Page 1
Page 2
WARNINGS
2. Warnings
Keep open flames
away from batteries
on charge.
Risk of battery
explosion.
Be aware of
battery fumes
and electrolyte.
Do not dispose
of batteries in
the garbage.
Electrical hazard
exists inside the
charger, do not
remove the
side cover.
Always recycle lead
acid batteries.
Battery electrolyte is
highly corrosive.
Wear eye protection
when working near
batteries.
Page 3
Contents .3
Contents
Warnings ....................................................................................................................................... 2
Contents ........................................................................................................................................ 3
Location ......................................................................................................................................... 4
Mounting Bracket Options ................................................................................................... 5
Installation ..................................................................................................................................... 6
FS3 Block Diagram .................................................................................................................. 9
Operating Instructions .......................................................................................................... 10
Front Panel (Set Equalize Charge) .................................................................................12
Charger Configuration Settings ....................................................................................... 14
Charger Alarms ........................................................................................................................ 15
Battery Alarms ..........................................................................................................................17
Troubleshooting ......................................................................................................................20
Exploded View .........................................................................................................................22
Spare Parts ................................................................................................................................ 23
Maintenance ..............................................................................................................................25
Service & Warranty ................................................................................................................26
Specifications ........................................................................................................................... 27
Charger Serial Number
Charger Part Number
Date Supplied
Vehicle Model
Purchaser
Purchase Invoice Number
Fleet Number
Page 4
4. Location
Location
The preferred installation is where the charger(s) can be located on a shelf,
protected against accidental contact with the lift truck or its forks.
With the charger on a shelf the risk
of damage to the charger or battery
cables is greatly reduced.
Avoid just placing the charger on
the floor next to the lift truck.
Page 5
Mounting Bracket Options .5
Mounting Bracket Options
Rear Mount
1. Fix the mounting bracket to the wall using a type
of fastener that suits the wall material.
2. Slide the rear of the FS3 onto the mounting bracket.
3.
With 2x M5x8 hex bolts (included with the mounting
bracket) secure the front of the mounting bracket to
the FS3.
4. When fitting the battery cable ensure the locking
screw is installed.
Base Mount
1. Fix the mounting bracket to a bench using a type
of fastener that suits the bench material.
2. Remove the 2x front case feet.
3. Slide the base of the FS3 onto the mounting bracket.
4. With 2x M5x8 hex bolts (included with the mounting
bracket) secure the front of the mounting bracket to
the FS3.
5. When fitting the battery cable ensure the locking
screw is installed.
Side Mount
1. Fix the mounting bracket to the wall using a type
of fastener that suits the wall material.
2. Slide the side of the FS3 onto the mounting bracket.
3.
With 2x M5x8 hex bolts (included with the mounting
bracket) secure the front of the mounting bracket to
the FS3.
4. When fitting the battery cable ensure the locking
screw is installed.
Page 6
6. Installation
Installation
Charger
Model
Number
Charger
Modules
Supply
Phase
DC
Output
Supply
Voltage
AC Supply
in Max.
Amps.
Per Phase
Aux.
Plug
Busbar
Selection
Config.
Number
FS3LUE-
512
2x
MP130
Single
Phase
24/36/
48V
208-
240
2830*
J5 1/2
FS3LUE-
522
2x
MP130
Three
Phase
24/36/
48V
208-
240
15.5-
23.2**
J5 3
FS3LUE-
513
3x
MP130
Single
Phase
24/36/
48V
208-
240
2830*
J5 1/2
FS3LUE-
523
3x
MP130
Three
Phase
24/36/
48V
208-
240
13.327**
J5 3
FS3LUE-
532
2x
MP330
Three
Phase
24/36/
48V
380-
480
8-
10
J6 4
FS3LUE-
533
3x
MP330
Three
Phase
24/36/
48V
380-
480
12-
15
J6 4
AC Input & Busbar Connection
Charger Model Number
FS3LUE-5xy
FS3 = Frame size.
MPx30 = 1 for MP130 or 3 for MP330.
y = 2 or 3 modules installed.
* in single phase mode the output power will reduce to maintain maximum AC current draw.
** in three phase mode the adding of the third charger module reduces the AC current draw
to achieve the same DC output as for two modules.
