Applied Energy Solutions Maverick User manual

Maverick
High Frequency Conventional Charger
Installation and Operating Instructions
OneTechnologyPlace
Caledonia,NY14423
(585)538–4421
www.appliedenergysol.com
The Power of Excellence FM1335
REV A

1

2
TABLE OF CONTENTS
SECTION 1 SAFETY INSTRUCTIONS...................................................................3
SECTION 2 RECEIPT AND INSPECTION OF THE CHARGER.................................4
SECTION 3 INTRODUCTION...................................................................................4
SECTION 4 CONTROL FEATURES ...........................................................................4
SECTION 5 INSTALLATION....................................................................................5
SECTION 6 OPERATING PROCEDURE.................................................................7
SECTION 7 CHARGING MODE...............................................................................8
SECTION 8 FAILURE MODE.................................................................................10
SECTION 9 CHARGER CABINET ............................................................................10
SECTION 10 MONTHLY PREVENTIVE MAINTENANCE ......................................10
SECTION 11 TROUBLESHOOTING GUIDE ..........................................................11
SECTION 12 SCHEMATICS ....................................................................................12

3
SECTION 1 SAFETY INSTRUCTIONS
IMPORTANT SAFETY INSTRUCTIONS
1. SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT SAFETY
AND OPERATING INSTRUCTIONS.
2. WORKING IN THE VICINITY OF A LEAD-ACID BATTERY IS DANGEROUS.
BATTERIES GENERATE EXPLOSIVE GASSES 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.
3. TO REDUCE RISK OF BATTERY EXPLOSION, FOLLOW THESE INSTRUCTIONS
AND THOSE ON THE BATTERY.
4. NEVER SMOKE OR ALLOW AN OPEN SPARK OR FLAME IN THE VICINITY OF THE
BATTERY OR ENGINE.
5. 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.
6. NEVER CHARGE A FROZEN BATTERY.
7. DO NOT OPERATE IN A CLOSED-IN AREA OR RESTRICT VENTILATION IN ANY
WAY.
8. DANGER: RISK OF ELECTRICAL SHOCK. DO NOT TOUCH UNINSULATED
PORTION OF OUTPUT CONNECTOR OR UNINSULATED BATTERY TERMINAL.
9. CAUTION: DISCONNECT SUPPLY BEFORE CHANGING FUSE.
INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITE
1. CONSERVER CES INSTRUCTIONS. CE MANUEL CONTIENT DES INSTRUCTIONS
IMPORTANTES CONCERNANT LA SECURITE ET LE FONCTIONNEMENT.
2. IL EST DANGEREUX DE TRAVAILLER A PROXIMITE D'UNE BATTERIE AU PLOMB.
LES BATTERIES PRODUISENT DES GAS EXPLOSIFS EN SERVICE NORMAL.
AUSSI EST-IL IMPORTANT DE TOUJOURS RELIRE LES INSTRUCTIONS AVANT
D'UTILISER LE CHARGEUR ET DE LES SUIVRE A LA LETTRE.
3. POUR REDUIRE LE RISQUE D`EXPLOSION, LIRE CES INSTRUCTIONS ET CELLES
QUI FIGURENT SUR LA BATTERIE.
4. NE JAMAIS FUMER PRES DE LA BATTERIE OU DU MOTEUR ET EVITER TOUTE
ETINCELLE OU FLAMME NUE A PROXIMITE DE CES DERNIERS.
5. UTILISER LE CHARGEUR POUR CHARGER UNE BATTERIE AU PLOMB
UNIQUEMENT. CE CHARGEUR N`EST PAS CONCU POUR ALIMENTER UN
RESEAU ELECTRIQUE TRES BASSE TENSION NI POUR CHARGER DES PILES
SECHES. LE FAIT D`UTILISER LE CHARGEUR POUR CHARGER DES PILES
SECHES POURRAIT ENTRAINER L'ECLATEMENT DES PILES ET CAUSER DES
BLESSURES OU DES COMMAGES.
6. NE JAMAIS CHARGER UNE BATTERIE GELEE.
7. NE PAS FAIRE FONCTIONNER LE CHARGEUR DANS UN ESPACE CLOS ET/OU NE
PAS GENER LA VENTILATION.
8. DANGER: RISQUE DE CHOCS ELECTRIQUES. NE PAS TOUCHER LES PARTIES
NON ISOLEES DU CONNECTEUR DE SORTIE OU LES BORNES NON ISOLEES DE
L'ACCUMULATEUR.
9. ATTENTION: COUPER L'ALIMENTATION AVANT DE REMPLACER LES FUSIBLES.

