DC Power Technologies FS3 User Manual

Enatel Motive Power Ltd.

Technical

FS3, FS5 & FS9 Series Industrial Battery Charger Version 3

Hardware Manual

may be representative, actual products may differ.

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Table of Contents

1. Definition of Model Numbering ................................................................ 5

2. Introduction ............................................................................................... 6

3. Modular Charger Philosophy ................................................................... 7

Modular ........................................................................................ 7

Flexible ......................................................................................... 7

Redundancy ................................................................................. 7

4. Hardware Description ............................................................................... 8

Housing .................................................................................................... 8

FS3 ............................................................................................... 9

FS5, FS9 ...................................................................................... 9

Air Inlet Filter .......................................................................................... 10

AC Input Filter Board ............................................................................. 10

FS3LU, FS5, FS9 ....................................................................... 10

FS3LU only – Input Voltage Configuration ................................. 10

FS3xN, FS3xJ ............................................................................ 10

AC Input Terminal .................................................................................. 11

FS3xN, FS3xJ only ..................................................................... 11

Charger Module Earth and AC Supply .................................................. 11

FS3LU, FS5 & FS9 ..................................................................... 11

FS3xN ........................................................................................ 11

FS3xJ ......................................................................................... 12

DC Output Bus Bars .............................................................................. 13

FS5, FS9 .................................................................................... 13

DC Output Connector ............................................................................ 14

FS3 ............................................................................................. 14

FS9L ........................................................................................... 14

FS5, FS9H .................................................................................. 14

Auxiliary Power Supply Unit (PSU) ........................................................ 14

FS3 ............................................................................................. 14

FS5, FS9 .................................................................................... 14

Backplane .............................................................................................. 14

FS3 ............................................................................................. 14

FS5, FS9 .................................................................................... 14

MPC35 / MPC37 Charge Controller ...................................................... 16

Blank Panel – Module Bay .................................................................... 16

Blank Panel – FS5/9 DC Output Connector .......................................... 16

Mounting Bracket ................................................................................... 16

FS3 ............................................................................................. 17

FS5/9 .......................................................................................... 17

Charger Modules ................................................................................... 18

Module Types ............................................................................. 18

Charger Module Front Panel ...................................................... 18

Charger Module LED Combination States: ................................ 19

Module Installation and Removal ............................................... 19

Orientation for Installation .......................................................... 19

Module Removal ........................................................................ 19

Electrical Interconnection....................................................................... 20

FS3 ............................................................................................. 20

FS5 & FS9 .................................................................................. 20

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MPC Controller Circuitry............................................................. 21

5. Hardware Configuration – FS3 ............................................................... 22

Introduction ............................................................................................ 22

FS3xU: AC Input & Bus Bar Connection ............................................... 22

AC Supply Configuration Table .................................................. 22

Field Wiring Connections ........................................................... 23

AC Input Configurations ............................................................. 24

FS3LN: AC Input Terminal Block Configuration .................................... 25

Single Phase (MP13x modules) ................................................. 25

Three Phase (MP33x and 3xMP13x modules) .......................... 25

FS3xJ: AC Input Terminal Block for Japan RST Mains Supply............. 25

Surge Protection of MP130 & MP133 modules ......................... 26

Earthed S-Phase Configuration ................................................. 26

Current Limiting ..................................................................................... 27

Relay Configuration for External Applications ....................................... 28

6. Hardware Configuration – FS5, FS9 ...................................................... 29

Field Wiring Connections ....................................................................... 29

AC Input Configuration .......................................................................... 29

7. Charger Display Interface ....................................................................... 30

Equalise Next Cycle Option ................................................................... 30

Service Menu ......................................................................................... 30

Service Mode ......................................................................................... 30

8. Alarm Functions ...................................................................................... 31

Charger Alarms ...................................................................................... 31

Charger Related Alarms ........................................................................ 31

Battery Related Alarms ......................................................................... 33

9. Self Test Process .................................................................................... 35

Introduction ............................................................................................ 35

Accessing Self Test ............................................................................... 35

Operating the Self Test Sequence ........................................................ 35

10. Maintenance, Service and Repair .......................................................... 37

Regular Maintenance ............................................................................. 37

