Applied Energy Solutions WorkHorse Series 1 User manual

WorkHorse SERIES 1
FERRORESONANT BATTERY CHARGERS
Installation and Operating Instru tions
Applied Energy Solutions, LLC.
One Technology Place
Caledonia, New York 4423
(585) 538-442
www.appliedenergysol.com
The Power of Excellence
FM1246
REV G

APPLIED ENERGY SOLUTIONS WorkHorse Series 1
INDUSTRIAL BATTERY CHARGER OWNER’S MANUAL
INSTALLATION: READ AND FOLLOW ALL SAFETY INSTRUCTIONS ON THE FOLLOWING PAGE. All AES SERIES 1 charg rs ar for
indoor us only. Charging ar as must b cl an, dry and fr from combustibl mat rials, and/or op n flam s. Charging ar as must b
prop rly v ntilat d and smoking should n v r b allow d in or n ar th charging ar a. Th t mp ratur of th charging room should b
b tw n 32o F and 104o F.
CAUTION To r duc th risk of fir , us only on circuits provid d with branch circuit prot ction indicat d in Tabl 1 (pag 2) in
accordanc with th NATIONAL ELECTRIC CODE ANSI/NFPA 70.
MOUNTING: SERIES 1 charg rs must b mount d on a surfac construct d from con-combustibl mat rial, such as ston , brick,
concr t or m tal.
INPUT POWER CONNECTION: Th INPUT POWER is to b conn ct d via th suppli d lin cord or to th short 10 AWG “pigtails”
(consult Tabl 1).
Batt ry charging products can caus s rious injury, d ath or damag to oth r quipm nt and prop rty if th saf ty rul s ar not strictly
follow d.
SERIES 1 CONTROL FEATURES:
1. Automatic fiv -s cond d lay d start upon conn ction of a prop rly siz d batt ry.
2. Batt ry voltag is continually monitor d.
3. Automatic charg t rmination 3 hours aft r th 80% charg point.
4. 80% charg point s l ctabl 2.37 or 2.45 volts p r c ll.(consult factory r pr s ntativ for 2.45 vpc s tting proc dur )
5. On / off Equaliz switch provid d to xt nd charg 3 additional hours aft r normal charg t rmination.
6. Backup tim r - 12 hours to th 80% point.
7. Automatic fault shut down: display d num rically on th 2 digit LED r adout:
a. Fault ode 1 - Low volts p r c ll - l ss than 1.7 vpc
b. Fault ode 2 - High volts p r c ll - gr at r than 2.7 or 2.80 vpc (s t with 80% point)
c. Fault ode 3 - Batt ry disconn ct d from charg r during charg
d. Fault ode 4 - Charg tim xc d d - backup tim r xpir d
. Fault ode 5 - Low charging curr nt - charging curr nt l ss than approximat ly 3 amps
8. M mory r t ntion during AC pow r loss.
9. R fr sh cycl (optional) - 30 minut s v ry 24 hours. (consult factory r pr s ntativ for s tting proc dur )
10. D lay start (optional) - 1 hour non-r s ttabl (consult factory r pr s ntativ for s tting proc dur )
11. Automatic LED t st - All LED’s flash alt rnat r d / gr n upon AC pow r and batt ry conn ction.
12. Fault ode 0 - Manual stop button - us d to nd th charging proc ss
13. Displays:
a. 2-digit LED r adout - displays charging curr nt and Fault cod s.
b. Equaliz LED - on solid wh n unit is s t to qualiz , flash s wh n unit is in qualiz charg mod .
c. Shutdown LED - on solid wh n charg r has compl t d a normal charg cycl , flash s wh n a fault has occurr d.
INPUT VOLTAGE CHANGEOVER: If th charg r is capabl of mor than on input voltag consult th attach d sch matic and
chang ov r lab l insid th charg r to r configur th charg r as r quir d. B sur to r configur both th pow r transform r taps and
control transform r voltag switch, and r plac th lin cord and plug ass mbly with on rat d p r th NATIONAL ELECTRIC CODE and
Tabl 1.
OPERATING PROCEDURE: V rify that th charg r is wir d for th input AC sourc availabl . Conn ct th charg r to AC sourc . Th
charg r’s 2 LED’s will flash s v ral tim s and a “0” (z ro) will scroll across th LED display.
Conn ct a prop rly siz d (sam c ll numb r and amp-hrs siz ) batt ry to th charg r. Th charg r LED’s will again flash s v ral
tim s. If th charg r and batt ry ar match d and all ar in good working ord r, th charg r will start charging and display th charging
curr nt on th digital LED display. If th charg r and batt ry ar mismatch d or ith r is d f ctiv th charg r will shutdown and display a
fault cod . Consult th charg r front pan l lab l for fault cod s.
Th charg r will automatically t rminat th charg cycl 3 hours aft r th 80% point is r ach d unl ss th qualiz button is
pr ss d or a fault condition occurs. Aft r a normal charg compl tion th charg r will r turn to displaying th s qu ncing z ro. Th batt ry
can now b saf ly unplugg d sinc all charging has stopp d. If th charg r was still in charg mod , pr ssing th STOP button will
t rminat th charging proc ss and allow th batt ry to b saf ly unplugg d.