4
SECTION 2 RECEIPT AND INSPECTION OF THE CHARGER
Upon receipt of the charger, the information on the shipping carton should be checked against
your order. All chargers can be handled with a lift truck by inserting the forks under the bottom
of the charger. Remove the carton and inspect the charger for damage. If there is any damage,
save the carton for inspection and notify the carrier immediately. Check the nameplate & labels
against your order & specifications. Any discrepancies should be reported immediately to the
nearest Applied Energy Solutions authorized representative.
SECTION 3 INTRODUCTION
The Maverick Industrial Battery Chargers are High Frequency chargers utilizing Insulated Gate
Bipolar Transistor technology. This charger is designed to output high rate current charge of
18A/100AH for standard charging applications.
SECTION 4 CONTROL FEATURES
Delayed start from fifteen minutes to two and one quarter hours in fifteen minute intervals
Equalize can be done manually or automatically if battery is left connected (every 5 cycles)
Automatic 12-hour refresh (selectable on/off)
Remote Control Interface for use when mounted above operator’s reach
Auto start with five second delay
Stackable without brackets
Manual jump start for over-discharged batteries
Full load power factor of 0.95
Automatic shutdown for the following:
o80% or final charge exceeds time limit
oVolts per cell outside safe limits
oCharging current too high or too low
oCharger internal temperature outside of specification
Digital readout displays:
oCharge current/voltage
oEqualize in process
oFault codes
LED charge status indicators
oCharging
o80% Charged
oCharge Complete
oEqualize
oRefresh
oFault Shutdown

5
SECTION 5 INSTALLATION
5.1 PHYSICAL LOCATION:
Charging areas should be clean and dry. The temperature of the charging room should be
between 32oF (0oC) and 104oF (40oC). Combustible materials, open flames and smoking must
not be permitted in or near the charging area. It is very important to keep all four sides,
including the fans, free from obstructions; there should be at least 2 feet between the charger
front or sides and any other object.
5.2 MOUNTING:
The Maverick charger cabinets must be mounted on a surface constructed from
non-combustible material, such as stone, brick, concrete or metal. Mounting holes are provided
in the frame for securing the charger. Do not use the charger while it is attached to the pallet.
5.3 INPUT POWER CONNECTION:
The Maverick chargers are shipped from the factory connected for 480VAC, 3 Phase.
WARNING
VERIFY THE AC ELECTRICAL SERVICE IS DISCONNECTED AT THE SOURCE
BEFORE ATTEMPTING TO CONNECT AC POWER TO THE CHARGER.
CAUTION To reduce the risk of fire, use only on circuits provided with branch circuit protection
indicated in Table 5.3.1 in accordance with the NATIONAL ELECTRIC CODE ANSI/NFPA 70.
The AC input terminals are identified by a red-on-white AC INPUT label, located behind the
access panel on the front of the charger. Removing the top is recommended for ease of
access. The AC input cable is to be connected to the proper AC INPUT terminals within the
charger cabinet. Refer to table 5.3.2 (next page) for input wire size and torque values.

6
Table 5.3.2
WIRE SIZE (STRANDED)
RECOMMENDED TORQUE
6 AWG
35 IN.LBS
8 AWG
25 IN.LBS
10-14 AWG
20 IN.LBS
A grounding wire (bare, green or green with yellow stripe) is to be connected from the
Grounding Terminal within the charger cabinet to the service system ground. The Grounding
Terminal is identified by a green-on-white Ground Terminal Label on top of the component
mounting plate, above the AC fuses. If a system ground is not available, the charger frame must
be connected to a driven ground rod, in accordance with National and Local electrical codes.
Proper application and tight terminal connections are important in avoiding future problems. The
ground terminal is rated for 14 awg to 6 awg wire. The recommended torque setting is shown in
Table 5.3.3
Table 5.3.3
Wire Gauge
Recommended Torque Setting
PANDUIT LAMA6-14Q
6 –10 AWG
40 in lbs
12 –14 AWG
15 in lbs
T&B ADR6
6 AWG
35 in lbs
8 –14 AWG
20 in lbs

