OWNER’S MANUAL 193111-055

Revised November 17, 2020

IMPORTANT: Read these instructions before installing, operating, or

servicing this system.

ACCU-CHARGER

Silicon Diode Ferroresonant

Transformer type
Battery Charger

DO NOT DESTROY

AMETEK/PRESTOLITE POWER , TROY, OHIO 45373-1099, U.S.A.

NOTE: Information regarding obtaining additional copies of this manual is located in the Introduction
chapter of this manual.

A battery charger is identified by model number. Incorporated into the model number is the 8-hour
ampere-hour capacity, case size, input power phase, and number of cells in battery for which charger is
intended. The following example explains the basic model numbering arrangement.

Model 750 C 3 18 R

80% Rated (Blank Indicates 100% Rated)

Number of Cells

Input Power Phase (1-Single Phase; 3-Three Phase)

Case Size (B, C,)

8-Hour Ampere-Hour Capacity

NOTE: This information is required for ordering certain replacement/service parts.

 193111-055
TABLE OF CONTENTS

INTRODUCTION .................................................................................................................................. 1
How to use this Manual .....................................................................................................1-1
Equipment Identification ....................................................................................................1-1
Receipt of Equipment ........................................................................................................1-1
SAFETY INSTRUCTIONS AND WARNINGS ............................................................... 2
DESCRIPTION OF EQUIPMENT.................................................................................................... 3
INSTALLATION .................................................................................................................................... 4
Location ............................................................................................................................4-1
Environmental Characteristics ...........................................................................................4-1
Grounding .........................................................................................................................4-1
Line Voltage Changeover Instructions...............................................................................4-2
Line Connections to Battery Charger ................................................................................4-2
Charging Cable Connectors ..............................................................................................4-3
Pre-operation Checks .......................................................................................................4-3
OPERATION .......................................................................................................................................... 5
Preliminary ........................................................................................................................5-1
Normal or Daily Charge ....................................................................................................5-1
Equalize or Weekend Charge ...........................................................................................5-1
Manual Stop ......................................................................................................................5-2
Battery Discrimination .......................................................................................................5-2
Refresh Charge.................................................................................................................5-2
Backup Timer Shutdown ...................................................................................................5-2
Battery Disconnect Shutdown ...........................................................................................5-3
Low Current Shutdown......................................................................................................5-3
AC Power Fail ...................................................................................................................5-3
MAINTENANCE ................................................................................................................................... 6
Inspection and Cleaning....................................................................................................6-1
Lubrication ........................................................................................................................6-1
Charging Rate Adjustment ................................................................................................6-1
Fuse Replacement ............................................................................................................6-2
Silicon Diode Testing ........................................................................................................6-2
Capacitor Testing ..............................................................................................................6-3
Troubleshooting ................................................................................................................6-4
OPTIONS ................................................................................................................................................ 7
Parallel Charging — Option 002 ........................................................................................7-1
Series Charging — Option 003 ..........................................................................................7-1
Remote Charge Control — Option 101 .............................................................................7-2
Fused Disconnect Switch — Option 500 ..........................................................................7-2
PARTS LIST ................................................................................................................. 8
DIAGRAMS
WARRANTY

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TABLE OF CONTENTS

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 193111-055
INTRODUCTION

INTRODUCTION
How To Use This Manual NOTE offers helpful information concerning
certain operating procedures. Notes will be
shown in italics.

Equipment Identification
The unit's identification number (specification, model,
IMPORTANT: It is especially
serial number) usually appears on a nameplate
important that all charger attached to the front panel.
internal components be kept
clean and dry, and all Receipt Of Equipment
electrical connections as When you receive the equipment, check it against the
tightened as instructed in the invoice to make sure it is complete and inspect the
Maintenance chapter of this equipment for possible damage due to shipping. If
manual. Replace any there is any damage, notify the carrier immediately to
precautionary or instruction file a claim. Furnish complete information concerning
label that cannot be easily damage claims or shipping errors to the company
read. shown on the cover of this manual. Include all
equipment identification numbers and group part
numbers (if any) as described above along with a full
description of the parts in error.

Move the equipment to the site of installation before

Throughout this manual, the words WARNING, uncrating. Use care to avoid damaging the equipment
CAUTION, and NOTE may appear. Pay particular when using bars, hammers, etc., to uncrate the unit.
attention to the information provided under these
headings. These special annotations are easily
recognized as follows: Additional copies of this manual may be purchased by
contacting the company shown on the cover of this
manual. Include the Owner's Manual number and
WARNING gives information equipment identification numbers.
regarding possible personal
injury. Warnings will be
enclosed in a box such as this.

CAUTION refers to possible equipment

damage. Cautions will be shown in bold
type.

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INTRODUCTION

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SAFETY INSTRUCTIONS AND WARNINGS

SAFETY INSTRUCTIONS AND WARNINGS

FOR OPERATION OF BATTERY Equipment – Electrical equipment must be installed
and maintained in accordance with the National
CHARGING EQUIPMENT Electrical Code, NFPA 70, and local codes. A
power disconnect switch must be located at the
equipment. Check nameplate for voltage and
phase requirements. If only 3-phase power is
available, connect single-phase equipment to only
IMPORTANT – READ AND two wires of the 3-phase line. DO NOT CONNECT
UNDERSTAND THESE the equipment grounding conductor (lead) to the
INSTRUCTIONS. DO NOT third live wire of the 3-phase line as this makes the
equipment frame electrically HOT, which can cause
LOSE THEM. ALSO READ a fatal shock.
OPERATING/INSTRUCTION
MANUAL BEFORE If a grounding lead (conductor) is part of the power
INSTALLING, OPERATING, supply cable, be sure to connect it to a properly
OR SERVICING THIS grounded switch box or building ground. If not part
of the supply cable, use a separate grounding lead
EQUIPMENT. (conductor). Do not remove a ground prong from
any plug. Use correct mating receptacles. Check
ground for electrical continuity before using
equipment.
A. General
The grounding conductor must be of a size equal
Battery charging products can cause serious to or larger than the size recommended by Code or
injury or death, or damage to other equipment or in this manual.
property, if the operator does not strictly observe
all safety rules and take precautionary actions. 2. Charging Leads – Inspect leads often for damage
to the insulation. Replace or repair cracked or worn
Safe practices have developed from past experience leads immediately. Use leads having sufficient
in the use of charging equipment. These practices capacity to carry the operating current without
must be learned through study and training before overheating.
using this equipment. Anyone not having
extensive training in battery charging practices 3. Battery Terminals – Do not touch battery terminals
should be taught by experienced operators. while equipment is operating.
Only qualified personnel should install, use, or 4. Service and Maintenance – Shut OFF all power at
service this equipment. the disconnect switch or line breaker before
inspecting, adjusting, or servicing the equipment.
B. Shock Prevention Lock switch OPEN (or remove line fuses) so that
the power cannot be turned ON accidentally.
Bare conductors, or terminals in the output circuit,
Disconnect power to equipment if it is to be left
or ungrounded, electrically-live equipment can
unattended or out of service.
fatally shock a person. To protect against shock,
have competent electrician verify that the
Disconnect battery from charger. Measure voltage
equipment is adequately grounded and learn what
on capacitors and discharge through an insulated
terminals and parts are electrically HOT.
screwdriver if there is any voltage reading.
The body’s electrical resistance is decreased when
Keep inside parts clean and dry. Dirt and/or
wet, permitting dangerous current to flow through the
moisture can cause insulation failure. This failure
body. Do not work in damp area without being extreme-
can result in high voltage at the charger output.
ly careful. Stand on dry rubber mat or dry wood and
use insulating gloves when dampness or sweat cannot
be avoided. Keep clothing dry.