Page 7
AC Filter Board Configuration - Step 1 of 3
AC Input
Terminal
Block
Installation .7
Configuration 1 - MP130
208-240V AC Single Phase.
Configuration 4 - MP330
480V AC Three Phase.
STEP
1
A
E
D
C
B
L1
N
Configuration 3 - MP130
208-240V AC Three Phase.
A
E
D
C
B
L1
L2
L3
Configuration 2 - MP130
208-240V AC Single Phase Split Leg.
A
E
D
C
B
L2
208-240
N
0
L1
208-240
Note: Terminal connections
to be tightened to 21 in.lbs
Note: It is common in the US that a fourth wire (neutral) be used in a triple
phase circuit. If present, it should be attached to the “E” terminal.
208-240V AC 208-240V AC
208-240V AC
480V AC
A
E
D
C
B
L1
L2
L3
Page 8
8. Installation
Installation
AUX power supply connection
to 480V outlet J6.
AUX power supply connection
to 208-240V outlet J5.
AC Input
Busbar
Selection
Terminals
J5 240V
J6 480V
STEP
3
STEP
2
AC Filter Board Configuration - Step 2 of 3
AC Filter Board Configuration - Step 3 of 3
J14 J15 J16
J17 J18 J19 J20
208-240V single
phase configuration.
208-240V three
phase configuration.
J14 J15 J16
J17 J18 J19 J20
480V three
phase configuration.
J14 J15 J16
J17 J18 J19 J20
Use an 8mm socket on the M5 hex head bolts to secure the busbars in place.
Unused busbar connections are bolted to the internal rear of the FS3 cabinet.
Page 9
FS3 Block Diagram .9
FS3 Block Diagram
Page 10
10. Operating Instructions
Operating Instructions
Set the rocker switch to START.
8
7
1
2
3
4
5
Connect the battery to the charger using the correct cable.
Check the voltage, amphr and battery type indicated on the
charger’s display matches the battery to be charged.
Plug the charger in and turn on the AC supply.
Set the rocker switch to STOP.
Check the battery leads are in good condition before proceeding.
The red CHARGING light will illuminate
to indicate charging has commenced.
When the green READY light illuminates, charging is complete.
9
Set the rocker switch to STOP and then
disconnect the battery from the charger.
6
Page 11
Operating Instructions .11
4
8
2
6
9
7
3
5
1
Page 12
12. Front Panel
Front Panel
When a Non-Urgent Alarm is indicated the charge cycle has still
completed and in most cases can be disregarded.
When an Urgent Alarm is indicated, the charge cycle has not been
completed and the occurrence must be reported to a Supervisor,
your servicing battery dealer or DC Power Technologies at
844-ECO-CHRG.
Controller display.
Displays information depending on the status of the charger.
1
4
START/STOP rocker switch.
0 = Stop charge.
I = Start charge.
5
READY/CHARGING indicator lights.
RED steady on, GREEN off = Charging.
RED off, GREEN steady on = Charge complete.
RED flashing, GREEN off = Non-Urgent Alarm.
RED flashing, GREEN flashing = Urgent Alarm.
3
Mini USB port.
2
Controller push buttons (Set Equalize Charge).
To enable equalize next cycle, plug in the battery
but before setting the rocker switch to START:
- Press
button to set equalize next cycle.
- Press ENTER to allow changing.
- Press
to select “Enable”.
- Press ENTER to accept change.
- Press
to select “Store”.
- Press ENTER to accept.
- Press
to return to “Connect Battery”.
- Set the rocker switch to START.
Page 13
Front Panel .13
Display when no battery
connected or rocker
switch set to STOP.
Display when
charging.
Display when charge
complete.
AMBER LED same
as GREEN indicator.
GREEN LED
illuminates when
charger is powered up.
RED LED same
as RED indicator.
UP
button.
ENTER
button.
DOWN
button.
48V
Flooded
200Ahr
40A
Config:
Voltage
Amphrs
Profile
Current
Charging
Flooded
57.6V
40A
Rolling
Display:
Current=
Amphr=
Charge Time=
State=
Batt Volt=
Cell Volt=
Complete
Finish Time=
04:30:15
Rolling
Display:
Charge Time=
Bulk Time=
Finish Time=
Termination=
Batt Volt=
Cell Volt=
Finish Volt=
Amphrs=
1 2
3
4
5
Page 14
14. Charge Configuration Settings
Charger Configuration Settings
Charge Profiles Available
Conventional IUIa/IEI.
