Applied Energy STEED User manual

STEED
WITH CONTROLLED FERRO-RESONANT TECHNOLOGY
Installation and Operating Instructions
OneTechnologyPlace
Caledonia,NY14423
(585)538–4421
www.appliedenergysol.com
The Power of Excellence FM1249
REV G

1
TABLE OF CONTENTS
SECTION 1 SAFETY INSTRUCTIONS 2
SECTION 2 RECEIPT AND INSPECTION OF THE CHARGER 3
SECTION 3 INTRODUCTION 3
SECTION 4 CONTROL FEATURES 3
SECTION 5 INSTALLATION 5
SECTION 6 CHARGER OPERATING PROCEDURE 8
SECTION 7 CHARGER CABINETS 11
SECTION 8 MAINTENANCE 12
SECTION 9 TROUBLESHOOTING GUIDE 15
SECTION 10 SCHEMATICS 17

2
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.

3
SECTION 2 RECEIPT AND INSPECTION OF THE CHARGER
Upon receipt of the STEED 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 STEED Charger is a full wave, silicon rectified ferro-resonant charger. Charging current
and voltage are controlled by the control circuit. This charger is capable of charging AGM
TYPE SEALED BATTERIES, SEALED GEL BATTERIES (GENERAL PROFILE), and
FLOODED BATTERIES.
A solid state, pre-programmed microprocessor provides total control of charge termination,
preventing both undercharging and overcharging. The charge is terminated automatically
when the control determines that the battery is fully charged. Refer to section 6.3 for charge
profiles
SECTION 4 CONTROL FEATURES
4.1 CONTROL FEATURES
Automatic five second delayed start upon connection of a proper sized battery in good
condition.
Battery voltage sensing determines if there is a proper sized battery connected to the
charger. This prevents charging if there is a bad battery, no battery connected, bad battery-
to-charger connection or battery voltage and charger mismatch.
Battery voltage and current are continuously monitored and controlled.
Automatic dv/dt charge termination.
Negative battery slope termination to prevent overcharge/thermal runaway.
Automatic 24 hour "REFRESH" charge adds a top off charge to a fully charged battery. The
charger will start a “refresh” charge 24 hours after a normal charge complete has been
reached, assuming that the battery was not disconnected during that time.
Back-up Timers prevent extended charging of a damaged battery. The first timer starts at the
beginning of the charge cycle and runs for 9 hours. If the battery has not reached the gassing
point the charger will shutdown. The second timer starts at the gassing point and runs for a
period of time determined by the charge profile. If the charger has not completed its cycle by
then it will shutdown.
Automatic Shutdown Lock-out will not allow a charge to start after a manual or problem
shutdown occurs. Automatic Shutdown Lock-out is cleared after the "Shutdown" battery is
disconnected. This allows a charge to begin upon connection of a proper sized battery.
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.
One to nine hour programmable delayed start thumbwheel switch. This rotary switch can be
set from 0 to 9 hours to delay the start of charge.

4
Equalize switch - This switch when depressed will turn on and off the three-hour additional
equalizing charge. When the equalize function is turned on an “E” will be displayed in the left-
most digit of the display and the CHARGE COMPLETE LED will flash on for 1/2 second and
then off for 3 seconds until the charger goes into the equalize mode. The “E” will flash during
the actual equalize charge cycle.
Refresh mode - When the CHARGING and 80% LED’s light continuously and the CHARGE
COMPLETE LED is flashing the charger is in the refresh mode. The refresh cycle is an
additional charge at the finish rate current. This added charge period will start when the
charger is left connected to a battery for 24 hrs after a normal charge cycle is complete. The
charger will automatically charge at the finish rate current until dv/dt is detected or until the
ceiling voltage limit is reached (Flooded battery only).
Automatic shutdown occurs for any of the following seven failure conditions. The
SHUTDOWN LED will flash when a shutdown occurs.
Manual Jump Start –If the battery voltage is lower than 1.5 V/Cell, the charger can be
manually started by pressing both STOP and EQUALIZE buttons. The charger will shut
down within 5 minutes if the battery voltage does not reach 1.5 V/Cell.
Fault Codes
Fault code “Lo U” - Low volts per cell - the battery voltage is less than 1.5 V/Cell. The charger
will not be “locked off”. The charger will automatically start charging when the battery voltage is
greater than 1.5 vpc.
Fault code “ Hi U”-High volts per cell - greater than 2.65,2.75 or 2.80 vpc (set with 80% point)
Fault code “dISC ”- Battery disconnected from charger during charge.
Fault code “dur“ - Charge time duration exceeded - backup timer expired during “high rate”
charge.
Fault code “Lo I”- Low charging current - charging current less than approx. 3 amps.
Fault code “Hi I” - The charger will shut down for high current if the output current is
imbalanced or over the range for that model.
Fault code “Ph ” (three phase units only) - the incoming AC Voltage has improper phase
rotation. Have a Qualified service person rotate the AC Input phasing to the charger.
LED Indicators
“CHARGING” - charger is charging the battery.
“80%” - the battery voltage is greater than the preset gassing voltage, see section 5 for setting.
“CHARGE COMPLETE” - the charge cycle has been terminated normally.
If flashing slowly (1/2 second every 4 seconds), the charger is set to equalize at the end of the
charge cycle.
If flashing on and off each second with the CHARGING and 80% LED’s lit continuously then the
charger is in the refresh mode.
“SHUTDOWN” - the unit has shut down for a fault.
AMMETER/TIMER Readout will display the following information:
Charging current
Fault codes
Delay start time
Equalize mode