1. Installation and Grounding of Electrically Powered

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193111-055
SAFETY INSTRUCTIONS AND WARNINGS

C. Burn and Bodily Injury Prevention

The battery produces very high currents when short
circuited, and will burn the skin severely if in contact
with any metal conductor that is carrying this current. DANGER: ELECTRICAL SHOCK
Do not permit rings on fingers to come in contact with CAN BE FATAL. If person is
battery terminals or the cell connectors on top of the unconscious and electric shock
battery.
is suspected, do not touch
Battery acid is very corrosive. Always wear correct eye person if he or she is in contact
and body protection when near batteries. with charging leads, charging
equipment, or other live electrical
D. Fire and Explosion Prevention parts. Disconnect (open) power
at wall switch and then use
Batteries give off explosive flammable gases which
easily ignite when coming in contact with an open flame First Aid. Dry wood, wooden
or spark. Do not smoke, cause sparking, or use open broom, and other insulating
flame near batteries. Charge batteries only in material can be used to move
locations which are clean, dry, and well ventilated. cables, if necessary, away from
Do not lay tools or anything that is metallic on top of person. IF BREATHING IS
any battery. All repairs to a battery must be made only
by experienced and qualified personnel. DIFFICULT, give oxygen. IF NOT
BREATHING, BEGIN ARTIFICIAL
E. Arcing and Burning of Connector BREATHING, such as mouth-to-
mouth. IF PULSE IS ABSENT,
To prevent arcing and burning of the connector BEGIN ARTIFICIAL CIRCULATION,
contacts, be sure the charger is OFF before connecting such as external heart massage.
or disconnecting the battery. (If the charger is
equipped with an ammeter, the ammeter should not
indicate current flow.) Always connect battery before
turning charger ON.

F. Medical and First Aid Treatment IN CASE OF ACID IN THE EYES, flush very well
with clean water and obtain professional medical
First aid facilities and a qualified first aid person should attention immediately.
be available for each shift for immediate treatment of
electrical shock victims.

G. Equipment Warning Labels

EMERGENCY FIRST AID: Call
physician and ambulance Inspect all precautionary labels on the equipment.
immediately. Use First Aid Order and replace all labels that cannot be easily read.
techniques recommended by the
American Red Cross.

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DESCRIPTION OF EQUIPMENT

DESCRIPTION OF EQUIPMENT
Charger
The AC1000 Control is “matched” to the output voltage
The basic charging circuit is the silicon diode, of the charger by means of a printed circuit board
rectifier-type with ferroresonant transformer (s). This mounted DIP switch. It will operate on 6, 12, 18, 24,
ferroresonant transformer design regulates charging 36, and “optional” cell batteries. “Optional” is provided
current by allowing the battery to determine its own to accommodate batteries between 6 and 36 cells that
charge cycle rate in accordance with its state of are not listed above.
discharge. It provides a constantly-tapering charge that
eliminates the possibility of overcharging, even with line The status of a normal charge cycle is indicated by the
voltage variations of ± 10%. Single-phase input four LEDs on the front panel. The “80% Charged”
chargers have one transformer, three-phase input LED will light when the battery voltage reaches the
chargers have three. The charger is internally 80% charged voltage. This voltage may be 2.37
protected from overload and short circuits. volts/cell or 2.45 volts/cell nominal, depending on the
status of DIP switch S1-7. See the AC1000 Setup
When charging lead acid batteries, with the same chapter of this manual. The “Charge Complete” LED
number of cells and ampere-hour capacity as shown will light only if the battery has completed the charge
on charger nameplate, the charging time will be cycle and is ready for use. The “Abnormal Shutdown”
approximately 8 hours. Batteries of smaller or larger LED will light if the charger terminates a charge
ampere-hour capacities can also be charged, but will prematurely. See the Troubleshooting chapter of this
require shorter or longer charging, respectively. manual to determine the cause of the fault. The
“Equalize” LED will light solid when a equalize charge
is requested by pressing the EQUALIZE push button.
Charge Control The “Equalize” LED will flash when the charger is
equalizing the battery.
The AC1000 Control is provided as the standard
charger control. It utilizes either a voltage/time (VT)
charge termination or a patented pT/dV/dT charge ter-
mination technique which eliminates excessive gassing WARNING: Do not connect a
by returning approximately 107% of the amp-hours battery to this charger if any LED
removed from the battery. is lit. Do not disconnect a battery
from this charger while a charge
Features of the AC1000 Control include manual is in progress. Otherwise, arcing
equalize, manual stop, back-up timer protection, two and burning of connector parts or
charge termination methods, 80% voltage point a battery explosion may result.
selection, high and low battery voltage discrimination, Batteries produce explosive gases.
and AC power fail recovery. Keep sparks, flame, and cigarettes
away. Ventilate when charging in
an enclosed area. Always shield
eyes when working near batteries.