Opportunity charge.
Amp Hr Ranges
Conventional profile:
24V (300-1200 amp hr).
36V (300-1200 amp hr).
48V (300-950 amp hr).
Opportunity profile:
24V (300-750 amp hr).
36V (300-750 amp hr).
48V (300-600 amp hr).
Battery Types
Flooded.
Sealed.
Gel.
AGM.
Environments
Standard.
Freeze/cold condition.
Cable Length
Adjustable to any length.
Equalize Charge Settings
Cycle count:
Adjustable to any number.
Default setting is to equalize
charge after every 5 complete
charge cycles.
Day/time:
Select day and time of the week to
trigger an equalize charge on the
next charge cycle. Can also select
to have it equalize charge every
other week.
Manual equalize:
Select to have an equalize charge
run from the display panel.
Contact DC Power Technologies
for assistance with the
adjustment of these settings.
Phone : 1-844-ECO-CHRG
www.DCPowerTechnologies.com
Page 15
Charger Alarms
Main Switch. Urgent Alarm, shows the status of the front panel START/STOP
rocker switch.
Inlet Filter. Non-Urgent Alarm, can give warning as to when the inlet filter needs
servicing but is not enabled by default.
Low Mains. Non-Urgent Alarm, gives a indication of variation in the input mains
voltage without actually affecting the ability of the charger to provide rated output.
Can also indicate a charger module being overloaded.
Mains Fail. Urgent Alarm, a mains loss situation and the charge cannot proceed.
Non-Urgent Module Fail. Non-Urgent Alarm, there is a charger module that is
not providing output but the charger is still operating, but redundancy has been
lost.
Urgent Module Fail. Urgent Alarm, if the number of charger modules not providing
output equals or exceeds the setting for urgent module count in the monitor tab
then the charger will stop. If urgent module count is set to one then the charger is
configured without redundancy and a single fault will stop the charge.
Module Fan Fail. Non-Urgent Alarm, in the event of a complete fail of the cooling
fans the effected module will back off the maximum output current available to
level where natural convection of heat will allow the module to continue operating.
Charger Alarms .15
Charger Alarms
Main Switch Non-Urgent Module Fail Configuration Error APC Communications Fail
Inlet Filter Urgent Module Fail Output Fuse APC Incorrect Voltage
Low Mains Module Fan Fail No Output Current APC Unknown Charger
Mains Fail Module Over Temperature Monitor ADC Fail
Urgent Alarms. When an urgent alarm is triggered, please note the charger will
terminate its change cycle prematurely.
Page 16
Module Over Temperature. Urgent Alarm, normally related to a blocked filter or
restricted exhaust air or installation in an inappropriate location.
Configuration Error. Urgent Alarm, the charger cannot meet the target current
required by the controller even with all fitted charger modules operating or the
configuration does not meet the limits set for a 10A mains input hardware limited
charger.
Output Fuse. Urgent Alarm, a blown fuse in nearly all cases is caused by
connecting a reverse polarity battery to the charger. When a fuse is blown, check
all batteries for reverse cable connection. A common problem is with first charge
of shift batteries that have not been previously tested in a lift truck. After replacing
a battery or charger cable always closely check the polarity before plugging the
battery onto the charger.
No Output Current. Urgent Alarm, the charger is not providing the expected
output current. Generally related to a premature disconnection of the battery, but
also could be an incorrectly inserted charger module.
Monitor ADC Fail. Urgent Alarm, internal watchdog of the controllers microcontroller indicating a major fault and potential unpredictable behaviour if the
charger is left running.
APC Communications Fail. Urgent Alarm, the APC module has failed to
communicate with the charger.
APC Incorrect Voltage. Urgent Alarm, the charger cannot produce the voltage
required by the battery.
APC Unknown Charger. Urgent Alarm, the charger cannot find the required
profile.
16. Charger Alarms
Charger Alarms
Page 17
Battery Alarms .17
Battery Alarms
Over Discharged Battery. Urgent Alarm, the battery is still under 1.9Vpc
after 30 seconds of charge which indicates a faulty battery that needs
investigation.
