Applied Energy Solutions WorkHorse User manual

WorkHorse
Series 2
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
FM1247
REV D

2

3
TABLE OF CONTENTS
SECTION PAGE
1 IMPORTANT SAFETY INSTRUCTIONS 4
2 RECEIPT AND INSPECTION 5
3 INTRODUCTION 5
4 CONTROL FEATURES 6
5 INSTALLATION 7
6 OPERATING PROCEDURE 9
7 CHARGER CABINETS 12
8 MAINTENANCE 13
9 TROUBLESHOOTING GUIDE 15
10 SCHEMATICS 18

4
1IMPORTANT SAFETY INSTRUCTIONS
. 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
. 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
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.
2RECEIPT AND INSPECTION
Upon receipt of the charger the information on the shipping carton should be checked
against your order. Any discrepancies should be reported to the nearest authorized
representative.
Whenever possible, move the charger to the installation site before uncrating. 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 and labels against your order and specifications. Any discrepancies
should be reported immediately to the nearest authorized representative.
3INTRODUCTION
SERIES 2 Industrial Battery Chargers are full wave silicon rectified ferroresonant
chargers.
Charging current is regulated by the ferroresonant transformer(s). The ferroresonant
transformers allow the battery to determine its own charge rate with respect to its state
of discharge.
The controllers are custom dv/dt-di/dt termination PCB assemblies for flooded lead-
acid battery chargers. A solid state, pre-programmed microcomputer provides total
control of charge termination, preventing both undercharging and overcharging. The
microcomputer incorporates built-in fault detection to ensure correct battery connection
and smooth operation. The charge is terminated automatically when the control
determines that the battery is fully charged.

6
4CONTROL FEATURES
Automatic five-second delayed start upon connection of a proper sized, good battery.
Battery voltage sensing determines if there is a proper sized battery connected to
the charger. This prevents charging if there is a bad battery connected, no battery
connected, bad battery-to-charger connection or battery voltage and charger
mismatch.
Battery voltage and current are continuously monitored.
Automatic dv/dt-di/dt charge termination.
Negative battery slope termination to prevent overcharge/thermal runaway.
Automatic 2-hour “REFRESH” adds a top off charge to a fully charged battery. The
charger will start a “refresh” charge 2 hours after a normal charge complete has
been reached, assuming that the battery was not disconnected during that time.
Backup Timers prevent extended charging of a damaged battery. The first timer
starts at the beginning of the charge cycle and runs for 9 hours. At 9 hours, if the
battery has not reached the 80% point, the charger will shutdown. The second timer
starts at the 80% point and runs for 6 hours. If the charger does not terminate by
then it will shutdown.
Automatic Shutdown Lockout will not allow a charge to start after a manual or
problem shutdown occurs. Automatic Shutdown Lockout is cleared after the
“Shutdown” battery is disconnected. This allows a charge to begin upon connection
of a good, proper sized battery.
Automatic shutdown occurs for any of five failure conditions:
Fault ode “Lo U” – Low volts per cell – the battery voltage is less than .7 vpc.
The charger will not be “locked off”. The charger will automatically start charging
when the battery voltage is greater than .7 vpc.
Fault ode “Hi U” – High volts per cell – greater than 2.8.
Fault ode “dISC” – Battery disconnected from charger during charge.
Fault ode “dur” – Charge time exceeded - backup timer expired.
Fault ode “Lo I” – Low charging current – charging current less than
approximately 3 amps.
Manual STOP switch - Will stop the charger from charging. The display will indicate
“OFF” until the battery is disconnected. When pressed with no battery connected
displays the delay start setting.

7
One to nine-hour programmable delayed start thumb wheel switch. This rotary
switch can be set from 0 to 9 hours to delay the start of charge.
Optional Automatic Equalization Cycle every 5th cycle. This option is enabled by
removing “W ” on the control PC board. For a completed charge cycle to be
counted, the battery must be on charge at less than 80% for hour or more from
start of charge.
Equalize switch - This switch when depressed will turn on and off the three hour
additional manual equalizing charge. When the Equalize function is turned on, an “E”
will be displayed in the leftmost digit of the display. The “E” will flash during the actual
equalize charge cycle (manual and automatic). If Auto-Equalize has been selected,
pressing this switch prior to connecting the battery will allow the number of charge
cycles remaining before auto-equalize cycle to be displayed in the format ‘E-#.’
LED Indicators:
“CHARGING” - charger is charging the battery.
“80%” - the battery voltage is greater than 2.37 volts per cell.
“CHARGE COMPLETE” - the charge cycle has been terminated normally.
“SHUTDOWN” - the unit has shut down for a fault.
80% Voltage Selection, factory set at 2.37 volts per cell. This may be changed to
2.45 volts per cell by removing “R32” on the PC control board assembly.
5INSTALLATION
5. PHYSICAL LOCATION:
Charging areas should be clean and dry. The temperature of the charging room should
be between 32F (0C) and 77F (25C), with occasional and brief periods of ambient
temperature as high as 04F (40C). Combustible materials, open flames and
smoking should not be permitted in or near the charging room.
WARNING
A BATTERY ON CHARGE WILL EMIT EXPLOSIVE GAS. VENTILATE THE
CHARGING ROOM TO PREVENT GAS ACCUMULATION.
5.2 MOUNTING:
The SERIES 2 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.