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DESCRIPTION OF EQUIPMENT

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INSTALLATION

INSTALLATION
Location electrical charges which tend to build up on the
surfaces of equipment. These static charges can
For best operating characteristics and longest unit life, cause painful shock to personnel, and can lead to the
take care in selecting an installation site. Avoid erroneous conclusion that an electrical fault exists in
locations exposed to high humidity, dust, high ambient the equipment.
temperature, or corrosive fumes. Moisture can
condense on electrical components, causing corrosion If a charger is to be connected to the AC power supply
or shorting of circuits (especially when dirt is also with a flexible jacketed cable, one having a separate
present). grounding conductor should be used. When included
in cable assembly, grounding conductor will be green,
Adequate air circulation is needed at all times in order green with a yellow stripe, or bare. When connecting
to assure proper operation. Provide a minimum of 6 input power to charger (as instructed in Line
inches of free air space at rear and sides of the unit. Connection to Battery Charger section of this manual),
Make sure that ventilation openings are not obstructed. connect grounding conductor to equipment grounding
Always remove the charger shipping skid from the unit terminal (stud with a green nut and a cup washer and
before installation. The charger must be installed over identified by the ground symbol), Connect other end of
a noncombustible surface such as concrete or metal. grounding conductor to the system ground.
Keep the charging area clear of all combustible
material such as wood, paper, and cloth. If, for any reason, an input cable which does not
include a grounding conductor is used, the equipment
WARNING: SPARKS OR MOLTEN METAL must be grounded with separate conductor. Minimum
falling through open bottom can cause fire or size and color coding requirements must be in
explosion. accordance with any applicable state or local code, or
the National Electrical Code.
• Install over noncombustible material such
as concrete or metal. If metallic armored cable or conduit is used, the metal
sheathing or conduit must be effectively grounded as
• Keep charging area clear of combustible required by state or local code, or the National
material. Electrical Code.

Environmental Characteristics If a system ground is not available, the charger frame

must be connected to a driven ground rod (at least 8 ft
[2438 mm] long), or to a water pipe that enters the
Operating Characteristics 0°C to 40°C
ground not more than 10 ft (3048 mm) from the
(32°F to 104°F)
charger. A grounding conductor must be connected to
Operating Altitude To 2000 Meters the rod or pipe in a manner that will assure a
(6562 Feet) permanent and effective ground. The conductor must
be sized in accordance with any applicable state or
Operating Humidity 80% up to 31°c,
local code, or by the National Electrical Code. If in
decreasing to 50% at
doubt, use the same size conductor as is used for the
40°C, non-condensing
conductors supplying power to the charger.
80% up to 88°F
decreasing to 50% at
104°F, non-condensing WARNING: ELECTRIC SHOCK
Grounding HAZARD – Under no circumstance
should you use a grounding
The frame of the power source must be grounded for conductor with a current carrying
personnel safety. Where grounding is mandatory
under state or local codes, it is the responsibility of the capacity less than the ampere
user to comply with all applicable rules and regulations. rating shown in Table 4-1.
Where no state or local codes exist, it is recommended
that the National Electrical Code be followed.

In addition to the usual function of protecting personnel

against the hazard of electrical shock due to fault in the
equipment, grounding serves to discharge the static

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193111-055
INSTALLATION

LINE DISCONNECT BRANCH FUSE COPPER CABLE SIZE AWG * *

AMPS SWITCH * SIZE (AMPERES)
POWER GROUND

0-2.5 30A 5 No. 14 No. 14

2.6-4.5 30A 7 No. 14 No. 14
4.6-7.5 30A 10 No. 14 No. 14
7.6-12 30A 15 No. 14 No. 14
12.1-16 30A 20 No. 12 No. 12
16.1-18 30A 25 No. 10 No. 10
18.1-22 30A 30 No. 10 No. 10
22.1-24.5 60A 35 No. 8 No. 10
24.6-32.5 60A 40 No. 8 No. 10
32.6-40 60A 50 No. 8 No. 10
40.1-45 60A 60 No. 6 No. 10
45.1-57.5 100A 80 No. 4 No. 8
57.6-78 100A 100 No. 2 No. 8
78.1-102.5 200A 125 No. 2 No. 6
102.6-135 200A 150 No. 1/0 No. 6

Table 4-1 Recommended AC Input and Branch Fusing

The above table (Table 4-1) is based on 75°C (167°F) rated conductors and 40°C (104°F) ambient temperatures. Refer to
National Electrical Code (2008) Tables 310-16 corrected to 40°C (104°F).

* For 115, 208, and 230-volt lines, use 250-volt disconnect switch.
For 440-480, 575-volt lines, use 600-volt disconnect switch.

** Two conductors and ground conductor required for single phase.

Three conductors and ground conductor required for three phase.

Recommended minimum size of grounding conductors (based on National Electrical Code 2008 – Table 250-95).

Line Voltage Changeover AND INCORRECT FUSE SIZE can damage

this equipment. Follow voltage changeover
Instructions instructions carefully.
1. Determine if the charger is connected for available
line voltage. A label located near AC input terminals
Line Connections to Battery Charger
is marked with the AC voltage for which the charger
is factory connected. Follow local code requirements if different than
instructions in this manual.
2. If charger is not connected correctly, check serial
nameplate to determine that charger is equipped 1. Turn charger OFF.
to be connected for available line voltage. If
charger is suitably equipped, make voltage change- 2. Be sure charger is connected correctly for available
over connections by following instructions on AC line voltage as instructed above.
INPUT label inside charger.
3. On charger nameplate, note the AC input amperes
3. If charger is reconnected, check input fuse (s) corresponding to the line voltage to which charger
ratings with ratings specified on label and replace is to be connected. Use that ampere value to select
if necessary. the proper disconnect switch, fuse, and power cable
sizes from Table 4-1. A “WARNING” label inside
charger also lists fuse sizes for each line voltage
(circled fuse rating is required for internal line
voltage connections made at factory).

CAUTION: INCORRECT CONNECTIONS

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INSTALLATION

4. Route AC power input cable in through knock-out

provided in side panel of charger cabinet. Securely Pre-operation Checks
fasten cable wires to a power input terminal inside
charger. Refer to Grounding section of this manual 1. Inspect charger thoroughly for damage; loose
for proper connection of grounding conductor. screws, nuts, or electrical connections.
(Charger cabinet top or side panel, or both, may
have to be removed to provide access to terminal
block.) WARNING: ELECTRICAL SHOCK
HAZARD – Before inspecting or
5. With disconnect switch (on AC input power line) in cleaning inside cabinet, turn OFF
“OPEN” or “OFF” position, connect power cable and remove fuses of disconnect
coming from charger, to the switch. Install fuses in switch (supplying AC power to
switch.
charger), disconnect battery, and
check for voltage on capacitors.
Charging Cable Connectors Discharge through insulated
If connectors are already attached to charging cables, screwdriver if there is any reading.
make sure that they’re attached so that positive charger
polarity will connect to positive battery terminal.
2. Remove all special tags that are tied to charger.
If connectors must be attached to charging cables, Keep tags with this manual for future reference.
follow instructions supplied with connectors. Leave all precautionary and instruction labels in
place on charger. Carefully read and follow
CAUTION: Make sure connectors are instructions on all tags and labels. Make sure all
securely attached to cables (good labels remain visible to anyone operating charger.
solder joint or well tightened set screws,
whichever is applicable). Be certain 3. Make sure all charger cabinet panels are fastened
that positive charger cable will connect in place, to assure proper flow of ventilating air
to positive battery terminal. If necessary, through cabinet.
trace cables into charger and use
supplied connection diagram to
determine polarity. The use of a DC
voltmeter may show polarity. Improper
connections will “blow” output fuse
and may cause other damage.