Deeply Discharge Battery. Non-Urgent Alarm, the battery at start is under
1.9Vpc but recovers within 30 secs of charge, normally comes up when the
battery is quickly unplugged from the lift truck and plugged into the charger.
Sulphated Battery. Urgent Alarm, deactivated by default.
Incorrect Battery. Urgent Alarm, the battery voltage is inappropriate for the
configuration of the charger and cannot be charged without reconfiguring
the charger to suit the battery.
Bulk Charge Timeout. Urgent Alarm, the battery has exceeded the maximum
time allowed for the initial constant current bulk charge phase. Could indicate
a faulty battery or the charger configuration is not correct for the size of
battery to be charged. May need additional charger modules added to the
charger.
Battery Alarms
Over Discharged Battery Bulk Charge Timeout Minimum dV/dt +dI/dt
Deeply Discharged Battery Finishing Charge Timeout Maximum Cell Voltage Minimum Current
Sulphated Battery Battery Disconnected Batt Over Temp - Start EQ/Refresh Timeout
Incorrect Battery Reversed Battery Batt Over Temp - Charge
Page 18
Finishing Charge Timeout. Non-Urgent Alarm, the battery has exceeded the
maximum time allowed for the finishing part of the charge cycle. Generally
not a major problem and indicates the battery did not quite perform as
expected. Not uncommon with new batteries that are still cycling up to full
capacity (allow 10 cycles) however if the alarm is a regular occurrence it
needs investigation and possible adjustment of the charger or service of the
battery.
Battery Disconnected. Urgent Alarm, the battery has been unplugged
before charge cycle has complete. This can damage the battery connector
and increase risks of battery explosions as sparks around batteries at their
top of charge whilst gassing can be very dangerous. If the battery needs to
be disconnected mid cycle, the toggle switch must be first set to STOP. This
will stop the charge and log a partial cycle in the charge log but allows safe
disconnection of the battery.
Reversed Battery. Urgent Alarm, a battery with it plus and minus cables
reversed has been connected to the charger. Generally this will also cause
an output fuse alarm and the need to replace the chargers DC output fuse(s).
Such a situation is not covered by warranty as new batteries should always
first be checked for correct polarity BEFORE plugging onto the lift truck or a
charger.
Minimum dV/dt. Non-Urgent Alarm, details the change in battery voltage
over time. The alarm occurs when the change in voltage exceeds the value
set in profile settings. This alarm also indicates the termination of a successful
charge.
Battery Alarms
18. Battery Alarms
Page 19
Battery Alarms .19
Maximum Cell Voltage. Non-Urgent Alarm, occurs when the voltage per
cell exceeds the value set in the profile settings. Typically 2.7V per cell for
lead acid batteries.
Batt Over Temp - Start. Urgent Alarm, occurs when the battery temperature
measured before a charge profile starts exceeds the value set in the controller
settings. This alarm will not allow the charge profile to continue.
Batt Over Temp - Charge. Non-Urgent Alarm, occurs when the battery
temperature measured during a charge profile exceeds the value set in the
controller settings. This alarm will allow the charge profile to complete.
+dI/dt. Urgent Alarm, occurs when the measured current in the constant
voltage stage is rising instead of falling. This alarm will terminate the charge
profile.
Minimum Current. Non-Urgent Alarm, occurs when using a IU profile and
the current in the constant voltage stage falls below the value set in the
profile settings. This alarm will not stop a profile and is considered normal
for some types of batteries.
EQ/Refresh Timeout. Non-Urgent Alarm, occurs when the time in a given
stage of the equalize profile has exceeded the value set for that stage of the
profile. This alarm will terminate the equalize charge but is not considered
an Urgent Alarm.
Page 20
20. Troubleshooting
Troubleshooting
Problem Possible Cause Remedy
Main Switch Alarm.
Front panel switch in
the STOP position.
Charge will start when the
switch is set to START.
Inlet Filter Alarm. Air inlet filter blocked. Clean the filter.
Low Mains Alarm.
AC mains supply is
low or charger modules
may be overloaded.
Check configuration of the
charger suits the application.
Non-Urgent Module
Fail Alarm.