IMPORTANT SAFETY INSTRUCTIONS
INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITE
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1. SAVE THESE INSTRUCTIONS. THIS MANUAL CONTAINS IMPORTANT SAFETY AND OPERATING INSTRUCTIONS.
CONSERVER CES INSTRUCTIONS. CE MANUEL CONTIENT DES INSTRUCTIONS IMPORTANTES CONCERNANT LA
SECURITE ET LE FONCTIONNEMENT.
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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.
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.
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3. TO REDUCE RISK OF BATTERY EXPLOSION, FOLLOW THESE INSTRUCTIONS AND THOSE ON THE BATTERY. POUR
REDUIRE LE RISQUE D'EXPLOSION, LIRE CES INSTRUCTIONS ET CELLES QUI FIGURENT SUR LA BATTERIE.
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4. NEVER SMOKE OR ALLOW AN OPEN SPARK OR FLAME IN THE VICINITY OF THE BATTERY OR ENGINE.
NE JAMAIS FUMER PRES DE LA BATTERIE OU DU MOTEUR ET EVITER TOUTE ETINCELLE OU FLAMME NUE A PROXIMITE
DE CES DERNIERS.
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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.
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.
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6. NEVER CHARGE A FROZEN BATTERY.
NE JAMAIS CHARGER UNE BATTERIE GELEE.
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7. DO NOT OPERATE IN A CLOSED-IN AREA OR RESTRICT VENTILATION IN ANY WAY.
NE PAS FAIRE FONCTIONNER LE CHARGEUR DANS UN ESPACE CLOS ET/OU NE PAS GENER LA VENTILATION.
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8. DANGER: RISK OF ELECTRICAL SHOCK. DO NOT TOUCH UNINSULATED PORTION OF OUTPUT CONNECTOR OR
UNINSULATED BATTERY TERMINAL.
DANGER: RISQUE DE CHOCS ELECTRIQUES. NE PAS TOUCHER LES PARTIES NO ISOLEES DU CONNECTEUR DE SORTIE
OU LES BORNES NON ISOLEES DE L'ACCUMULATEUR.
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9. CAUTION: DISCONNECT SUPPLY BEFORE CHANGING FUSE.
ATTENTION: COUPER L'ALIMENTATION AVANT DE REMPLACER LES FUSIBLES.
Tabl 1
BRANCH CIRCUIT PROTECTION AND CORD/PLUG SIZING
MODEL INPUT BRANCH CIRCUIT PLUG TYPE
NUMBER VOLTAGE PROTECTION REQUIRED SUPPLIED
06A0380Y0A, 06A0600Y0A,
12A0380Y0A, 12A0510Y0A, 120 15A NEMA 5-15
12A0510Y0A-NA
12A0600Y0A 120 20A NEMA 5-20
12A0750Y1A 120 20A “PIGTAILS” ONLY
12A0750Y1C 240 10A NEMA 6-20
18A0450Y0A, 120 20A
“PIGTAILS” ONLY
18A0600Y1A 120 30A
18A0600Y1C 240 15A NEMA 6-20
18A0750Y1A 120 30A “PIGTAILS” ONLY
18A0750Y1C 240 15A NEMA 6-20
24A0350Y0A 120 20A NEMA 5-20
24A0600Y1A 120 30A “PIGTAILS” ONLY
24A0600Y1C 240 15A NEMA 6-20
48A0350Y1A 120 30A “PIGTAILS” ONLY
48A0350Y1C 240 20A NEMA 6-20

Applied Energy Solutions
1 Technology Place Caledonia, NY 14423

Applied Energy Solutions
1 Technology Place Caledonia, NY 14423

CHARGER WARRANTY
APPL ED ENERGY SOLUT ONS 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 APPL ED ENERGY
SOLUT ONS, (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
APPL ED ENERGY SOLUT ONS WorkHorse 1 ndustrial Battery Chargers are warranted for 2 Years(1) (10 years on power transformers and diodes)(2), which begins on the
date of shipment from APPL ED ENERGY SOLUT ONS.
NOTES: (1) Warranty covers parts and labor, (2) Warranty covers parts only
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 APPL ED ENERGY SOLUT ONS only to the original user (purchaser) of new equipment from APPL ED
ENERGY SOLUT ONS 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.
REPA R L M TAT ONS. APPL ED ENERGY SOLUT ONS has the right to site inspection and judgment of the claimed defects in any product covered by this warranty.
APPL ED ENERGY SOLUT ONS' liability is limited to the repair of any defects found to exist by APPL ED ENERGY SOLUT ONS or, at APPL ED ENERGY
SOLUT ONS' option, the replacement of the defective product.
APPL ED ENERGY SOLUT ONS and its authorized agents shall not be liable for direct or indirect damages in excess of such repair or replacement. n 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.
CONT NUED USE OF DEFECT VE PRODUCTS. The continued use of an APPL ED ENERGY SOLUT ONS ndustrial Battery Charger that is known to be defective VO DS
ALL WARRANT ES.
REPA R OF MOD F ED EQU PMENT. Except as authorized in writing the warranty specified does not cover any equipment that has been repaired by any party other than
APPL ED ENERGY SOLUT ONS 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 APPL ED ENERGY SOLUT ONS.
WARRANTY EXPENSE L M TAT ONS. APPL ED ENERGY SOLUT ONS 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 goods. APPL ED ENERGY SOLUT ONS neither assumes or authorizes any persons to assume for APPL ED ENERGY
SOLUT ONS 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.