act preventive maintenance guide
TRANSCRIPT
710-00040.3
ACT Preventive Maintenance
Guide
710-00040.3 2 2
Table of Contents
Quantum Charger Preventive Maintenance........................................................................................................................... 3
1) Air Filter..................................................................................................................................................................................... 3
2) Power Modules Inspection ...................................................................................................................................................... 3
3) DC Backplane Inspection ........................................................................................................................................................ 4
4) Battery Cables Inspection ....................................................................................................................................................... 4
Quantum GSE Preventive Maintenance ................................................................................................................................ 6
1) Air Filter..................................................................................................................................................................................... 6
2) Power Modules Inspection ...................................................................................................................................................... 6
3) DC Backplane Inspection ........................................................................................................................................................ 7
4) Rust Inspection ........................................................................................................................................................................ 7
5) Battery Cables Inspection ....................................................................................................................................................... 8
6) Gasket Inspection .................................................................................................................................................................. 10
7) Screen Cover Inspection........................................................................................................................................................ 10
8) General Inspections ............................................................................................................................................................... 10
BATTview Preventive Maintenance ..................................................................................................................................... 10
1) Wash the battery .................................................................................................................................................................... 10
2) Inspect the wiring (annually) ................................................................................................................................................. 11
ACT Service & Warranty Contact information ...................................................................................................................... 12
710-00040.3 3 3
Quantum Charger Preventive Maintenance The Quantum charger streamlined design emphasizes ease of maintenance. Preventive Maintenance is mandatory annually to maintain warranty – twice a year is recommended. Below is the list of maintenance procedures:
1) Air Filter Regularly inspect air filter and clean or replace as necessary. Location and environmental conditions must be taken into account when determining the frequency that the filter is cleaned or replaced. The air filter can be blown out or washed in warm soapy water (the filter must be completely dried prior to reinstall).
The following are general guidelines in regard to cleaning or replacing the air filter:
Environmental Condition
Application Example Recommended Filter Replacement Cycle
Normal A normal daily operation of Conventional Charging, basic material handling of clean product in dry environments.
Annually
Severe Extended operating hours or constant use when Fast or Opportunity Charging in dusty, hot but dry environments.
Bi-Annually
Extreme
All dusty or sandy conditions such as cement plants, lumber or flour mills, coal dust or stone-crushing areas.
Corrosive atmosphere such as chlorine or salt-sea air environments.
Quarterly
2) Power Modules Inspection Pull out the power modules (PMs) and inspect DC connector for any discoloration or deformation. Reinstall the PMs and ensure that the PMs are fully seated, and the tabs are flushed. Tighten the bolts all the way by hand and make sure they are secured.
710-00040.3 4 4
3) DC Backplane Inspection Remove the charger back cover and inspect the DC backplane for any discoloration or damage. Report any discoloration or damage to ACT Service.
Clean DC connector contacts Slight discoloration of DC connector contacts
Damaged receptacle of DC connector
4) Battery Cables Inspection Regularly inspect the DC cables for wear. If the DC cables or connectors become worn or damaged, they should be immediately replaced with a cable of the same rating by qualified personnel. Inspect the connector housing and make sure there is no damage. Inspect the tips of the battery connector for signs of pitting due to arcing. Replace the tips as needed. Inspect the DC fuse and battery cables, make sure the torque lines are straight. If a torque line is not straight, set torque on the DC connection.
Torque nuts on external threaded Power Elements on DC Backplanes to a maximum of 79 lbf*inch +0/-10% (6.6 lbf*ft) (9.0N*m). See next image for an example of an external threaded Power Element. CAUTION, DO NOT OVERTIGHTEN AS THIS MAY DAMAGE THE PCB.
710-00040.3 5 5
Torque all other fasteners for DC main fuses or DC output cables to 120 lbf*inch +0/-10% (10 lbf*ft) (13.5N*m).
Reapply torque lines after torquing fasteners as necessary using a suitable indelible marker.