Charger module not providing
output, there is capacity to
charge at a reduced rate.
Replace the faulty charger
module(s).
Urgent Module
Fail Alarm.
Faulty charger modules are
affecting the ability of the
charger to charge the battery.
Replace the faulty charger
module(s).
Module Fan Fail. Faulty charger module fan. Replace charger module.
Module Over
Temperature.
Charger module
is overheating.
Check air inlet filter is
not blocked, check the
charger is installed without
any obstructions to air
inlet and outlet.
Configuration
Error.
Charger cannot provide the
target output current.
Check the controller
configuration matches
the quantity of power
modules installed, add
charger modules if necessary.
Output Fuse. Blown output fuse.
Check battery polarity.
Replace blown fuse.
No Output
Current.
Charger failing
to provide the
required current.
Check operator has not been
unplugging battery mid charge
cycle or the charge profile
has allowed the battery
current to fall below 0.7A.
Monitor
ADC Fail.
Faulty MPC31
controller module.
Replace the MPC35
controller module
ensuring the replacement
is correctly configured.
Page 21
Troubleshooting .21
Problem Possible Cause Remedy
Over Discharged
Battery.
Battery is <1.9Vpc
at connection but
recovers within 30
seconds of charge.
Typically due to the battery
being quickly unplugged from
the truck and plugged onto
the charger without allowing
the battery to recover. Regular
occurrences might need
investigation of work practices.
Deeply Discharged
Battery.
Battery is still
<1.9Vpc after 30
seconds of charge.
Check battery for faults.
Incorrect
Battery.
Battery is not the
correct voltage for
the charger.
Check the configuration
matches the battery, check
the operator is not trying
to plug an incorrect battery
type onto the charger.
Bulk Charge
Timeout.
The bulk charge
part of the cycle is
longer than expected.
Check the charger
configuration matches
the battery, check the
battery for problems.
Finishing Charge
Timeout.
The finishing charge part of the
cycle is longer than expected.
Check that the configuration
matches the battery, regular
timeouts may indicate a
problem with the battery.
Battery
Disconnected.
Battery has
been disconnected
mid charge cycle.
Remind the operator if there
is a need to disconnect the
battery mid charge cycle they
must first set the front panel
toggle switch to STOP.
Reversed
Battery.
A reverse polarity
battery has been
connected to the charger.
Correct the incorrect battery
wiring and replace the blown
charger output fuse(s).
Inability to set a 36V
configuration to greater
than 46A or a 48V config
greater than 35A.
Charger only
has a 10A AC
input lead.
Upgrade the AC input circuit
and remove the hardware AC
current limit function.
Page 22
22. Exploded View
Exploded View
Page 23
Spare Parts .23
Spare Parts
Image Description
MP130
Module
MP330
Module
3 Across Backplane
Assembly
SM31 Large Display
Assembly
Voltage Sensor
MPC35 Main
Board Assembly
FS3 AC Filter and
Voltage Selection Assembly
Stud Diode 150A 300V
Fuse HRC180A
150VDC 240VAC
Front Control
Panel Membrane
USB Hole Plug
Carry Handle
Page 24
24. Spare Parts
Image Description
Mounting Bracket
Case Foot
FS3 Cabinet
FS3 Lid
FS3 Side
Panel
DC Output
Loom
Blanking
Plate Oval
Blanking
Plate Conduit
Welded Filter
Assembly
Front Panel
Green Indicator
Front Panel
Red Indicator
Front Panel
Rocker Switch
Spare Parts
Page 25
Maintenance .25
Maintenance
Provided it is correctly installed in an appropriate location and is not abused, the
charger will require little maintenance. The only requirement is to monitor the air inlet
filter at the front of the charger for dirt accumulation. The charger modules internal to
the charger housing require a good supply of cooling air during the charge cycle and
a blocked filter will affect the cooling. A blocked filter could lead to the charger turning
down its maximum output to prevent overheating of the charger modules. An extremely
blocked filter could cause longer charge times, inability to charge the battery correctly
or premature wear of the charger modules.
