QuarterHorse - Applied Energy Solutions
Contents
1. 13 SECTION 9 FAILURE MODE 15 SECTION 10 CHARGER 16 SECTION 11 MONTHLY PREVENTIVE 16 SECTION 12 TROUBLESHOOTING 0 2222 19 SECTION 13 SCHEMATICS 20 4 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 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 OF2. Table 6 1 1 Press Equalize or Stop Press DATAA Review Menu Description to select the digit to select the menu Press Data A or Data V to change the values or settings CLOCK Clock Setting DD HH MM MM DD YY 80 OFF Charger Turns Off at YES Gassing Point NO Disabled Enabled FULLCH Full Charge Period DD HH MM BLKOUT Block out Timer YES Disabled Enabled NO BLOCK Block out Timer Setting OFF DD HH MM EQUAL Auto Equalize NO EQU 5 CYL TIMED Press ENTER DD HH MM DLY ST Delay Start Setting SD 0 00 SD 0 15 SD 4 00 GASS V Gassing Point Setting GPV 2 37 GPV 2 45 RATE Start Rate Setting HR 25A HR 18A REFRSH Refresh Charge YES Disabled Enabled NO TEMP Temperature YES Sense Compensation NO Disabled Enabled 10 6 2 DEFAULT SETTINGS Table 6 2 1 80 OFF Charger turns off at gassing point Enabled FULLCH Full Charge Period From 1 00 to 5 00 each day BLKOUT Block out Timer Disabled BLOCK Block out Period 7 00 to 16 00 each day EQUAL Auto Equalize at 02 00 Saturday DLY ST No Delay Start GASS V Gassing point set at 2 37VPC RATE Start Rate set at 25A 100AH REFRSH Refresh Cycle Enabled TEMP Temperature Sensing Compensation Disabled Optional Sensor Required SECTION 7 REVIEW MODE PRIOR TO CHARGE ONLY All programmed setup items and charge data can be reviewed in the Review Mode Setup Data can only be reviewed prior to charge with b
3. F OF ON ON ON OF ON ON F ON ON ON ON ON ON ON Charger Cell Count S1 5 S1 6 S1 7 6 OFF OFF OFF 9 ON OFF OFF 12 OFF ON OFF 18 ON ON OFF 24 OFF OFF ON 36 ON OFF ON 40 OFF ON ON 48 ON ON ON Table 5 5 3 Output Cable Length ft S2 1 S2 2 10 15 20 25 30 35 40 45 SECTION6 SETUP MODE Most programming features are accessible from the front panel Setup mode is password protected All setting parameters are saved in the memory and the power rest does not affect the setting Press and hold ENTER for 5 seconds to enter the Setup Mode Press and hold ENTER 5 seconds again to exit the Setup Mode The display will automatically return to Charger Ready Mode in one minute if no activities are detected Press DataA or Data to change between menus increment decrement the values or toggle yes no Press Enter to go to the sub menu proceed to the next sub menu or save the setting Press 4 or Stop to select the digit to be changed 6 1 SETUP PROCEDURES Password is required to enter the setup mode The factory set password for the first time setup is 123 The user can enter the setup mode using this then change the password If an incorrect password is entered the display returns to 000 Use Data A Data Equalize and Stop to change the password Write the new password down and keep it in a safe place
4. AVANT DE REMPLACER LES FUSIBLES 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 amp labels against your order amp specifications Any discrepancies should be reported immediately to the nearest Applied Energy Solutions authorized representative SECTION INTRODUCTION The QuarterHorse Industrial Battery Chargers are full wave silicon rectified ferro resonant chargers This charger is designed to output high rate current charge of 25A 100AH for opportunity charging and 18A 100AH for standard charging applications providing the ideal solution for users to convert to Opportunity Charging with the safest and most effective method eliminating battery handling A real time clock built in controller e Provides total control of output current and voltage throughout the charge cycle e Terminates the charge cycle when the battery voltage reaches the gassing point to prevent the battery from gassing then allows the charger to complete the full charge by real time control Provides lock out timer for off peak operation Provides an opportunity to automatically equalize the batt
5. 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 ALA 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 CHARGEUR PAS CONCU POUR ALIMENTER UN RESEAU ELECTRIQUE TRES BASSE TENSION NI POUR CHARGER DES PILES SECHES LE D UTILISER LE CHARGEUR POUR CHARGER DES PILES SECHES POURRAIT ENTRAINER L ECLATEMENT DES PILES ET CAUSER DES BLESSURES OU DES COMMAGES 6 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