5
Number of charge cycles remaining until the next Auto Equalize mode.
Amp-Hours returned for this charge cycle.
Charging time - the length of time the charger was charging.
Volts per Cell - the average battery cell voltage.
DISPLAY MODE BUTTON:
Press once to display the AMP-HRS returned this charge cycle.
Press twice to display the length of CHARGE this cycle.
Press three times to display the AVERAGE VOLTS per CELL of the battery.
The display will show the above function for approximately 10 seconds and than return to display
charge current or the sequencing dash.
LED TEST BUTTON: Pressing the LED TEST button will illuminate all display segments
and all LED's.
SECTION 5 INSTALLATION
5.1 PHYSICAL LOCATION:
Charging areas should be clean and dry. The temperature of the charging room should be
between 32 deg F (0 deg C) and 77deg F (25 deg C), with occasional and brief periods of
ambient temperature as high as 104 deg F (40 deg C). Combustible materials, open flames
and smoking should not be permitted near or in the charging room.
5.2 MOUNTING:
The 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.
5.3 INPUT POWER CONNECTION:
THE 3 PHASE STEED CHARGERS ARE PHASE ROTATION SENSITIVE; PLEASE
ENSURE THAT CLOCKWISE PHASE ROTATION IS OBSERVED. SEE SECTION 4.1 FOR
IMPROPER PHASE ROTATION FAULT CODE, OR SECTION 9 (TROUBLE SHOOTING
GUIDE).
The chargers are shipped from the factory connected for the input voltage specified on your
purchase order. A "STOP/CAUTION" label, located inside the door, indicates the factory set
input voltage.
WARNING
A BATTERY ON CHARGE WILL EMIT EXPLOSIVE GAS.
VENTILATE THE CHARGING ROOM TO PREVENT GAS ACCUMULATION.
WARNING
VERIFY THE AC ELECTRICAL SERVICE IS DISCONNECTED AT THE SOURCE
BEFORE ATTEMPTING TO CONNECT AC POWER TO THE CHARGER.

6
The AC input terminals are identified by a red-on-white AC INPUT sticker located on the base
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 14 AWG to 2 AWG wire. The recommended torque
is listed on the fuse block itself.
A bare wire, green or green with yellow striped 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 terminal is rated for 14 awg
to 6 awg wire. The recommended torque setting is shown in Table 5.1
Table 5.1
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
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 is 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.
5.4 Setting Charger DIP Switches
The STEED chargers are designed to charge both flooded and sealed batteries. The charger
is equipped with switches that determine the charge profile settings. The utmost care
must be used when setting the switches as incorrect settings can
undercharge, overcharge or even damage the battery and / or charger.

7
Table 1. Amp-Hour Rating
S6-1
S6-2
S6-3
S6-4
AMPERE-HOUR RATING
1 PH (AH)
AMPERE-HOUR RATING
3 PH (AH)
OFF
OFF
OFF
OFF
180
380
ON
OFF
OFF
OFF
260
475
OFF
ON
OFF
OFF
380
600
ON
ON
OFF
OFF
475
750
OFF
OFF
ON
OFF
540
865
ON
OFF
ON
OFF
600
965
OFF
ON
ON
OFF
680
1050
ON
ON
ON
OFF
750
1200
OFF
OFF
OFF
ON
865
1450
ON
OFF
OFF
ON
965
Reserved
OFF
ON
OFF
ON
Reserved
Reserved
ON
ON
OFF
ON
Reserved
Reserved
OFF
OFF
ON
ON
Reserved
Reserved
ON
OFF
ON
ON
Reserved
Reserved
OFF
ON
ON
ON
Reserved
Reserved
ON
ON
ON
ON
Reserved
Reserved
Table 2. Profiles
S2-1
S2-2
BATTERY
PROFILE
OFF
OFF
GEN GEL Sealed LA
I/E/I 16.0A/2.40V/1.5A
ON
OFF
AGM Sealed LA
I/E/I 15.5A/2.37V/3.0A
OFF
ON
Flooded (Regular) LA
P/E/I 18.0A/2.37V/5.0A
ON
ON
Flooded (Tubular) LA
P/E/I 18.0A/2.45V/5.0A
S2-3 & 4 are reserved
Table 3. Auto Equalize
S6-5
AUTO EQUALIZE
OFF
Disabled
ON
Every 7th Charge Cycle
Table 4. Cool-down Display
S6-6
COOL-DOWN TIME DISPLAY
OFF
Display Time Since Last Complete Charge Cycle
ON
Disabled
Table 5. Auto Refresh
S6-7
AUTO REFRESH
OFF
Disabled
ON
Enabled
Table 6. Auto Refresh Information
S6-8
REFRESH INFORMATION
OFF
Excluded
ON
Included
Note: Shaded areas are default setting.