Service Interval
The recommended service interval is 6 months but this will vary depending on the
location of the charger and the number of charge cycles performed. The fans in the
charger modules only run during charging and are speed controlled. If the charger
output is small the fans will only be turning slowly. At full power there is a considerable
requirement for cooling air and the fans will be working hard with considerable hot
air being exhausted from the rear of the charger. The exhaust air from the rear of the
charger should never be restricted. The intermittent nature of the fans results in a long
fan service with no scheduled replacement of fans being required.
Intake Filter
The filter material is an electrostatic polypropylene type that is easy to clean with
compressed air to blow out any accumulated dirt and dust. Before attempting to clean
the filter it is necessary to remove it from the housing by unscrewing the two captive
screws and unhinging the filter from the housing. The electrostatic filters provide a
good compromise between filtering and clogging, but a small quantity of dust will enter
the charger modules during normal operation. A small quantity of dust in the charger
modules will generally not cause problems, however excessive accumulation or where
the material ingested is corrosive, conductive or wet will cause issues, resulting in
premature wear of the charger modules.
Removing
the filter
from the
housing.
1. Unscrew the 2x
captive screws and
unhinge the filter
from the housing.
2. Blow out any dirt
& dust buildup with
compressed air to
clean the filter.
Page 26
26. Service & Warranty
Service & Warranty
Service
If both the RED and GREEN indicators are flashing there has been an Urgent
Alarm that has prevented the charge cycle from completing. Take note of the
error displayed on the display and contact your servicing battery dealer or
call DC Power Technolgoies (DCPT) at 1-844-ECO-CHRG for assistance.
If the RED indicator is flashing, but the GREEN indicator is on steadily, the
charge has completed satisfactorily but with a Non-Urgent Alarm. Contact
DCPT only if this is occurring on a regular basis.
Warranty
DCPT warrants that the product is free from defects in material
and workmanship and agrees to remedy any defect (or at its option
replace the product) for a period of one year from the date of purchase.
This warranty covers both parts and labour. Parts may be replaced
under this warranty with new or remanufactured parts.
This warranty will not apply to any product that has been improperly
installed, misused, abused, used in ways the product was not designed,
altered or repaired in any way which may affect the performance or reliability
of operation, sustained damage by power surges or electrical storms, or
sustained shipping damage, or repaired by any unauthorised repair centre.
Please contact DCPT Customer Service to obtain a Returned
Materials Authorisation (RMA) prior to shipping any products for repair. All
shipments must be shipped prepaid and include proof of the date of
your original purchase. Please include your name, address, phone number,
email address and a brief description of the problem.
DCPT makes no other warranties, express or implied, including any
warranty of fitness for a particular purpose. In no event shall DCPT be
responsible for indirect or consequential damages or lost profits even if
DCPT has been advised of the possibility of such damages. DCPTs sole
obligation shall be the repair or replacement of a nonconforming product.
Page 27
Page 28
FS3 Cabinet
Dimensions (in): 7.75W x 15.25D x 15.25H
Weight: 46 pounds (with 3 modules)
MP130 & MP330 Modules
AC Input MP130 MP330
Single phase 208/240V Three phase 480V
Three phase 208/240V
Nominal Input Voltage: 208-278V AC 380-480V AC
Operating Voltage Range: 90-300V AC 340-580V AC
Frequency Range: 45-65Hz >0.99PF 45-65Hz >0.92PF
Typical Efficiency: Max. 93% @ 48V Max. 93% @ 48V
DC Output
Range: 25-65V DC
60A DC output up to 50V
52A DC output to 57.6V
Ripple: <2mV
Broadband Noise: 2mV (<100hz)
200mV p-p (0-22Mhz)
Environmental Requirements
Ambient Temp. Range: -50ºF to 104ºF
(max. output power is derated above 122ºF)
Storage Temperature: -68ºF to 158ºF
Humidity: 5-95% RH (non-condensing)
Compliances
UL Listed: E333392 - UL 1564
Safety: EN60950
EMC: EN61000-6-2, EN61000-6-4
AC Harmonics & Flicker: EN61000-3-2, EN61000-3-3
California Appliance Large Battery
Efficiency Program: Charger Systems
Specifications .27
Specifications
BC
C
A
L
I
F
O
R
N
I
A
E
N
E
R
G
Y
BC
C
O
M
M
I
S
S
I
O
N
C
O
M
P
L
I
A
N
T
Page 29
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