8
5.3 INPUT POWER CONNECTION:
All chargers are shipped from the factory connected for the input voltage specified on
your purchase order. A “STOP” label, located inside the door, indicates the factory set
input voltage.
WARNING
VERIFY THAT THE AC ELECTRICAL SERVICE IS DISCONNECTED AT THE
BREAKER BEFORE ATTEMPTING TO CONNECT AC POWER TO THE CHARGER.
The AC input terminals are identified by a red-on-white AC INPUT label, located on the
side near the fuse block. The AC input cable is to be connected to the proper AC
INPUT terminals within the charger cabinet.
The fuse block’s input terminals are rated for 4 AWG to 2 AWG wire. The
recommended torque is listed on the fuse block itself.
A green grounding wire 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 the charger base. 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 lug is rated for 4
AWG to 6 AWG wire. The recommended torque setting is shown in Table 5. .
Table 5.
Wire Gauge Recommended Torque Setting
PANDUIT LAMA2- 4Q
6 – 0 AWG 40 in lbs
2 – 4 AWG 5 in lbs
T&B ADR-2
6 AWG 35 in lbs
8 – 4 AWG 20 in lbs
The charger is normally furnished with an output charge plug or receptacle. Verify that
the connectors on both the battery and the charger are correct. Verify that when
connected, the positive polarity (red) of the charger is connected to the positive
terminal of the battery.
If the charger is to be used at a different AC voltage than presently set for, the charger
may be adjusted to operate for the different AC service. Refer to SECTION 8.2
CHANGING THE AC INPUT LINE VOLTAGE.

9
6OPERATING PROCEDURE
6. PRELIMINARY SET-UP:
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 the charge from one to nine
hours 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 (0-hour delay).
If a power failure occurs, no damage will occur to the battery or the 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.
Remove AC power from the charger.
Open the charger cabinet door.
Locate the DELAY START thumb wheel switch behind the front panel at the bottom
of the control board. Adjust the DELAY START thumb wheel switch until the
NUMBER INDICATOR on the switch yields the desired number of delay hours.
Close and secure the cabinet door.
Apply AC power to the charger.
When a good, proper sized battery is connected to the charger, the display will
indicate the amount of time before the charge is initiated, and the control will begin a
countdown to charge.
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. Once the battery to be charged has been
determined to match the charger, then connect the battery to the charger. The control
will measure the average V/Cell of the connected battery.
If the control has verified the connection of a good battery (between .7 and 2.8 V/Cell),
the display will show a countdown to charge initialization and the LED’s will be flashing.
When the countdown reaches zero, the control will turn on the charging transformers.

0
If the average V/Cell reading is less than .7 volts, the display shows “Lo U,” the
charge will not begin, and the red SHUTDOWN LED will be flashing. If the average
V/Cell is greater than 2.8 volts, the display shows “Hi U,” and the red SHUTDOWN
LED will illuminate. Again, the charge will not begin.
Once the charge begins, the display will show the output charging current in amperes.
The green CHARGING LED will illuminate. The yellow 80% CHARGED LED will
illuminate if the average V/Cell of the battery is greater than 2.37 V/Cell.
6.4 TERMINATION OF CHARGE:
There are three ways in which the charge may be terminated. These three termination
methods are, CHARGE COMPLETED TERMINATION, MANUAL TERMINATION and
PROBLEM SHUTDOWN TERMINATION.
CHARGE COMPLETED TERMINATION occurs when a battery reaches full charge.
The control monitors the battery charge characteristics. The control utilizes di/dt
current compensation to obtain an accurate battery voltage charging slope, dv/dt
measurement. Once the control has verified the battery charge slope has reached
the pre-determined value for full charge, the charge is terminated automatically.
Once the charge is completed and terminated, the green CHARGE COMPLETED
LED will illuminate and the display will be in the idle mode.
MANUAL TERMINATION is accomplished by pressing the STOP push-button switch
located on the front panel while charging,
To remove a harging battery from the harger, it is important to press the
STOP push-button swit h before dis onne ting the battery from the harger.
Failure to do this may damage the harger.
When the charge has been terminated due to MANUAL TERMINATION, the red
SHUTDOWN LED will be on continuously (until the battery is removed). The display
will show “OFF”.
PROBLEM SHUTDOWN
Each PROBLEM SHUTDOWN termination is indicated by a flashing red
SHUTDOWN LED and a FAULT code.* After the battery is removed, the red
SHUTDOWN LED will remain flashing for one hour. The display indicator will remain
on until the battery is disconnected from the charger.
*Refer to Section 4 for a more complete explanation of the diagnostics.