Note: If this charger is equipped with certain

optional features, the connector attaching
procedure may be modified. Refer to
OPTIONS chapter of this manual for details.

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OPERATION

OPERATION
Preliminary STOP key, then disconnect the battery
from the charger.
1. Make sure that charger is installed and grounded as
instructed in this manual. Equalize or Weekend Charge
2. Make sure the charge control is set to the proper The AC1000 features Auto Equalize every 5th charge
cell size via the charge control DIP switch cell cycle and is shipped with auto equalize feature ena-
selector. bled. With auto equalize disabled, an equalize charge
can be selected or de-selected for any charge cycle
3. Turn on main fused disconnect switch that supplies using the sequence below.
AC power to charger.
1. Insure that battery size matches the charger.
4. Maintain electrolyte level in batteries to be charged, (Number of cells and ampere-hour capacity are within
as instructed by battery manufacturer. The volume charger nameplate rating.)
of electrolyte will expand during the charge.
Therefore, to avoid overfilling, do not add water 2. Securely engage the battery and charger connect-
until the battery has received at least an 80% ors.
charge. This will usually be reached at the time
3. After a 5 second countdown (all LED’s will be lit),
gassing starts.
the charger will turn on. The “Charge in Progress”
LED will indicate charging current.
4. Press the “Equalize” key. The “Equalize” LED will
Normal or Daily Charge light solid. Press the key again to cancel the equalize
charge.
WARNING: DO NOT connect a
battery to this charger if any LED NOTE: The equalize charge cannot be cancelled
is lit. Do not disconnect a battery once the battery reaches the equalize charging
from this charger while a charge period. Press the STOP key to terminate the
is in progress; otherwise, arcing charge.
and burning of connector parts
or a battery explosion may result. 5. The “80% Charged” LED will light when the battery
Batteries produce explosive gases. on charge reaches the 80% charged voltage.
Keep sparks, flame and cigarettes
away. Ventilate when charging in 6. The battery reaches the normal termination point
an enclosed area. Always shield (pT/dV/dT or VT). However, the battery is charged an-
eyes when working near batteries. other 3 hours. The “Equalize” LED will flash during this
equalize period.
7. The charger will automatically turn off, and the
1. Insure that battery size matches the charger. “Charge Complete” and the “Equalize” LED will light
(Number of cells and ampere-hour capacity are when the equalized charge has finished. The LED’s
within charger nameplate rating.) will remain on until the battery is disconnected from the
2. Securely engage the battery and charger charger.
connectors.
3. After a 5 second delay (all LED’s will be lit), the
charger will turn on. The “Charge in Progress” LED
will indicate charging current.
4. The “80% Charged” LED will light when the battery
on charge reaches the 80% charged voltage.
5. The charger will automatically turn off and the
“Charge Complete” LED will light when the charge
has finished. The light will remain on until the
battery is disconnected from the charger.

NOTE: To disconnect battery from charger

before charge is complete, first press the

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OPERATION

WARNING: DO NOT connect a battery

to this charger if any LED is lit. Do not Refresh Charge
disconnect a battery from this charger
while a charge is in progress; otherwise, In order to guarantee that a fully charged battery is
arcing and burning of connector parts always ready for use, a “Refresh” feature has been in-
or a battery explosion may result. corporated into the AC1000 Control. If a battery is
Batteries produce explosive gases. left connected to the charger for 72 hours after a
Keep sparks, flame and cigarettes away. “Charge Complete” has been reached, the AC1000 will
Ventilate when charging in an enclosed start a charge sequence. The running time of this
area. Always shield eyes when working “Refresh” charge will depend on the depth of self-
near batteries. discharge of the battery.

Backup Timer Shutdown

Manual Stop
A backup timer will shut down the charger and all 4
1. To turn the charger off during any part of a charge LEDs will flash then the “Charge Complete” LED will
cycle, press the STOP key. All four LEDs will flash. flash if the battery on charge does not reach the 80%
voltage during the first 10 hours of charging.
2. To restart the charger, disconnect and reconnect the
battery. A new charge cycle will begin. Likewise, if the AC1000 Control is set to terminate via
the pT/dV/dT methodology (DIP switch S1-2 set to
DVDT) and the charger does not reach the termination
Battery Discrimination point within 5 hours after reaching the 80% charged
voltage, all 4 LEDs will flash then the “Charge Com-
The AC1000 Control has the ability to reject batteries plete” LED will flash.
with cell sizes that do not match the cell size that the
control is set up for (via DIP switch S2-1 through S2-6).
If the battery connected to the charger has an average
terminal voltage of greater than 2.30 volts/cell, the
charger will not start and all 4 LEDs will flash, then the WARNING: DO NOT connect a
“Charge in Progress” LED will flash (high battery fault battery to this charger if any LED
indication). If the battery voltage eventually falls below is lit. Do not disconnect a battery
2.30 volts/cell, the control will begin a normal charge from this charger while a charge
sequence. is in progress. Otherwise, arcing
and burning of connector parts or
If the battery connected to the charger has an average a battery explosion may result.
terminal voltage of less than 1.75 volts/cell, the charger Batteries produce explosive gases.
will not start and all 4 LEDs will flash, then the “80% Keep sparks, flame, and cigarettes
Charged” LED will flash (low battery fault indication). If away. Ventilate when charging in
the battery voltage eventually rises above 1.75 volts/ an enclosed area. Always shield
cell, the control will start a normal charge sequence. eyes when working near batteries.
If the battery connected to the charger has a terminal
voltage of less than 1.75 volts/cell and the operator
wishes to start the charge regardless of this low battery
voltage, the charge cycle will start if both the
EQUALIZE and the STOP keys are held pushed in until
all LEDs go out (approximately 5 seconds). Release
the key at this time.