6. block See schematic Is phase wiring as indicated on the label at the AC Fuse Block connected to terminal of the main transformer T1 through the contactor main transformer 1 has the 12 position terminal block See schematic Is phase wiring as indicated on the label at the AC Fuse Block connected to terminal C of the tickler transformer T2 through the contactor tickler transformer T2 has the 6 position terminal block See schematic Are the cables from capacitor winding 7 of the main transformer T1 and from terminal M3 of the inductor board connected to the same side of the resonant capacitor Is the cable from capacitor winding 8 of the main transformer T1 connected to the power resistor mounted near the capacitor Are the cables from the other side of the power resistor and from terminal M4 of the control assembly connected to the same side of the capacitor Are the cables from capacitor winding 7 of the second transformer T2 and from terminal M1 of the inductor board connected to the same side of the resonant capacitor Is the cable from capacitor winding 8 of the second transformer T2 connected to the power resistor mounted near the capacitor Are the cables from the other side of the power resistor and from terminal M2 of the control assembly connected to the same side of the capacitor SYMPTOM 4 CHARGE TERMINATES EARLY e Fault code LOVOLT Low volts per cell the average battery v
7. of the 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 If the secondary voltage is extremely high or low verify that the AC voltage is connected to the proper primary inputs of the control transformer Refer to SECTION 11 2 2 Locate the Main Control Board and the Cell Select Board Verify the proper connection of the boards and cables SYMPTOM 2 DISPLAY IS ON BUT CHARGER WILL NOT START e CHARGER READY is displayed check the battery connections and the output fuse for open fuse f HIVOLT is displayed verify that the number of cells of the battery to be charged matches the number of cells on the nameplate located on the external surface of the door e If LOVOLT 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 SYMPTOM 3 DISPLAY COUNTS DOWN BUT SHUTDOWN IMMEDIATELY e f ERR 2 is displayed check the 20 pin flat cable between main control board on the back of the front panel and inductor board mounted on the chassis e If ERR 1 ERR 3 or HICURR is displayed within first 10 seconds after power up try reversing two of the AC input leads to see if this solves the pro
8. QuarterHorse Opportunity Charger with TCC 2 0 Controller Installation and Operating Instructions owt APPLIEDENERGY SOLUTIONS One Technology Place Caledonia NY 14423 585 538 4421 www appliedenergysol com The Power of Excellence FM1317 REV 3 TABLE OF CONTENTS OPPORTUNITY CHARGER 1 WITH TCC 2 0 1 SECTION 1 SAFETY 8 2 0 2222 411 1 1 4 44 4 4 44041 1 44 4 SECTION 2 RECEIPT AND INSPECTION THE 5 SECTION 3 INTRODUCTION ianeraacteeassaitdavaclaanascaamestenbecaet 5 ei eecanrui du E 5 SECTION 4 CONTROL FEATURES 6 SECTION 5 INSTALLATION 7 SECTION SETUP MODE 5 5 9 SECTION 7 REVIEW MODE PRIOR CHARGE 10 SECTION 8 CHARGING 11
9. Voltage FV V VV 13 8 2 When proper battery is connected the display will count down from 5 to 0 then the red CHARGING LED will illuminate The cycle starts with high rate constant current of 25A 100AH 18A 100AH until the gassing voltage is reached The LED will illuminate at the beginning of charge cycle The Gas Gauge LEDs will indicate the state of charge 80 point can be programmed at 2 37 2 40 2 42 or 2 45V Cell in the Setup mode When the battery voltage reaches the 80 point the charger enters the constant voltage mode and the current gradually tapers off When the programmed gassing point is reached e If the Gassing Shut off function is enabled and during the full charge disabled period the charger shuts off and goes to idle mode in order to prevent the battery from gassing The charger will display STOP AT 80 and the 80 CHARGED LED will illuminate When the full charge enabled period begins the charger will automatically turn on to complete the full charge cycle The cool down time will be displayed and the CHARGE COMPLETE LED will illuminate when the cycle is complete e If the Gassing Shut off function is set or during the full charge enabled period the charger will continue the regular full charge cycle 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 con