7
SECTION 6 OPERATING PROCEDURE
6.1 PRELIMINARY SETUP
Once power has been applied to the charger, a “dash” will sequence across the display on the
front panel. This indicates the charger is in the “IDLE MODE” of operation, awaiting a battery
connection.
6.2 IMMEDIATE/DELAY START
The control may be programmed to delay the start of charge from fifteen minutes to two hours
and fifteen minutes as well as an immediate start of the charge upon battery to charger
connection. Note: all units are shipped from the factory set for immediate start (no start delay).
If a power failure occurs, no damage will occur to the battery or charger. If a battery is still
connected when power returns, the control will override any delayed start setting and initialize
an immediate start of the charge. Once the charge has been terminated, the delay start will
function normally thereafter.
Changing the Start Delay:
Remove AC power from the charger
Remove either the top panel and/or the front access cover
Locate the DELAY START thumbwheel switch at the bottom of the main control board
Adjust the thumbwheel switch for the desired delayed start by rotating the switch clock-
wise to increase the delay
The first setting past zero is fifteen minutes; each increment will increase the delay by
fifteen minutes until two hours and fifteen minutes is reached then it resets back to zero
(no delay)
Apply AC power to the charger
Without a battery connected, press and hold the STOP button to display the DELAYED
START value, disconnect AC if further adjust is necessary
Replace top panel and/or front access cover
Connect battery
6.3 CHARGING THE BATTERY
Compare the number of cells and amp-hour capacity of the battery to be charged with the
charger rating found on the charger nameplate. The number of cells in the battery to be
charged MUST match the nameplate data. The Amp-Hour ratings should also match for timely
charging of the battery.
6.2 DEFAULT SETTINGS
12 HR REFRESH ENABLED
NO AUTO EQ

8
SECTION 7 CHARGING MODE
8.1 DISPLAY AND CONTROL
The front panel provides the following displays and controls to the user during charge:
Six digit Numeric Display: The display will alternate between charging current (AMPS) and
average volts per cell (VOLTS)
Charger Indicator:
- Charging LED (Yellow)
- 80% Charged (Amber)
- Charge Complete (Green)
- Shutdown/Fault (Red)
EQUALIZE Push Button Switch
Press EQUALIZE to set the Equalize Cycle manually
STOP Push Button Switch
Press STOP to shut down the charger manually
8.2 CHARGING THE BATTERY
When a proper battery is connected, the display will count down from 9 to 0, if there is no
delayed start set. After a few seconds, the display will show the charging current and average
volts per cell. The cycle starts with high rate, constant current of 18A/100A. After 2.10vpc is
reached, the charger switches to constant power until the gassing voltage is reached.
When the battery voltage reaches the 80% point, the charger enters the constant voltage mode
and the current gradually tapers off.
In the regular full charge cycle, once the current drops to the finish rate current setting (5A per
100AH), the charge phase will change from constant voltage to constant current. The charge
cycle will terminate by DV/DT sensing.
8.3 EQUALIZE
Equalize cycle provides a timed three hour charge extension at the finish rate current after
DV/DT termination has been reached.
Auto Equalize: The Auto Equalize is selected by DIP switch setting–every 5 charge cycles. The
first digit of the front panel display will display “E” and the COMPLETE LED will flash to indicate
that the Equalize charge is selected. When the charger is actually in the Equalize mode, the “E”
will be flashing.
Manual Equalize: The EQUALIZE button, when pushed, will request the Equalize cycle. The first
character of the front panel display will display “E” and the COMPLETE LED will flash to indicate
that the Equalize charge is selected. When the charger is actually in the Equalize mode, the “E”
will be flashing. Depressing the EQUALIZE button, prior to the Equalize cycle, will cancel the
Equalize function.