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OPERATION

Battery Disconnect Shutdown AC POWER FAIL

If the battery is disconnected from the charger during a During an AC power failure, the AC1000 Control stores
charge cycle, the charger will be shutdown. All LEDs key information about the charge cycle. The infor-
will be off. mation is retained by powering some of the control’s
key components with a battery derived power supply.
Low Current Shutdown This causes the control to resume the charge where it
left off when the AC power is returned, unaffecting tim-
If the charger output current falls below a predeter- ers and equalize requests.
mined level, a low current shutdown will occur. All 4
LEDs will flash, then the “Equalize” LED will flash. The
display will read ACLo.

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OPERATION

Figure 5-1

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193111-055
MAINTENANCE

MAINTENANCE
Lubrication
WARNING: ELECTRICAL SHOCK
HAZARD — Before inspecting or None required.
cleaning inside cabinet, turn OFF
and remove fuses of disconnect
switch (supplying AC power to Charging Rate Adjustment
charger), disconnect battery, and
check for voltage on capacitors. Although it is normally not required, the charging rate
Discharge through insulated can be adjusted to accommodate unusually high or low
screwdriver if there is any reading. AC power line voltages, unusually high or low ambient
temperatures, or aged battery.

A rate adjustment is necessary if battery consumes

Inspection And Cleaning more water than normal or if its specific gravity after a
normal (daily) charge is not within 10 points of its
For uninterrupted, satisfactory service from this gravity after a weekend (equalizing) charge.
charger, it's necessary to keep unit clean, dry, and
well ventilated. At least every three months, or more
often as necessary, wipe and blow out all dirt from CAUTION: Before adjusting charging
unit's interior components, with clean, dry air of not rate, make sure that bad connections
over 25 psi (172 kPa) pressure. Use a hand bellows or damage to charger isn't affecting
if compressed air isn't available. charging process. Also make sure
proper charging procedure has been
Check and tighten all electrical connections as followed (thoroughly read Operation
necessary to eliminate unnecessary losses and to chapter of this manual).
avoid subsequent trouble from overheating or open
circuits. Check for broken wiring or damaged
Insulation on wiring.

WARNING: ELECTRICAL SHOCK

HAZARD — Before adjusting charging
WARNING: ELECTRICAL SHOCK rate, turn OFF and remove fuses of
HAZARD — Failure to keep internal disconnect switch (supplying AC power
parts clean and dry may allow to charger), disconnect battery, and
transformer (s) to short out, check for voltage on capacitors.
causing secondary circuits to Discharge through insulated screwdriver
carry dangerously high voltage. if there is any reading.

Be sure to replace all charger cabinet panels after

any servicing, to assure proper flow of cooling air
through unit and to protect internal components.

WARNING: ELECTRICAL SHOCK

HAZARD — All cabinet panels must
be replaced to protect personnel from
contact with hazardous voltages.

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MAINTENANCE

Table 6-1 Charging Rate Adjustment Table

1. Locate charging rate adjustment label inside charger Fuse Replacement

cabinet (same as Table 6-1). The factory set
charging rate is indicated on this label by circles The silicon diodes in this charger are protected by a
around terminal numbers to which YELLOW jumper “fast-clearing” type fuse.
and ORANGE lead were connected.
CAUTION: The use of any other type
2. Locate YELLOW jumper and ORANGE lead on each fuse besides the “fast-clearing” type
transformer terminal block present in your unit (one may cause damage to silicon diodes.
transformer for single-phase, three for three-phase).

3. Mark present location of YELLOW jumper and Silicon Diode Testing

ORANGE lead on charger rate adjustment label and
on Table 6-1 if different from that marked by factory.
WARNING: ELECTRICAL SHOCK
4. Reconnect YELLOW jumper and ORANGE lead to HAZARD — Before checking electrical
the terminals giving the desired change of charging components, turn OFF and remove
rate, as shown in Table 6-1. fuses of disconnect switch (supplying
AC power to charger), disconnect
CAUTION: Do not change connections battery, and check for voltage on
more than one step before observing capacitors. Discharge through insulated
effect on charging rate. On fully charged screwdriver if there is any reading.
battery (approx. 1.270 to 1.290 specific
gravity), rate should not exceed 22% of
“MAX AMPS” on charger nameplate. 1. Disconnect one diode lead to isolate diode on each
On fully discharged battery (approx. transformer from electrical circuitry.
1.140 specific gravity), rate should not
exceed 110% of “MAX AMPS”. 2. Use a good quality ohmmeter (preferably one having
a mid-scale value of approximately 50 ohms) to
On three-phase chargers, all measure resistance values.
transformer terminal blocks must
be identically connected. 3. Zero ohmmeter on R x 1 scale.

4. Record indicated resistance while placing either

ohmmeter lead on threaded end of diode and other
ohmmeter lead on diode lead.
5. Reverse ohmmeter leads on diode and record
indicated resistance.

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193111-055
MAINTENANCE

6. Consider diode good if one resistance reading is 3. If capacitor is good, pointer will deflect, indicating
infinitely (or very) high and the other is extremely capacitor is being charged, followed by a deflection
low. in the opposite direction indicating partial discharge.

NOTE: An acceptable low resistance value If there is no deflection, capacitor is “open” and must be
or range of values can't be given because of replaced. Also, if meter needle moves and stops at one
different readings from different ohmmeters, value, replace capacitor.
and differences in diodes of the same rating.
Replacement capacitors must be ordered from factory.
Capacitor Testing When ordering, supply serial number of charger and
microfarad (MFD) or (µF) value printed on capacitor.
1. Heed WARNING in Silicon Diode Testing section.

2. Disconnect capacitor and connect leads of

ohmmeter (set to highest scale) to capacitor
terminals.

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MAINTENANCE

Troubleshooting
DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components,
turn OFF and remove fuses of disconnect switch (supplying AC power to charger),
disconnect battery, and check for voltage on capacitors. Discharge through insulated
screwdriver if there is any reading.

CAUTION: HIGH VOLTAGE FROM TEST EQUIPMENT can damage silicon diodes and other
parts. Short silicon diodes with extremely short leads, or disconnect, before applying voltage
from a "megger" or other high voltage test equipment.

The following chart contains information which can be used to diagnose and correct unsatisfactory operation
or failure of various components of the unit. Each malfunction is followed by a suggested checking or inspection
procedure. Refer to Connection/Schematic Diagram in the Diagrams chapter included in this manual.

