only if event is completed - zero percent is displayed if the event is terminated by a user disconnection)
• Date of event
8 1/2” (216mm)
11 1/2” (283mm) for P80-800-R25
• Time of event
• Duration of event
The up and down arrow keys allow the user to scroll through the history of
recent events.
2.4.4 Manual Operations Display
There are several operations that the user can initiate from the keypad:
• Manual equalization
• Manual watering
• Manual operation of external scavenging fan
2.4.4.1 Manual Equalization
In automatic operation, equalization proceeds if either (a) a Finishing
charge event completes when the equalization window is open, or (b) if
a battery that has completed a Finishing charge when the equalization
window is not open is left connected to the charger until the equalization
window opens. By invoking manual equalization, the user effectively
forces the equalization window open at the end of the present charging
event, such that an equalization will be carried out regardless of time of
day or day of week. After the single forced equalization, the Charging
Station reverts to automatic operation, i.e., the forced equalization is a
one-time event.
19” (482mm)
Manual equalization is invoked by using the down arrow to get to the
manual equalization window, and using the left and right arrows to toggle
between force equalize off and on.
10
IOOC Rev. 10282013
IOOC Rev. 10282013
7
A.C.T. HF Opportunity Charger System
Installation & Operation Manual
1.3 AC Power Connection
2.0 OPERATION
AC power connections should be made by a licensed electrician only.
Verify if the charger’s ratings match the available utility voltage. The
charger should be connected to meet local electrical or National Electrical
Code requirements.
2.1 Start Charging
• A knock out is provided on the right side of the charger for AC installation.
• The ground connection should be made to the compression lug provided on the side wall of the charger.
• Use copper conductors only.
• The charger must be grounded in accordance with the Facilities Utility grounding method.
• All connections must comply with all local codes and ordinances.
A.C.T. HF Fast Charger System
DANGER
DANGER
Risk of High Voltages – Lethal voltages are present within the
RISK OF ELECTRIC SHOCK - After turning off AC power for
charger enclosure whenever the AC mains supply is energized
servicing, allow 5 minutes for the system to bleed down before
and/or the
battery
or
loadCharger
is connected.
HFconnections.
Fast
SystemThe bus bars and other
touchingA.C.T.
the AC
internal components present the risk of electric shock.
WARNING
DANGER
Risk
Gases
– CAUTION
Working
in the
vicinity
of lead
Risk of
of Explosive
High Voltages
– Lethal
voltages
are
present
withinacid
the
POTENTIAL
SYSTEM
DAMAGE
– Turn charger
off before
batteries
is
dangerous.
Batteries
generate
explosive
gases
charger enclosure whenever the AC mains supply is energized
applying AC power.
Use external circuit
breaker
to turn
on
during
and
To reduce
battery
and/or charging
the battery
or discharging.
load is connected.
The the
busrisk
barsofand
other
AC
power.
explosion,
ensure
adequate
ventilation
and
follow
these
internal components present the risk of electric shock. instructions as well as those published by the battery manufacturer.
WARNING
WARNING
Risk
Gases – Working
in the vicinity
of connected
lead acid to
Risk of
of Explosive
Improper Grounding
– The charger
must be
batteries
is
dangerous.
Batteries
generate
explosive
gases
an AC mains supply incorporating an earth/ground. The
groundduring
charging
and
discharging.
To
reduce
the
risk
of
ing conductor must be of a size equal or larger than thebattery
line
explosion,
ensure adequate ventilation and follow these instruc(phase) conductors.
tions as well as those published by the battery manufacturer.
WARNING
WARNING
Protect
Eyes andGrounding
Skin – Wear
safety
goggles
and
protec- to
Risk of Improper
– The
charger
must
beskin
connected
tionAC
when
installing
or servicing the
battery charging
an
mains
supply incorporating
an earth/ground.
Thesystem
groundor working
in the
vicinity
ing
conductor
must
be ofofa lead-acid
size equalbatteries.
or larger than the line
(phase) conductors.
8
WARNING
IOOC Rev. 10282013
WARNING
To
reduce
theand
risk Skin
of injury,
onlysafety
charge
rechargeable
Protect
Eyes
– Wear
goggles
and skinlead-acid
protecbatteries.
Charging
or
trying
to
charge
other
types
of batteries
tion when installing or servicing the battery charging
system
may
cause in
damage
or result
in personal
injury.
or working
the vicinity
of lead-acid
batteries.
To charge a battery, connect the Euro connector of the charger to the
battery. Charging will start automatically.
2.2 Stop Charging
Press the STOP Button, then unplug the connector from the battery.
When Euro connectors are used, there is no need to press the STOP
button first.
2.3 LED and Stack Light Operational Status Indicators
2.3.1 Front Panel LED Indicators
The Front Panel LEDs indicate the activity status of the Charging Station.
2.4 Front Panel Display and Keypad Operation
2.4.1 Display Mode Overview
There are four top-level menu categories:
• Real-time charging status
• Charging history
• Manual operations
• Fault log
The left and right arrows allow the user to select between these categories.
Up and down arrows allow the user to navigate within categories.
2.4.2 Real-Time Status Display
The Real-time Status Display shows the real-time value of several
charger and battery parameters:
• Charging current
• Battery voltage
• Amp-hours returned during the present charging event
• Battery state of charge
• Battery temperature
• Duration of present charging event
The Real-time Status Display has no sub-categories.
IOOC Rev. 10282013
9