10. W VOLTS OVERRIDE If the battery voltage measures less than 1 7 VPC the charger may be started manually by pressing and holding two push buttons ENTER and EQUALIZE 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 10 CHARGER CABINET SECTION 11 MONTHLY PREVENTIVE MAINTENANCE 11 1 MONTHLY PREVENTIVE MAINTENANCE WARNING HIGH VOLTAGES EXIST WITHIN THE CHARGER WHICH CAN CAUSE SEVERE INJURY OR DEATH SERVICE SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL IMPROPER SERVICING MAY DAMAGE THE CHARGER lf abattery is being charged terminate the charge by pressing the STOP button e Disconnect the battery from the charger e Remove AC power from the charger e Using compressed air remove any dust from the inner cabinet walls and internal components of the charger 17 Wipe the exterior of the cabinet and clear any obstructions from the ventilation louvers 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 The QuarterHorse chargers are designed to operate at different voltag
11. attery disconnected Charge Data can be reviewed any time While CHARGER READY is scrolling press DATAA or DATAY to toggle between SETUP setup information and CHDATA charge data Press ENTER to make a selection 7 1 REVIEW SETUP DATA Press DATAA to select the main menu press ENTER to review setup and press DATAY to exit the review menu Table 7 1 Review Main Menu Review Menu Description Review Sub Menu Press DATAA to select Press ENTER to view CLOCK Clock Setting DD HH MM MM DD YY 80 Y Charger Turns Off at Gassing 80 N Disabled Enabled FULLCH Full Charge Period DD HH MM BLKT N Block out Timer Disabled Enabled BLKT Y BLOCK Block out Timer Setting OFF DD HH MM NO EQU Auto Equalize 5 CYL TIMEEQ DD HH MM SD 0 00 Delay Start Setting SD 0 15 50 4 00 2 37 Gassing Point Setting GPV 2 45 HR 25A Start Rate Setting HR 18 REFH Y Refresh Charge REFH N Disabled Enabled TEMP Y Temp Sense Compensation TEMP N Disabled Enabled 7 2 11 REVIEW CHARGE DATA Press DATAA to select the charge cycle press ENTER to review the setup and press DATAY to exit the review menu SECTION 8 CHARGING MODE 8 1 DISPLAY AND CONTROL Table 7 2 Review Main Menu Review Menu Description Review Sub Menu Press DATA A to select Press ENTER to view LAST Charge Data of the Last Cycle Start Month Date MMM DD Start Hour Minute ST HH MM Amp Hour Returned 0000 Fi
12. blem e f ERR 1 ERR 3 or HICURR is displayed after 10 seconds the following checklist should be performed to resolve this problem 15 cable harness connected properly between the main control board and the inductor board 15 COMMON of the control transformer connected to the AC input phase see schematic 15 the other terminal of the control transformer connected to the AC input phase A see schematic Check all diodes and capacitors 20 For 240 480 575 input models Is phase wiring as indicated on the label at the AC Fuse Block connected to terminal of the main transformer T1 through the contactor main transformer 1 has the 12 position terminal block See schematic Is phase wiring as indicated on the label at the AC Fuse Block connected to terminal B of the main transformer T1 through the contactor main transformer T1 has the 12 position terminal block See schematic Is phase wiring as indicated on the label at the AC Fuse Block connected to terminal C of the tickler transformer T2 through the contactor tickler transformer T2 has the 6 position terminal block See schematic For 480 575 600V input models Is phase wiring as indicated on the label at the AC Fuse Block connected to terminal B of the main transformer T1 through the contactor main transformer T1 has the 12 position terminal
13. c refresh charge every 24 hours Programmable charge block out time Programmable charge termination when battery voltage reaches the gassing point to prevent excessive gassing Low electrical noise superior in applications with other electrical equipment and controls Remote Control Interface Auto start with five second delay Automatic shutdown for the following conditions 80 or final charge exceeds time limit Volts per cell outside safe limits Charging current too high or too low Maximum battery temperature exceeded requires optional battery temperature sensor Controlled Ferro resonant technology for Total Charge Control over the complete charging cycle Digital readout displays Time remaining to 80 amp full charge Charge current voltage Equalize in process Charge data 25 cycles time AH returned and voltage Charger setup Fault codes LED charge status indicators Gas gauge Charging 80 Charged Charge Complete Equalize Fault Shutdown Cool down time displayed Manual jump start for over discharged batteries 5 INSTALLATION 5 1 PHYSICAL LOCATION Charging areas should be clean and dry The temperature of the charging room should be between 32 F 0 C and 104 F 40 C Combustible materials open flames and smoking must not be permitted near or in the charging area 5 2 MOUNTING The QuarterHorse charger cabinets must be mounted on a surface construc
14. e 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