8
SECTION 6 CHARGER OPERATING PROCEDURE
6.1 PRELIMINARY SET-UP:
With all power removed from the charger set the DIP switches per the previous tables before
attempting to charge a battery.
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 that 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 charger 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.
The following steps are to set the start delay:
Remove AC power from the charger.
Open the charger cabinet door.
Locate the DELAY START thumbwheel switch behind the front panel at the bottom of the
main control board. Adjust the DELAY START thumbwheel switch until the NUMBER
INDICATOR on the switch yields the number of delay hours desired.
Close and secure the cabinet door.
Apply AC power to the charger.
Without a battery connected the setting may be checked by pressing and holding the stop
button. 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 timer will countdown.
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
volts/cell of the connected battery.
If the control has verified the connection of a good battery (between 1.5 and 2.7 volts/cell), the
display will show a countdown to charge initialization and the LED’s will be flashing. When the
countdown reaches zero, the charger control will start the charging operation.
If the average volts/cell reading is less than 1.5 volts, the display shows “Lo U”, the charge will
not begin and the Red SHUTDOWN LED will be flashing. If the battery voltage “floats” above
1.5 V/Cell the charger will automatically begin a normal charge cycle.

9
To override the “Lo U” condition press and hold the Stop and Equalize buttons for ten
seconds. The charger will begin charging. If the battery voltage does not rise above the 1.5
V/Cell limit within 5 minutes the charger will be locked off and the override function will not
work.
When charging an overly discharged or sulfated battery the battery voltage may rise very
quickly for the first few minutes and then return to the “normal” voltage. If the peak voltage
reaches the gassing point and then falls more than 50 MV per cell below the gassing point the
charger will shut off. The SHUTDOWN LED will be flashing and the readout will display a
sequenced bar.
If the average volts/cell is greater than 2.7 volts, display shows “HI U”; and the Red
SHUTDOWN LED will turn on. Again, the charge will not begin. Once the charge begins, the
display will count down from 9 to 0 then show the output charging current in amperes. The
Green CHARGING LED will be on. The chargers offer a three-stage charge cycle. The Green
CHARGING LED will illuminate throughout the charge cycle. The cycle starts with high rate,
constant current. The 80% CHARGED LED will illuminate when the gassing point is reached.
SET FOR GEN GEL BATTERY
The charger’s microprocessor adjusts the output so that the charger is in constant current
mode (16A/100Ahr) until the battery reaches the gassing voltage (2.40V/Cell). After the
gassing voltage is reached the charger maintains this battery voltage and allows the charging
current to slowly decrease until it reaches the finish current (1.5A/100Ahr). When the current
reaches the finish current value, the charger will maintain the constant current mode
(1.5A/100Ahr) for three hours.
SET FOR AGM SEALED GEL BATTERY
The charger’s microprocessor adjusts the output so that the charger is in constant current
mode (15A/100Ahr) until the battery reaches the gassing voltage (2.37V/Cell). After the
gassing voltage is reached the charger maintains the battery voltage and allows the charging
current to slowly decrease until it reaches the finish current (3A/100Ahr). When the current
reaches the finish current value, the charger again returns to the constant current mode until
one of the following conditions is reached:
oDV/DT, OR
o3.5 hours from the gassing point
SET FOR FLOODED BATTERY (REGULAR OR TUBULAR)
The charger’s microprocessor adjusts the output so that the charger is in constant power
mode (18A/100Ahr @2.235V/Cell) until the battery reaches the gassing voltage (2.37 or 2.45
V/Cell). When the gassing voltage is reached the charger maintains the battery voltage and
allows the charging current to slowly decrease until it reaches the finish current value
(5A/100Ahr). When the current drops to the finish current the charger will stay in the constant
current mode until one of the following conditions is reached:
oDV/DT, OR
o6 hours from the gassing point.