Troubleshooting Guide
No charging current (Ammeter reads zero)
Check line voltage.
Close fused disconnect switch or repair open circuit.
Check for proper line voltage.
Refer to Line Voltage Changeover instructions in Installation chapter.
Check for blown fuses.
Replace blown fuses. See Table 4-1 for proper fuse sizes.
Check for internal short circuit (diode, winding, wiring).
Repair short circuit, or replace faulty component.
Check for "open" battery circuit.
Clean and tighten connections, especially battery cable connections.
Check Charge Control.

If control has electromechanical timer, check contacts. If they are not closing,
repair or replace timer.
Connect a jumper from the red-white lead of Control Transformer T1 to the red
lead of Contactor K1 coil. If charger starts and ammeter shows charging current
when a battery is connected, check further for faulty printed circuit card on control
and replace as necessary.
Check output circuit fuses. If fuse has blown, check for problem causing fuse to blow.
a. Reverse battery connections, if polarity is wrong.
b. Determine whether a diode is shorted. Refer to Silicon Diode Testing in
Maintenance chapter.

Low charging current at beginning of cycle (battery fully discharged)

Check for failed capacitor (s) (one or more).

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193111-055
MAINTENANCE

Replace capacitor if can is ruptured or fails test. Refer to Capacitor

Testing in Maintenance chapter.

Check charging rate for "too low" adjustment.

Refer to Charging Rate Adjustment in Maintenance chapter.

Check line voltage for connection to proper input voltage.

Refer to Line Voltage Changeover instructions in Installation chapter.

Check battery for one or more defective cells.

Less than rated output on fully discharged battery (approximately 1/2 rated output) (3-phase
chargers only)

Check input fuses (one probably blown). Check for either a shorted transformer, or
wiring short circuit.

Replace as necessary.

High charging current at beginning of cycle (battery overcharged)

Check charging current for "too high" adjustment.

Refer to Charging Rate Adjustment in Maintenance chapter.

Charger does not shut OFF automatically or start automatically

Check Charge Control.

1. If equipped with electromechanical timer

A. Check timer switch contacts. If they are "welded" together and show continuity when
timer is off, replace timer.

B. Check to see if timer control motor is running.

C. Replace timer if there is not continuity of timer motor field. Check AC power supply
to motor.

2. If charger does not start automatically, check for 24 volts AC between the red-white lead and
the red-black lead of control transformer T1. If 24V AC is present, connect a jumper from the
red-white lead of control transformer T1 to the red lead of contactor K1 coil. If charger starts,
check further for faulty printed circuit card on control and replace as necessary.

3. If charger does not stop automatically when equipped with voltage time or dV/dT controls,
check to be sure charging voltage rises above 2.37 volts/cell during the cycle. If not, see low
charging current or less than rated output above. If battery on-charge voltage rises above
2.37 volts/cell during the cycle, check for defective control printed circuit card.

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MAINTENANCE

DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and
remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for
voltage on capacitors. Discharge through insulated screwdriver if there is any reading.

November 17, 2020 6-6

193111-055
MAINTENANCE

DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and
remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for
voltage on capacitors. Discharge through insulated screwdriver if there is any reading.

6-7 November 17, 2020

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MAINTENANCE

DANGER: ELECTRICAL SHOCK HAZARD — Before checking electrical components, turn OFF and
remove fuses of disconnect switch (supply AC power to charger), disconnect battery, and check for
voltage on capacitors. Discharge through insulated screwdriver if there is any reading.

November 17, 2020 6-8

193111-055
OPTIONS

OPTIONS
The options listed in the following table of contents are those most commonly available. Special options not
listed here will be covered by enclosed “addendum” sheets.

OPTION NUMBER OPTION DESCRIPTION PAGE

002 Parallel Charging..……………………………………….….7-1

003 Series Charging……………………………………...……...7-1
101 Remote Charge Control and Ammeter……….…..……..7-2
500 Fused Disconnect Switch and 24V Control Circuit…...7-2

Parallel Charging – Option 002

This option provides cables allowing two batteries to
be charged at the same time (batteries connected in
parallel to charger).

To prevent premature charger turn on, this option

requires the use of a battery connector with auxiliary
contacts (Anderson “SBX” or equivalent). The same
type connector must be specified on the battery and
vehicle. The connector on the battery must have the
auxiliary contacts jumpered together. Figure 7-1 Parallel Charging Connections
NOTE: The safety interlock circuit is protected Series Charging – Option 003
by an in-line 1 Amp AGC Fuse inside the battery
charger. This option provides a cable allowing two batteries to
be charged at the same time (batteries connected in
When charging two batteries, each must be of the series to charger).
same voltage (or number of cells). The total rated
ampere-hour capacity of both batteries plus the voltage CAUTION: With the batteries required to be
(number of cells of only one of the batteries) must be connected in series, this charger cannot be
within the range of the charger. Refer to charger used to charge one battery only.
nameplate for ratings. For example: two 12-volt
(6 cell), 225 ampere-hour batteries would make a 12 Both batteries must be of the same ampere-hour rating.
-volt (6 cell), 450 ampere-hour load. The total rated voltage (or number of cells) of both
batteries (add the two), plus the ampere-hour capacity
Operate this charger as instructed in Operation of only one battery, must be within the charger name-
chapter of this manual except that batteries are to be plate range ratings. For example: two 12-volt (6-cell),
connected as shown in Figure 7-1, plus the total 450 ampere-hour batteries would make a 24-volt
ampere-hour capacity must be used to calculate (12-cell), 450 ampere-hour load.
charging time.

CAUTION: Make sure all connections are

made positive to positive and negative to
negative as shown.

7-1 November 17, 2020

 193111-055
OPTIONS

For series charging, both batteries must be at identical Option 500 (Refer to Figure 7-3)
depths of discharge (DOD); ie, they are used in series
in the vehicle. A mismatch in DOD of the two batteries This option is provided to meet certain “JIC” require-
will result in severe overcharge of the lightly ments. The switch must be in the open (OFF) position
discharged battery and severe undercharge of a to disconnect all AC power into charger and to allow
deeply, discharged battery. front door to be opened. With switch in open position,
door can be opened by turning slotted latch screw to
Operate this charger as instructed in Operation the left.
chapter of this manual, except that charger must be
connected to both batteries instead of just one. Disconnect switch is for emergency or service use only.
Refer to Figure 7-2.
Charge cycle should continue until automatically shut
off. If cycle must be interrupted, turn timer to “OFF” or
CAUTION: Make sure all connections are made push “STOP” button.

A control circuit operating on 24 volts is also provided

to help assure operator safety.

Figure 7-2 Series Charging Connections

positive to positive and negative to negative as

shown.

Remote Charge Control –

Option 101
This option provides a separate remote control box
containing charger’s Charge Control.

This remote control box must be connected to charger

as instructed on label provided with remote charge
control. Closely observe wire color coding.

Operate this charger as instructed in Operation

chapter of this manual and as instructed under any
applicable option descriptions.

Figure 7-3 Fused Disconnect Switch

Fused Disconnect Switch –

November 17, 2020 7-2

193111-055
PARTS LIST

Figure 8-1 “A” Case

8-1 November 17, 2020

 193111-055
PARTS LIST

“A” CASE PARTS LIST

ITEM NO. PART NO. DESCRIPTION

1 197157 Panel, Rear
2 197159 Panel, Side, Right
3 197158 Panel, Side, Left
4 197163 Top
5 197164 Door
6 197165 Hinge
7 197324 Base
8 357205-357 Lead, Yellow (1 Req'd)
9 357205-127 Lead, Orange (1 Req'd)
10 357205-128 Lead, White (1 Req'd)
11 357205-060 Jumper, Orange (2 Req'd)
12 357205-061 Jumper, White (2 Req'd)
13 See Table Capacitor, Transformer
14 194530 Latch, Door
15 See Table Transformer, Control
16 196036 Label, Prestolite
17 See Table Transformer, Power
18 Contact Factory Terminal Block
19 193114 Insulator, Fuse & Shunt
20 392458 Bus Bar
21 See Table Shunt, Meter
22 See Table Fuse, Output
23 See Table Block, Input Fuse
24 See Table Fuse, Input
25 See Table Contactor, AC Input
26 402832-003 Diode, Silicon (2 Req'd)
27 197024 Heat Sink
28 406338 Label, Identification
29 378234-013 Cover, Outer Neoprene
30 W10085-005 Connector, Strain Relief
31 See Table Cable, DC Output
32 See Table Label, AC Input
33 194335 Label, Danger, AC Volts & Fuse
34 404099 Label, Danger
35 191892 Label, Rain Exposure
36 402717 Label, Charging Rate
37 406434 Label, Input Warning
38 195531 Label, DC Output Fuse
39 406593 Label, AC Input Fuse
40 197290 Harness, Wire (For Modular Control)

November 17, 2020 8-2

193111-055
PARTS LIST

Figure 8-2 “B” Case

8-3 November 17, 2020

 193111-055
PARTS LIST

“B” CASE PARTS LIST

Item No. Part No. Description

1 194457 Panel, Top
2 405548 Label, Frame Ground
3 Table 8-3 Block, Fuse, Input
4 Table 8-3 Fuse, Input
5 Table 8-3 Contactor, Line
6 Table 8-4 Transformer, Control
7 400092 Label, L1
8 400096 Label, L2
9 194827-1 Grommet, Mounting
10 406593 Label, Supply Connections
11 194447 Panel, Interior
12 Table 8-5 Panel, Side, Right
13 Table 8-5 Switch, Disconnect
14 194454 Panel, Rear
15 404033 Insulator, Heat Sink
16 TRY174-3 Bracket, Mtg., Capacitor
17 Table 8-6 Capacitor, Transformer
18 191191 Heat Sink, Flat
19 191192 Heat Sink, Fin, 45
20 406518 Label, Warning, Heat Sink
21 191193 Heat Sink, Fin, 90
22 Table 8-1 Diode, Silicon
23 Table 8-3 Block, Terminal, Transformer
24 Call Factory Transformer
25 W10080-5 Connector, Strain Relief
26 378234-13 Cover, Neoprene
27 Table 8-2 Cable, Output Charging
28 Table 8-4 Label, AC Input
29 194335 Label, Danger, Input Volt. & Fuse
30 191892 Label, Warning, Rain Exposure
31 406434 Label, Warning, Sparks
32 Table 8-5 Latch, Door, Disconnect
33 402717 Label, Charging Rate
34 404099 Label, Danger
35 Table 8-5 Label, Disconnect Switch
36 Table 8-2 Fuse, Output
37 Table 8-2 Shunt, Current
38 194455 Panel, Side, Left
39 193114 Insulator, Shunt / Fuse
40 392458 Bus Bar
41 194453 Base, Charger
42 192266-1 Suppressor, Harness
43 196096 Harness, Interior Panel
44 405026 Label, Fuse, DC Output
45 194377 Hinge, Door
46 194458 Door, Hinged
47 193101-1 Rivet, Snap
48 Call Factory Control, Charger
49 196036 Label, Prestolite Power
50 404079 Label, UL and CUL
51 Table 8-7 Label, Charger
52 194530 Latch, Door

November 17, 2020 8-4

193111-055
PARTS LIST

Figure 8-3 “C” Case

8-5 November 17, 2020

 193111-055
PARTS LIST

“C” CASE PARTS LIST

Item No. Part No. Description

1 405548 Label, Frame Ground
2 Table 8-3 Block, Fuse, Input
3 Table 8-3 Fuse, Input
4 194376 Panel, Top
5 Table 8-3 Contactor, Line
6 Table 8-4 Transformer, Control
7 400092 Label, L1
8 400096 Label, L2
9 400097 Label, L3
10 194827-1 Grommet, Mounting
11 406593 Label, Supply Connections
12 194447 Panel, Interior
13 Table 8-5 Panel, Side, Right
14 Table 8-5 Switch, Disconnect
15 194373 Panel, Rear (See Note 1)
16 404033 Insulator, Heat Sink
17 TRY174-3 Bracket, Mtg., Capacitor
18 Table 8-6 Capacitor, Transformer
19 392456 Heat Sink, Flat
20 191192 Heat Sink, Fin, 45
21 191193 Heat Sink, Fin, 90
22 406518 Label, Warning, Heat Sink
23 W10080-5 Connector, Strain Relief
24 378234-13 Cover, Neoprene
25 Table 8-2 Cable, Output Charging
26 Table 8-4 Label, AC Input
27 Table 8-5 Latch, Door, Disconnect
28 194335 Label, Danger, Input Volt. & Fuse
29 191892 Label, Warning, Rain Exposure
30 406434 Label, Warning, Sparks
31 404099 Label, Danger
32 Table 8-5 Label, Disconnect Switch
33 Table 8-1 Diode, Silicon
34 Table 8-3 Block, Terminal, Transformer
35 Table 8-2 Fuse, Output
36 Table 8-2 Shunt, Current
37 194374 Panel, Side, Left (See Note 2)
38 193114 Insulator, Shunt / Fuse
39 392458 Bus Bar
40 Call Factory Transformer
41 194372 Base, Charger
42 194371 Support, Transformer
43 405026 Label, Fuse, DC Output
44 192266-1 Suppressor, Harness
45 196096 Harness, Interior Panel
46 194377 Hinge, Door
47 196038 Label, Prestolite Power
48 Call Factory Control, Charger
49 193101-1 Rivet, Snap
50 Table 8-7 Label, Charger
51 194378 Door, Hinged
52 404079 Label, UL and CUL
53 194530 Latch, Door