15. e levels The chargers can be ordered for 240 480 575 volts or 480 575 600 volts 60 Hz electric services If the charger is to be operated on a different rated input voltage than the ordered value follow the voltage changeover instructions described below Refer to Figures 11 1 1 or 11 1 2 11 2 2 Voltage Changeover Instructions Manually terminate the charging battery by pressing the STOP button and disconnect battery from charger Remove AC power from the charger Locate the Terminal Block with Jumpers and the label describing the various voltage jumper configurations Refer to Figures 11 1 1 or 11 1 2 The Terminal Block with Jumpers is located on the Ferro resonant Transformer Change the jumpers in accordance with the Jumper label located within the charger cabinet for the voltage input configuration desired Locate the AC fuses and fuse label Change the fuses to the appropriate value as indicated by the circled values on the fuse label Locate the Control transformer Change the primary input connection in accordance with the voltage printed on the transformer Refer to Figure 11 2 Change the voltage level on the STOP label to the new voltage level Check list Verify that the Terminal Block s with Jumpers are configured correctly and screw connections are tight Make sure that all of the Terminal Blocks with Jumpers have been changed properly Verify the installation of properly rated fuses Verify that the Con
16. ery at a programmable time of day and day of the week a Data t proper sized battery to charger lt 2 5 second countdown with all LEDs flashing 3 Display 1 charge time remaining hrs mm PAPPLIEDIENERGYA y Data Battery Charge Level 4 Display 2 alternating charging current A and battery volts vpc 7 5 Press DATA to change display mode 4 oE oy Display will return to default 60 SOLUTIONS 6 To change default display press A DATA to select display then Enter Charging ENTER save Gne Technniagu Piace 7 Charger will stop automaticall ime Caledonia 14423 80 Charge 9 automatically Battery cool down time COOL 0 836 2132 www appliedenergysol com Complete Equalize Total Charge Contol TCC 2 0 Made in U S A VIEW OF FRONT PANEL SECTION 4 CONTROL FEATURES 25 recharge in one hour 80 recharge in approximately three hours and 100 recharge in approximately six hours No battery modifications are required Easy access for programming all features User selectable features Charge rate of 18 or 25A 100Ah Delayed start from 30 minutes to four hours in 15 minute intervals Equalize can be selected manually automatically with day time setting or every 5 cycles Gassing point options 2 37VPC default 2 40VPC 2 42VPC 2 45VPC Automati
17. he Auto Equalize setup AUTO EQUALIZE CANCELLATION e 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 e Manual equalize select be cancelled by pressing the Equalize button again 14 AUTO EQUALIZE ACTIVATION When the set time and set day are matched equalize cycle can be activated at the following conditions When the charge is in progress the equalize cycle will start immediately after completing the 100 charge cycle When the 100 charge cycle is already completed the charger will automatically turn on to equalize charge the battery for 3 hours When the 100 charge cycle is not complete because the battery voltage reached 80 before the full charge enable window was reached 1 00 to 5 00 is default setting of the full charge enable window the charger will immediately resume to complete the 100 charge then add three hours of equalize charge When the battery is not connected the Equalize Cycle will be accomplished the next time the battery is connected The charger will remain on throughout the cycle until the Equalize cycle is complete and will not shut off at the gassing point FULL CHARGE TIME WINDOW When the battery voltage reaches the 80 point within this window the charge cycle will continue to fully charge the battery When the battery voltage reaches the 80 poin
18. n 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 ar
19. ng Voltage Current and Charge Time Remaining Display DATAY Push Button Switch Press DATAY to enter the Charge Data Review Mode Refer to Table 7 3 ENTER Push Button Switch Press ENTER to lock in the display mode Charging Voltage Current or Charge Time Remaining Display EQUALIZE Push Button Switch Press EQUALIZE to set the Equalize Cycle manually STOP Push Button Switch Press STOP to shut down th e charger manually REVIEW CHARGE DATA DURING CHARGE Press DATAY then ENTER to review the current cycle data press DATAA to select the next charge cycle then press ENTER to review the charge data of the selected cycle Pressing DATAY again will exit the review menu and return to the charging display Table 7 3 Review Main Menu Review Menu Description Review Sub Menu Press DATA A to select Press ENTER to view DATA Charge Data of the Last Cycle Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned 0000 CYL 1 1 Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned XXXXAH Finish Month Date MM DD Finish Hour Minute FT HH MM Finish Voltage FV V VV CYL 2 Cycle 2 Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned XXXXAH Finish Month Date MM DD Finish Hour Minute FT HH MM Finish Voltage FV V VV CYL 24 Cycle 24 Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned XXXXAH Finish Month Date MM DD Finish Hour Minute FT HH MM Finish
20. nish Month Date MM DD Finish Hour Minute FT HH MM Finish Voltage FV V VV CYL 1 Cycle 1 Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned XXXXAH Finish Month Date MM DD Finish Hour Minute FT HH MM Finish Voltage FV V VV CYL 2 Cycle 2 Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned XXXXAH Finish Month Date MM DD Finish Hour Minute FT HH MM Finish Voltage FV V VV CYL 24 Cycle 24 Start Month Date MM DD Start Hour Minute ST HH MM Amp Hour Returned XXXXAH Finish Month Date MM DD Finish Hour Minute FT HH MM Finish Voltage FV V VV The front panel provides the following displays and controls to the user during charge Six_digit Alphanumeric Display The default display is Charge Time Remaining the time remaining until 80 charge and until full charge will be displayed It also displays the fault codes and charge data of the last 25 charge cycles Gas Gauge Indicator The gas gauge contains 5 LED indicator bar and two extra LED indicators for and The five level indicator displays the battery capacity returned The indicator illuminates until the battery capacity reaches 20 recharged the F indicator illuminates when the battery is fully charged Charger Indicator Charging LED Red 12 80 Charged Amber Charge Complete Blue DATAA Push Button Switch The default display is Charge Time remaining Press to toggle between Chargi
21. oiding future problems The ground terminal is rated for 14 awg to 6 awg wire The recommended torque setting is shown in Table 5 3 Table 5 3 1 Wire Gauge Recommended Torque Setting PANDUIT LAMA6 14Q 6 10 AWG 40 in lbs 12 14 AWG 15 in Ibs T amp B ADR6 6 AWG 35 in lbs 8 14 AWG 20 in Ibs 8 54 TEMPERATURE SENSOR INSTALLATION OPTIONAL The battery temperature sensor kit KT1109 SBX or KT1150 EBC is designed for use with QuarterHorsellChargers It senses the battery electrolyte temperature and provides the temperature information to the charger control module Refer to manual FM1299 for installation details 5 5 SETTING CHARGER DIP SWITCHES FOR FIELD REPLACEMENT ONLY The QuarterHorse battery chargers are equipped with switches on the main control board that are programmed to the charger specifications Care must be used when changing the switch settings as incorrect settings can undercharge overcharge or damage the battery and or charger Table 5 5 1 Charger Amp Hour Rating 51 1 51 2 51 3 51 4 510 ing 260 380 425 475 540 600 680 750 765 865 965 1050 1190 1360 1450 Table 5 5 2 O O O O O O O O F ON OF OFF OF F ON OFF OF ON ON OFF OF F OF ON OF ON OF ON OF F ON ON OF ON ON ON OF F OF OFF ON ON OF OFF ON F ON OFF ON ON ON OFF ON
22. oltage is less than 1 5 V Cell Check for bad cells e Fault code HIVOLT 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 or 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 e Fault code LOCURR Low charging current no charging current detected or charging current is too low Check the DC fuse for open fuse and defective AC contactor circuit Display STOP Charge cycle is terminated by pressing the STOP button SECTION 13 SCHEMATICS See following page 21 AYOA 32 14 56801101065 7 4 91417 OLLVWAHOS 43553844405 39dns coe EER osr 53504 Ov e cae 4 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
23. 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 QuarterHorse Industrial Battery Chargers are warranted for 10 Years which begins on the date of shipment from APPLIED ENERGY SOLUTIONS NOTES 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 optio