Air Filter.................................................................................................. 37

Blown DC Fuse ...................................................................................... 37

Charger Module Fault ............................................................................ 37

Charger MPC Fault ................................................................................ 37

Backplane Replacement ........................................................................ 38

11. Troubleshooting ...................................................................................... 40

12. Spare Parts – Common to all models.................................................... 42

13. Spare Parts – FS3 Specific ..................................................................... 44

14. Spare Parts – FS5, FS9 Specific ............................................................ 46

15. Appendix .................................................................................................. 48

Interconnection – FS3LN/FS3HN .......................................................... 48

Interconnection – FS3LU/FS3H ............................................................. 49

AC Input Terminal Detail – FS3xN Standard ......................................... 50

AC Input Terminal Detail – FS3xJ (RST Mains) .................................... 51

Interconnection – FS5L/FS5H ............................................................... 52

Interconnection – FS9L/FS9H ............................................................... 53

Input Current by Output Current ............................................................ 54

Exploded Diagram – FS3LU .................................................................. 55

Exploded Diagram – FS5, FS9 .............................................................. 56

16. Glossary ................................................................................................... 57

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1. Definition of Model Numbering

Model Number: eg. FS3LUV-532-US01 where

FS3 = Frame size, 3, 5 or 9 modules maximum L = 24 – 65V DC output, H = 70 – 130V DC output

U = UL, N = Non-UL, J = Japan V = branding: V=VForce, E=EcoCharge, H=Hawker 5 = Controller MPC35, 7 = MPC37 3 = module type, 1=MP130, 2=MP133, 3=MP330,

4=MP333 2 = number of modules fitted US01 = internal manufacturer designation

exempt. Pictures may be representative, actual products may differ.

2. Introduction

This manual provides comprehensive technical information about all aspects of the FSx series charger. It is intended for use by technically skilled individuals responsible for second level support of the chargers. It contains considerably more information than required for a first level field service technician.

Distribution of this manual is to be restricted as the information contained is not suitable for individuals who do not already have some knowledge of the correct method to charge forklift batteries. This information is commercial in confidence and is not to be distributed to a third party without the express permission of Enatel Motive Power.

An Operator/Installer manual is available for each charger and is suitable for distribution to a wider audience.

A software manual is also available covering use of the Charger Interface software to configure, troubleshoot and customize operation of the FSx series charger.

It is expected that an individual responsible for the support of the FSx series chargers will read and understand both the hardware manual and the companion software manual.

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3. Modular Charger Philosophy

The modular charger concept represents a fundamentally different approach to the way in which a forklift battery charger is designed.

Historically battery chargers have been designed to match a specific battery type and rating. These uncontrolled chargers need to be very closely matched to the intended battery. Due to the large number of combinations of voltage, amp-hours, cell type and recharge times, this results in a wide range of charger models being required.

Modular

The modular charger is based on the deployment of paralleled, high frequency charger modules with microprocessor oversight controlling the charge parameters. Modules can be easily added or removed as required and the controller is configured via PC software to set the charger’s particular rating.

Flexible

The modular charger series is capable of charging batteries of any nominal voltage in the range of 24V - 80V and offer the choice to operate on AC supply ranges of 208V single phase through to 480V three phase. The modules can be paralleled to a maximum of three, five or nine depending on the charger model.

Redundancy

Using parallel-connected charger modules also introduces the capability to offer redundancy, which is a unique and desirable feature for a forklift battery charger. Redundancy offers the capability to complete a charge with backup modules should an issue arise, albeit at a slower rate

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4. Hardware Description

FS3

FS3LU

Low voltage, UL Listed

FS3LN

Low voltage, Non-UL

FS3HN

High voltage, Non-UL

FS5

FS5LU

Low voltage, UL Listed

FS5HN

High voltage, Non-UL

FS9

FS9LU

Low voltage, UL Listed

FS9HN

High voltage, Non-UL

Three base models make up the FSx modular charger series. For each of the FS3, FS5 and FS9, a low and high output voltage model cover the battery voltage range. Logical model name modifiers allow differentiation, shown in the table below.

The FS5 and FS9 utilize a common larger chassis - only internal components differ between the two - while the FS3 takes a more compact form, suited to single-person handling.