November 17, 2020 8-6

193111-055
PARTS LIST

Note 1: Item 15 (Rear Panel), for chargers with weather-resistant enclosure (Opt. 013), is 196546.

Note 2: Item 37 (Left Side Panel), for chargers with weather-resistant enclosure (Opt. 013), is 1965561.

DIODE PART NUMBER

NO. CELLS 3-Phase 3-Phase
from Charger having Charger having
charger DC OUTPUT MAX. AMPS DC OUTPUT MAX. AMPS
nameplate 1-Phase nameplate rating nameplate rating
Charger less than equal to or greater
150A than 150A

6-24 402832-3 193143-1 402832-3

25-36 402832-4 193143-1 402832-4
37-48 402832-6 193143-2 402832-6

Table 8-1 Power Diodes

DC OUTPUT DC Output Fuse Shunt DC Output Cables

MAX. AMPS
Nameplate Rating Amp Rating Part No. Amp Rating Part No. Size Part No.
0 – 50 70 Amp Y1890-1 100 Amp 193125-1 #4 396263-94
51 – 76 100 Amp Y1890-3 100 Amp 193125-1 #4 396263-94
76 – 80 100 Amp Y1890-3 100 Amp 193125-1 #2 396263-80
81 – 120 150 Amp Y1890-4 200 Amp 193125-2 #2 396263-80
121 – 150 200 Amp Y1890-5 200 Amp 193125-2 1/0 396263-81
151 – 176 250 Amp Y1890-6 200 Amp 193125-2 1/0 396263-81
177 – 210 300 Amp Y1890-7 400 Amp 193125-3 2/0 396263-82
211 – 240 350 Amp Y1890-8 400 Amp 193125-3 2/0 396263-82
241 – 280 350 Amp Y1890-8 400 Amp 193125-3 3/0 396263-95
281 – 320 350 Amp Y1890-8 400 Amp 193125-3 4/0 396263-93

Table 8-2 DC Output Components

8-7 November 17, 2020

 Transformer
AC INPUT AC Input Fuse Input Fuse Block Terminal Block Line Contactor
MAX. Part No. * Part No. * Part No. *
AMPS Amp 250 VAC ** 600 VAC ** 1-Phase 1-Phase 3-Phase
Nameplate Rating Part No. Part No. 250 VAC ** 600 VAC ** 600 VAC ** 1-Phase 3-Phase 1-Phase 3-Phase
0 – 12 15 W10085-5 W10386-5 405357-1 406207-1 404605-4 402520 402520 406240-1 406243-1

November 17, 2020

12.1 – 16 20 W10085-6 W10386-6 405357-1 406207-1 404605-4 402520 402520 406240-1 406243-1
16.1 – 20 25 W10085-7 W10386-7 405357-1 406207-1 404605-4 402520 402520 406240-1 406243-1
20.1 – 24 30 W10085-8 W10386-8 405357-1 406207-1 404605-4 402520 402520 406240-1 406243-1
24.1 – 28 35 W10085-9 W10386-9 405752-1 406207-2 404605-5 408174 402520 406240-1 406243-1
28.1 – 32 40 W10085-10 W10386-10 405752-1 406207-2 404605-5 408174 402520 406241-1 406243-1
32.1 – 36 45 W10085-11 W10386-11 405752-1 406207-2 404605-5 408174 402520 406241-1 406243-1
36.1 – 40 50 W10085-12 W10386-12 405752-1 406207-2 404605-5 408174 402520 406241-1 406243-1
40.1 - 48 60 W10085-13 W10386-13 405752-1 406207-2 404605-5 N/A 408174 406244-1 406244-1

* Part Number is determined by the highest AC INPUT MAX. AMPS nameplate rating.
** The highest AC INPUT VOLTS nameplate rating is equal to or less than this voltage.

Table 8-3 AC Input Components

Charger Output AC Input

AC INPUT VOLTS Control Transformer Label
Nameplate Rating 24V AC Part No.
Part No.

120/208/240 406247-1 406465

208/240/480 406247-2 406461

220/380/415 406247-3 406928

240/480/575 406247-4 406365

Table 8-4 Control Transformer

8-8
PARTS LIST
193111-055
193111-055
PARTS LIST

Disconnect Disconnect Door Latch Label, Disc. Sw. “B” Case “C” Case
Switch Switch (for Disc. Sw.) Part No. Right Side Panel Right Side Panel
(Option 500) Part No. Part No. Part No. Part No.
Without Disc. Sw. None None None 194565 194521
196562
(w/Opt 013)
With Disc. Sw. 403956-1 194379 407250 194456 194375
(up to 30A Input 196564
Fuses) (w/Opt 013)
With Disc. Sw. 403956-2 194379 407250 194456 194375
(35-60A Input Fus- 196564
es) (w/Opt 013)

Table 8-5 Disconnect Switch

MFD Rating marked

on capacitor
(Replace with same
Part Number exact rating)

TRY-154-1 3

TRY-154-2 6

TRY-154-3 8

TRY-154-4 12

TRY-154-6 24

Table 8-6 Capacitor

Label Description Part Number

Accu-Charger 406338
Battery-Mate 100 196665
Battery-Mate 80 196664
Battery-Mate 60 196663

Table 8-7 Charger Label

8-9 November 17, 2020

 193111-055
DIAGRAMS

DIAGRAMS

Model no. Information DIAGRAM OUTLINE

OUTPUT SCHEMATIC DIMENSION
CASE SIZE LAST 2 DIGITS
A — 197325 197203
B — 396513 194449
C3 — 396520 194449
C1 — 196612 194449
C1 — 193536 194449

See model number description inside front cover.

November 17, 2020

SCHEMATIC

LEGEND

NOTES