24. rge rate of the battery will be monitored with DV DT termination occurring typically within 45 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 8 6 TEMPERATURE SENSING OPTIONAL Refer to the user manual of the Temperature Sensor Kit for details SECTION9 FAILURE MODE 9 1 PROBLEM SHUTDOWN The problem shutdown terminations are indicated in Table 9 1 1 The Fault LED display will remain until the battery is disconnected from the charger If the battery is disconnected during charge the display will remain until the battery is connected again Table 9 1 1 Fault Codes Conditions LEDs STOP STOP button is pressed Fault LED On DISC Battery is unplugged during charge causing Fault amp Equalize LED Flashing internal overload DISC Battery is unplugged during charge Fault LED On ERR 1 Reversed Phase or Internal Fault Fault LED On Cable between Inductor Board and Control Fault LED On ERR 2 Board is disconnected or defective ERR 3 Reversed Phase or Internal Fault Fault LED Flashing HIVOLT Hi Volts gt 2 8V 2 85V Fault LED On LOVOLT Low Volts lt 1 7VPC HICURR Output Current is High gt 110 Fault LED On LOCURR Output Current is Low lt 7 Amps Fault LED On Fault LED On DUR HR Hi Rate Duration gt 6 Hours DUR LR Lo Rate Duration gt 6 Hours Fault LED On 16 9 2 BATTERY LO
25. stant voltage to constant current The charge cycle will terminate by DV DT sensing The cool down time COOL HH MM will display the F and CHARGE COMPLETE LEDs will illuminate at the completion of the full charge cycle 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 Setup Mode every charge 5 cycles or at a specific time of day and day of week once a week The first digit of the front panel display will display E and the EQUALIZE LED will flash to indicate that the Equalize charge is selected When the charger is actually in the Equalize mode the 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 EQUALIZE 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 8 4 AUTO EQUALIZE DETAIL The timed equalize charge if selected will occur once a week The following paragraph outlines this feature in detail AUTO EQUALIZE SELECT Auto Equalize can be disabled activated every 5 charge cycles or once a week at a specific time of day and day of week Refer to Section 6 1 for t
26. t outside this window the charger will shut off and resume when the ON time is reached When the OFF time is reached the charge will continue until the charge cycle is complete When the Equalize Time is set before the ON time of the full charge cycle the charge cycle will resume the charger will fully charge the battery then continue the 3 hour Equalize cycle AUTO EQUALIZE AND FULL CHARGE ENABLE EXAMPLES TIEINE CASE CASE CASES TIEINE CASE CASE CASES E LOHRGE EMBIE MOON HIRATE CHARGE GHRATE CHARGE i th HIRATE CHARGE FNSH RATE CHARGE in 1 ARATE CHARGE FSH RATE CHARGE w so woo wi w am m l Li Je 1 HIRATE CHARGE FISH RATE CHARGE EILE CHARGE ARATE CHARGE FSH RATE CHARGE CHARGE HIRATE CHARGE FNSHRATE CHARGE EQUAUZE CHARGE moen SAME D OD ON ALLCASES 15 8 4 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 5 REFRESH CHARGE When a battery remains connected to the charger for 24 hours after the charge has been completed and the Refresh Function is enabled the control will restart another charge cycle The cha
27. ted 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 QUARTERHORSE THREE PHASE CHARGERS ARE PHASE ROTATION SENSITIVE PLEASE ENSURE THAT CLOCKWISE PHASE ROTATION IS OBSERVED The QuarterHorse 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 VERIFY THE AC ELECTRICAL SERVICE IS DISCONNECTED AT THE SOURCE 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 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 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 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 av
28. trol Transformer primary taps have been changed correctly Verify that the STOP label located inside the door has been corrected to the new input voltage level that the charger is set for Close and secure the cabinet Connect the AC power to the charger 18 AC INPUT PHASE FIGURE 11 1 1 VOLTAGE SELECTOR BLOCKS 240 480 575V AC INPUT PHASE A B FIGURE 11 1 2 VOLTAGE SELECTOR BLOCKS 480 575 600V NOTE INPUT VOLTAGE SETTING FOR CONTROL TRANSFORMER LEADS FROM AC INPUT MUST BE EXACT TO AC LINE CONTACTOR 480V 480 PHASE c PHASE iis 7 LF 7 LS E p40v J PHASE C 540 2 J PHASE FIGURE 11 2 A C VOLTAGE SELECTION ON PRIMARY SIDE OF CONTROL TRANSFORMER 19 HIGH VOLTAGES EXIST WITHIN THE CHARGER WHICH CAN CAUSE SEVERE INJURY OR DEATH SERVICE SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL IMPROPER SERVICING MAY DAMAGE THE CHARGER SECTION 12 TROUBLESHOOTING GUIDE SYMPTOM 1 POWER IS APPLIED BUT THE DISPLAY IS NOT ON sure the input line from the AC power outlet is connected at the AC fuse block properly Verify the AC voltage at the fuse block e Locate the control transformer Verify the voltage at the primary of the transformer If there is no voltage check the wiring between the control transformer and the contactor e Verify the secondary voltage
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