EXTERNAL THREADED POWER ELEMENT
Torque Lines
710-00040.3 6 6
Quantum GSE Preventive Maintenance The Quantum charger streamlined design emphasizes ease of maintenance. Preventive Maintenance is mandatory annually to maintain warranty – twice a year is recommended. Below is the list of maintenance procedures:
1) Air Filter Regularly inspect air filters and clean or replace as necessary. Location and environmental conditions must be taken into account when determining the frequency that the filter is cleaned or replaced. In the outdoor environment, the filters should be checked at least quarterly.
The air filters are located in the front and back covers. The filters need to be changed or blown out or washed in warm soapy water (the filter must be completely dried prior to reinstall). Ensure that the filter is clean with no tears and in good sound condition before installation.
2) Power Modules Inspection Pull out the power modules (PMs) and Inspect DC connector for any discoloration or deformation. Reinstall the PMs and ensure that the PMs are fully seated, and the tabs are flushed. Tighten the bolts all the way by hand and make sure they are secured.
710-00040.3 7 7
3) DC Backplane Inspection Remove the charger back cover and inspect the DC backplane for any discoloration. Report any discoloration to ACT Service.
Clean DC connector contacts Slight discoloration of DC connector contacts
4) Rust Inspection The charger should be inspected for rust formation quarterly. The charger chassis is made of aluminum that is resistant to rust. However, the rust needs to be checked near the inlet fans of the power modules as shown in the picture below. In order to expose the power module, please remove the front cover and front labyrinth.
710-00040.3 8 8
5) Battery Cables Inspection Regularly inspect the DC cables for wear. If the DC cables or connectors become worn or damaged with signs of cracks or tears, they should be immediately replaced by qualified personnel with a cable of the same rating.
Inspect the EURO connector housing and make sure there is no damage.
Inspect the tips of the battery connector for signs of pitting due to arcing. Replace the tips as needed.
Inspect the DC fuse and battery cables, make sure the torque lines are straight. If a torque line is not straight, set torque on the DC connection.
Torque nuts on external threaded Power Elements on DC Backplanes to a maximum of 79 lbf*inch +0/-10% (6.6 lbf*ft) (9.0N*m). See next image for an example of an external threaded Power Element. CAUTION, DO NOT OVERTIGHTEN AS THIS MAY DAMAGE THE PCB.
Torque all other fasteners for DC main fuses or DC output cables to 120 lbf*inch +0/-10% (10 lbf*ft) (13.5N*m).
710-00040.3 9 9
Reapply torque lines after torquing fasteners as necessary using a suitable indelible marker.
EXTERNAL THREADED POWER ELEMENT
Torque Lines
710-00040.3 10 10
6) Gasket Inspection Check the gasket for ailments, issues or tears. The gasket needs to have sponginess to it and should flex back to the original shape after pressure is applied.
7) Screen Cover Inspection The plastic front screen cover needs to be inspected to ensure it is not brittle. If a screen protector is used, check the screen protector as well.
8) General Inspections Since this is an outdoor charger, insect nests might form and could block the airflow. Check the chassis cavity to ensure there is no air restriction.
BATTview Preventive Maintenance The BATTview streamlined design emphasizes ease of maintenance. Preventive Maintenance is mandatory annually to maintain the 5 year extended warranty (if extended warranty was purchased).
The following are the recommended maintenance procedures for BATTview devices:
1) Wash the battery Wash the battery regularly to ensure there is no acid accumulation around the BATTview wire
harnesses.
710-00040.3 11 11
2) Inspect the wiring (annually) Inspect integrity of BATTview wires (kinks, breaks, insulation, etc.)
Ensure that all terminal connections are tight and clean (no corrosion)
Dirty terminal connections with corrosion
BATTview wires tangled with kinks BATTview wires with no tangles or kinks
Clean terminal connections with no corrosion
710-00040.3 12 12
ACT Service & Warranty Contact information If you experience any problems AFTER performing the necessary maintenance above,
please contact:
ACT Service & Warranty Department
(877) 228-5922