The principal components of the FSx series comprise a number of paralleled charger modules each monitored and controlled by a system level microprocessor. The charger output characteristics are controlled depending on the charge requirements, battery type and state of charge.

The following sections describe the primary and auxiliary components of the FSx series, including where relevant, detail on model-specific features.

Housing

The FSx charger housings are 1.2 mm electro galvanized and powder coated steel. An internal chassis provides support for charger modules as well as primary and auxiliary circuitry. The housing front contains the charger display, status LEDs, pushbuttons, and air filter assembly.

Access to internal charger circuitry for service is gained by removing exterior panels.

Note: Before exterior housing panels are removed the charger must be isolated from both the AC supply and battery.

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FS3

The front of the FS3 housing takes up to three charger modules in a vertical, side-by-side orientation. Top and side covers allow access to the main serviceable internal areas of the FS3, removable in that order.

FS5, FS9

These models share a common frame and external housing, the 5/9 designation is determined by internal hardware and circuitry with the FS5 and FS9 supporting an operating maximum of five and nine modules respectively.

Access to the module bays is via the air filter assembly on the front face of the housing. Installed in the module bays, each charger module is supported in a horizontal orientation by the internal chassis.

The FS5 and some FS9 models require a single rather than double DC output connectors. These models are fitted with a steel blanking plate in place of the DC connector location.

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Air Inlet Filter

A stainless steel grille incorporating an electrostatic particulate air filter ensures cooling air drawn through the charger modules is free of dust and particulate matter.

The filter assembly is fastened to the front of the housing with thumbscrews.

The Maintenance section of this document covers the air filter cleaning procedure.

AC Input Filter Board

FS3LU, FS5, FS9

The AC Filter Board distributes AC supply to the modules and auxiliary power supply while providing protection to these components from surges in the supply voltage. AC input cables are terminated onto the AC filter board input terminal via a five way terminal strip.

FS3LU only – Input Voltage Configuration

Configuration possible for single and three phase, 208V-480V supplies. Configurable bus bars provide AC input type selection and two headers allow either 240V or 480V connection to the auxiliary power supply.

FS3xN, FS3xJ

See AC Input Terminal

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AC Input Terminal

Colour

Notation

Red

White

Blue

Black*

Yellow/Green

FS3xN, FS3xJ only

FS3 chargers not fitted with an AC input filter board instead utilize an input terminal block providing AC supply to the charger modules and the auxiliary power supply via their respective looms.

The terminal block is configurable for single and three phase supply via jumpers fitted to the terminal block. Refer to the Hardware Configuration section for details on terminal block configuration.

Charger Module Earth and AC Supply

AC is delivered to the backplane via the AC Loom consisting of

2.5mm² cable for each phase and neutral*.

*FS3 option only

FS3LU, FS5 & FS9

Earth connections are grouped together, bolted to the chassis and fed to the charger modules via the AC Loom. The chassis is connected to the mains earth via a ground trace on the AC Filter Board PCB, where a mounting screw provides connection.

FS3xN

Earth connections are grouped together, bolted to the chassis and fed to the charger modules via the AC Loom. The chassis is connected to the mains earth via 2.5mm² cable to the Input Terminal earth block. See

exempt. Pictures may be representative, actual products may differ.

FS3xJ

The FS3LJ and FS3HJ models are earthed the same as the FS3xN, however, some models (Toyota specific) wired for Japan’s RST mains feature an earthed S-Phase at the AC Input Terminal Block. See the Appendix for wiring diagrams.

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DC Output Bus Bars

The DC output bus bars are solid copper bars mounted inside the charger on the internal chassis frame. The bus bars provide DC connectivity from the backplane to the output connector(s) at the front of the charger.

Mounted on the bars are several key components of the charger self-protection features. In all models, a crowbar diode and high current fuses provide protection for the charger modules in the event that a reverse polarity battery is connected to the charger. Fuse status is monitored by the MPC controller using voltage sense looms attached to the bus bars either side of the fuses.

FS3

FS5, FS9

Calibrated current shunts fitted to the output circuit allow accurate current measurement at high amperages. These shunts are fitted with voltage sense looms monitored by the MPC controller.

exempt. Pictures may be representative, actual products may differ.