9
8.4 AUTO EQUALIZE DETAIL
The auto equalize charge, if selected, will occur every 5th cycle. The following paragraph
outlines this feature in detail. The DIP switches are located on the back of the main board. Be
sure to disconnect the AC power source prior to changing switch settings. Removing the top
cover makes accessing the switches easier. Switch settings are as follows:
S6-2 –OFF = NO AUTO EQ
S6-2 –ON = AUTO EQ EVERY 5TH CYCLE
AUTO EQUALIZE CANCELLATION
Automatic equalize request cannot be cancelled by pressing the Equalize button. To cancel
auto equalize select, press the STOP button to interrupt charge, disconnect then reconnect
the battery.
Manual equalize select can be cancelled by pressing the Equalize button again.
8.5 MANUAL TERMINATION
To manually terminate the charge cycle, press the STOP push-button switch located on the
front panel. When the charge has been terminated due to manual termination, the red Fault LED
will be ON solid until the battery is removed. The display will show “STOP”.
8.6 REFRESH CHARGE
When a battery remains connected to the charger for 12 hours after the charge has been
completed and the Refresh Function is enabled, the control will restart another charge cycle.
The charge rate of the battery will be monitored with termination occurring in approximately 35
minutes. When the charger is in this refresh mode the CHARGING and 80% CHARGED LED's
will be ON and the CHARGE COMPLETE LED will be blinking.
Changing the Refresh Setting is done by changing DIP switch settings. The DIP switches are
located on the back of the main board. Removing the top cover makes accessing the switches
easier. Switch settings are as follows:
S6-1 –OFF = 12 HR REFRESH ENABLED
S6-1 –ON = 12 HR REFRESH DISABLED

10
SECTION 8 FAILURE MODE
9.2 BATTERY LOW VOLTS OVERRIDE
If the battery voltage measures less than 1.7 VPC, the charger may be started manually, by
pressing and holding the STOP button for more than 10 seconds. If the battery does not
increase above 1.7 V/Cell in 5 minutes the charger will shut off and indicate Low Volts Alarm
again, otherwise the normal charge cycle will continue. This "grace period" is intended to give
the battery time to recover from its over-discharged condition.
SECTION 9 CHARGER CABINET
SECTION 10 MONTHLY PREVENTIVE MAINTENANCE
11.1 MONTHLY PREVENTIVE MAINTENANCE
WARNING
HIGH VOLTAGES EXIST WITHIN THE CHARGER WHICH CAN CAUSE SEVERE
INJURY OR DEATH. TO ALLOW INTERNAL COMPONENTS TO DISCHARGE,
PLEASE WAIT AT LEAST 3 MINUTES AFTER DISCONNECTING THE AC POWER
BEFORE SERVICING. SERVICE SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL. IMPROPER SERVICING MAY DAMAGE THE CHARGER.
If a battery is being charged, terminate the charge by pressing the STOP button.
Disconnect the battery from the charger.
Remove AC power from the charger.

11
Using compressed air, remove any dust from the two heatsinks (both have fans attached),
internal cabinet walls and internal components of the charger.
Wipe the exterior of the cabinet and clear any obstructions from the fans and ventilation slots.
Make sure that all bolted or screwed electrical connections are tight.
Make sure that the insulation on all cables and wires are in good condition. Replace if
necessary.
11.2 CHARGER ADJUSTMENTS
11.2.1 Changing the AC Input Line Voltage
Maverick chargers are designed to operate at 480VAC only. The input voltage cannot be changed.
SECTION 11 TROUBLESHOOTING GUIDE
SYMPTOM 1 POWER IS APPLIED BUT THE DISPLAY IS NOT ON
Make sure the input line from the AC power outlet is connected at the AC fuses properly. Verify
the AC voltage at the fuses.
Locate the control transformers. Verify the voltage at the primary of each transformer. If there is
no voltage, check the wiring between the control transformers and the filter.
Verify the secondary voltage of the large control transformer across terminals 5 and 7. The
voltage should be approximately 18-20 Volts RMS. If there is no voltage, the transformer is
defective and should be replaced.
SYMPTOM 2 DISPLAY IS ON BUT CHARGER WILL NOT START
WARNING
HIGH VOLTAGES EXIST WITHIN THE CHARGER WHICH CAN CAUSE SEVERE
INJURY OR DEATH. TO ALLOW INTERNAL COMPONENTS TO DISCHARGE,
PLEASE WAIT AT LEAST 3 MINUTES AFTER DISCONNECTING THE AC POWER
BEFORE SERVICING. SERVICE SHOULD ONLY BE PERFORMED BY QUALIFIED
SERVICE PERSONNEL. IMPROPER SERVICING MAY DAMAGE THE CHARGER.
If the Sequencing DASH is displayed, check the battery connections and the output fuse for
open fuse.
If “HIU”is displayed, verify that the number of cells of the battery to be charged matches the
number of cells on the nameplate.
If “Lo U” is displayed, verify that the number of cells of the battery to be charged matches the
number of cells on the nameplate. If the number of cells matches, the battery might have been
over-discharged. Refer to Section 9.2 for Low Volts Override operation.

12
SYMPTOM 3 CHARGE TERMINATES EARLY
Fault code “Lo U” - Low volts per cell - the average battery voltage is less than 1.7 V/Cell.
Check for bad cells.
Fault code “HIU”- High volts per cell - the average battery voltage is greater than the high
voltage limit. The battery may be fully charged before connecting to the charger.
Fault code “diSC”-Battery is disconnected from charger during charge.
Fault code “dur”- Charge time exceeded –the battery voltage did not reach the gassing
point within the specified time in High Rate or does not shut off within 6 hours from Gassing
Point. Check for bad cells or deep discharge condition.
Fault code “Lo I” -Low charging current –no charging current detected or charging current
is too low. Check the DC fuse for open.
Display “OFF” - Charge cycle is terminated by pressing the STOP button.
SECTION 12 SCHEMATICS
See following page

13
Applied Energy Solutions 1 Technology Place Caledonia, NY 14423

CHARGER WARRANTY
APPLIED ENERGY SOLUTIONS warrants that each new and unused battery charger manufactured and supplied with good workmanship is free from any known mechanical defect,
provided that (A) the product is installed and operated in accordance with the accepted industrial standards and in accordance with the printed instructions furnished by APPLIED
ENERGY SOLUTIONS, (B) the product is used under normal conditions for which designed, (C) the product is not used in a corrosive, abnormally dusty or high humidity moisture
condensing environment, and (D) the product is not subjected to misuse or negligence, and the product receives proper care, protection and maintenance under supervision of
competent personnel. Warranty Terms and Conditions
APPLIED ENERGY SOLUTIONS Maverick Industrial Battery Chargers are warranted for 2 Years(1), which begins on the date of shipment from APPLIED ENERGY SOLUTIONS.
NOTES: (1) Warranty covers parts and labor,
AC fuses and DC fuses are not warranted unless they are found to be defective prior to use.
NON-TRANSFERABLE WARRANTY. This warranty is extended by APPLIED ENERGY SOLUTIONS only to the original user (purchaser) of new equipment from APPLIED
ENERGY SOLUTIONS or one of its authorized agents. The product purchased under this agreement shall be used exclusively by the buyer. There shall be no third party beneficiary
of this warranty.
REPAIR LIMITATIONS. APPLIED ENERGY SOLUTIONS has the right to site inspection and judgment of the claimed defects in any product covered by this warranty. APPLIED
ENERGY SOLUTIONS' liability is limited to the repair of any defects found to exist by APPLIED ENERGY SOLUTIONS or, at APPLIED ENERGY SOLUTIONS' option, the
replacement of the defective product.
APPLIED ENERGY SOLUTIONS and its authorized agents shall not be liable for direct or indirect damages in excess of such repair or replacement. In no event shall the purchaser
be entitled to recover for contingent expenses from, but not limited to, telephone calls, telegrams, travel expenses, lodging, duties and taxes, labor, rental or replacement equipment,
loss of business or profit or other commercial losses.
CONTINUED USE OF DEFECTIVE PRODUCTS. The continued use of an APPLIED ENERGY SOLUTIONS Industrial Battery Charger that is known to be defective VOIDS ALL
WARRANTIES.
REPAIR OF MODIFIED EQUIPMENT. Except as authorized in writing the warranty specified does not cover any equipment that has been repaired by any party other than
APPLIED ENERGY SOLUTIONS or its authorized agents. Except as authorized in writing the warranty specified does not cover any equipment that has been modified, mechanically
or electrically, by any party other than APPLIED ENERGY SOLUTIONS.
WARRANTY EXPENSE LIMITATIONS. APPLIED ENERGY SOLUTIONS will limit the warranty expense of all chargers to be paid at a maximum of the original purchase price
of the charger.
The provisions of this warranty shall not apply to product in use outside of the continental USA.
Except as stated above, all other warranties and conditions, either expressed or implied, including implied warranties of merchantability and fitness for a particular purpose, are
excluded and buyer assumes all risk and liability resulting from the use of the goods. APPLIED ENERGY SOLUTIONS neither assumes or authorizes any persons to assume for
APPLIED ENERGY SOLUTIONS any other liability in connection with the sale or use of the goods sold and there are no oral agreements or warranties collateral to or affecting this
written warranty When installing, servicing or operating these products, safe practices should be used by skilled and qualified technical persons.