DC Output Connector

The DC output connector fitted to the FSx series is a high current SB350 connector designed for low resistance connections.

FS3

A single SB350 connector mounted horizontally. Special applications may require an SB175 connector fitted in place of the SB350.

FS9L

Frame allows for two connectors to manage large output currents.

FS5, FS9H

A single DC output connector is fitted.

All models provide for fixing of the connecting battery cable by way of the supplied threaded screws fastened through the cable connector into the internal chassis.

Auxiliary Power Supply Unit (PSU)

The FSx series chargers contain a power supply unit to provide a DC supply to the charger controller. A feed from this supply also

holds the charger modules in a default “standby” state, ready to

commence charging.

FS3

The auxiliary PSU is integrated into the backplane PCB and can be configured at the AC filter board (UL models) or Input Terminal block (Standard models) for 208VAC or 480VAC input voltages.

The FS3 PSU outputs a nominal 24VDC.

FS5, FS9

The auxiliary PSU is located on a dedicated PCB assembly mounted on the side of the internal chassis frame above the controller and bus bars.

The FS5-9 PSU provides a regulated 54VDC output from a 480VAC supply.

Backplane

At the rear of the FSx housing is the backplane PCB providing connectivity to the charger modules. The backplane features a multi-pin connector in each supported module bay for connection with an installed charger module. The connector passes AC from the AC Loom and DC output into the backplane. The connectors also contain a pin for communications between the modules and the MPC controller.

FS3

The backplane also incorporates the auxiliary PSU circuitry and three module connectors.

FS5, FS9

Backplanes each support five and nine module connectors respectively.

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MPC35

MPC37

Operating Voltage

12-65VDC

65-150VDC

Module Compatibility

MP130/MP330

MP133/MP333

MPC35 / MPC37 Charge Controller

The MPC controller provides the monitoring and control functions of the charger.

Operating on a 12-65VDC supply, the MPC35 controls the low voltage MP130 & MP330 range of modules while the MPC37 operates at 65-150VDC controlling the high voltage MP133 & MP333 modules.

The MPC allows the charger to be configured easily to charge different battery types. The MPC can also be set to automatically reconfigure when connected to a battery fitted with a battery module (Automatic Profile Configuration – APC).

The MPC also features configurable relays for operation of optional accessories such as battery auto-watering systems.

The MPC indicates the charger configuration and status on an LCD display, LED status lights, push button controls and a mini-USB port located on the front panel of the charger.

Blank Panel – Module Bay

Unused charger module positions should be fitted with a blank panel fixed to the housing metalwork. The blank panel prevents high temperature exhaust air recirculating inside the charger enclosure to the module air intake, ensuring the modules receive cool externally-sourced air.

To fasten to the chassis, two self-tapping screws are required per blank panel.

Blank Panel – FS5/9 DC Output Connector

The FS5-9 Output Blank Panel covers the lower output connector opening in models where a second connector is not fitted.

The blank panel is fastened to the charger chassis with two M5 captured washer hex-head bolts.

Mounting Bracket

The charger mounting bracket enables the charger to be secured at an elevated position and is recommended to protect the charger against accidental physical damage from vehicles or other hazards.

Bracket fasteners should be appropriate for the wall construction and material, and the wall should be capable of supporting the weight of the charger.

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FS3

The optional FS3 mounting bracket allows the charger to be fixed to a surface via the base, rear or left side.

The bracket can be mounted to an appropriate surface suitable for the particular configuration of the charger.

An FS3 with three modules can weigh up to 21kg.

The charger incorporates two slots for locating the bracket and two captured thumbscrews then secure the charger to the bracket.

FS5/9

The FS5/9 wall mounting bracket requires eight fasteners to secure it to the supporting wall.

An FS9 with nine modules can weigh up to 90kg.

The charger can be positioned on and fixed to the bracket using M5 machine screws fastening into the charger base frame. The same base mounting points may be used for a standard shelf, rack or table-top. The base mounting measurements are as follows:

FS5-9 base screw spacing (mm, c-c): 333W x 275D

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+ 42 hidden pages

DC Power Technologies FS3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual