Enatel Motive Power FS5, FS9 Operator And Installation Manual

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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.

Contents

Warnings ...................................................................................................................................... 2

Contents

....................................................................................................................................... 3

Overview

...................................................................................................................................... 4

Installation

................................................................................................................................... 5

Operation

..................................................................................................................................... 6

- Front Panel .......................................................................................................................... 8

- Conﬁguration Settings .................................................................................................. 10

Charger Alarms

........................................................................................................................ 11

Battery Alarms

..........................................................................................................................13

Troubleshooting

......................................................................................................................15

Maintenance

..............................................................................................................................17

Spare Parts

................................................................................................................................ 18

Service & Warranty

............................................................................................................... 20

Speciﬁcations

........................................................................................................................... 21

Charger Serial Number

Charger Part Number

Date Supplied

Vehicle Model

Purchaser

Purchase Invoice Number

Fleet Number

Overview

Small LED Indicators

Controller Push Buttons

AC Input (Rear)

START/STOP Rocker Switch

Filter Cover Assembly

READY/CHARGING Indicator Lights

Mini USB Port

1 2

Controller Display

FS5 & FS9 XHF Series Charger

DC Output

Installation

Location

The recommended installation is where the charger(s) can be located

at ground level or on a raised platform, protected against accidental

contact with the lift truck or its forks. Installation above ground level is

recommended to reduce the level of dust ingested by the charger.

AC Input

The FS5 and FS9 chargers require 480V, 3 phase AC supply. Care must be

taken to install your charger with the appropriate rated AC supply cable.

FS5: 6 AWG Copper Conductors

FS9: 6 AWG Copper Conductors, rated 167°F / 75°C minimum

Refer to the rating label on your charger for AC supply requirements

speciﬁc to your conﬁguration.

AC Supply Wiring Conﬁguration

480V AC

Delta

Earth

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.

Operation

Check the battery leads are in good condition before proceeding.

Set the rocker switch to STOP.

Plug the charger in and turn on the AC supply.

Check that the Voltage, Ampere-Hr and Battery Type indicated on the charger display is appropriate for the battery to be charged. BMID equipped batteries will automatically conﬁgure the charger provided the charger has APC conﬁguration enabled.

Connect the battery to the charger using the correct cable.

Set the rocker switch to START.

The red CHARGING light will illuminate to indicate charging has commenced.

When the green READY light illuminates, charging is complete.

Set the rocker switch to STOP and then disconnect the battery from the charger.

* A battery module may be either an Automatic Proﬁle Conﬁguration (APC) module

or a Battery Monitoring Module (BMM).

The XHF Series charger can be paired with a battery-mounted module* allowing automatic charge-conﬁguration of the charger as well as additional data logging features. The battery module is required for any FS9 charger, or any XHF Series charger configured for Fast or High Rate charging. Refer to your battery module manual for correct installation and operation of your battery module with this charger.

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 should be reported to a supervisor.

Controller display

Displays information depending on the status of the charger.

START/STOP rocker switch

0 = Stop charge. I = Start charge.

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.

Mini USB port

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

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.

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=

Conﬁguration Settings

Charge Proﬁles Available:

Conventional Charge IUIa/IEI Opportunity Charge Fast Charge (battery module required)

Battery Types: Flooded, Sealed, Gel. Environments: Standard, Freeze/cold condition. Cable Length: Combined charger and battery cable length in metres. 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 your local Eco Charge / Dealer for assistance with the adjustment

of these settings.

Ampere-Hour Ranges:

FS5 FS9

Low limit (Ahr) Upper Limit (Ahr) Low limit (Ahr) Upper Limit (Ahr)

Conventional Proﬁle (16A/100Ahr)

24V 300 1875 300 3375 36V 300 1875 300 3375 48V 300 1575 300 2810

Opportunity Proﬁle (25A/100Ahr)

24V 300 1200 300 2160 36V 300 1200 300 2160 48V 300 1000 300 1800

Fast Proﬁle (40A/100Ahr)

24V 300 750 300 1350 36V 300 750 300 1350 48V 300 625 300 1125

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 an 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.

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.

Module Fan Fail. Non-Urgent Alarm, in the event of a complete failure 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.

Module Over Temperature. Urgent Alarm, normally related to a blocked ﬁlter or restricted exhaust air or installation in an inappropriate location.

Charger Alarms

Main Switch

Inlet Filter

Low Mains

Mains Fail

Non-Urgent Module Fail

Urgent Module Fail

Module Fan Fail

Module Over Temperature

Conﬁguration Error

Output Fuse

No Output Current

Monitor ADC Fail

APC Communications Fail

APC Water Level Low

APC Voltage Imbalance

APC Water Level Low. Non-Urgent Alarm, for APC equipped batteries, indicates the APC Electrolyte Sensor has detected a low level of electrolyte.

APC Voltage Imbalance. Non-Urgent Alarm, for APC equipped batteries, indicates the midpoint voltage varies from nominal by more than 0.5V. APC will schedule an equalize charge to rectify this variation.

Main Switch. Urgent Alarm, shows the status of the front panel START/STOP rocker switch.

Urgent Module Fail

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 the selected AC supply.

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 controller’s microcontroller indicating a major fault and potentially 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 APC.

APC Unknown Charger. Urgent Alarm, the charger cannot ﬁnd the required pro

ﬁle required by APC.

Charger Alarms - continued

Mains Fail. Urgent Alarm, a mains loss situation and the charge cannot proceed.

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 interrupt the charge cycle.

Deeply Discharged Battery. Non-Urgent Alarm, the battery at start is under

1.9V per cell 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.

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 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

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 pro

ﬁle settings. This alarm also indicates the termination of a successful charge.

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 - 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 not allow the charge proﬁle to continue.

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.

Battery Disconnected. Urgent Alarm, the battery has been unplugged before

charge cycle has completed. 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 positive and negative cables reversed has been connected to the charger. Generally this will also cause an output fuse alarm and the need to replace the charger’s 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.

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.

+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.

Battery Alarms - continued

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.

Over Discharged Battery. Urgent Alarm, the battery is still under

1.9V per cell after

30 seconds of charge which indicates a faulty battery that needs investigation.

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. Note: An incorrectly conﬁgured APC can cause this alarm.

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. BMID/battery requires more current than modules or AC supply can support.

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 MPC35 controller module.

Replace the MPC35 controller module ensuring the replacement is correctly conﬁgured.

Problem Possible Cause Remedy

Low Output Current

Only one battery cable connected (FS9).

Ensure two battery cables are connected (FS9 only).

Over Discharged Battery

Battery is <1.9Vpc at connection but recovers within 30 seconds of charge.

Allow approximately 1 minute between truck-battery disconnect and charger-battery connect. Regular occurrences might need investigation of work practices.

No Output Current

Battery unplugged during charge.

Charge proﬁle allows current to fall below 0.7A

Ensure battery has not been unplugged before charge completion. Check that the charge proﬁle is appropriate for the battery type.

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.

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 charger conﬁguration matches the battery, regular timeouts may indicate a problem with the battery.

Battery Disconnected

Battery has been disconnected during charge cycle.

Front panel toggle switch must be set to STOP before disconnecting battery.

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).

Troubleshooting - continued

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.

Spare Parts

Image Description

MP330 Module

SM31 Large Display Assembly

MPC35 Main Board Assembly

300A Current Shunt

Current Sense Loom

Voltage Sense Loom

FS5-9 AC Filter Board

Auxiliary PSU

Stud Diode 240A 400V

Fuse HRC180A 150VDC 240VAC

Front Control Panel Membrane

USB Hole Plug

Image Description

FS5 Cabinet

FS9 Cabinet

Blanking Plate - Module Bay

Welded Filter Assembly

Front Panel Green Indicator

Front Panel Red Indicator

Front Panel Rocker Switch

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 center.

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. DCPTQs sole obligation shall be the repair or replacement of a nonconforming product.

Speciﬁcations

FS5 & FS9 Cabinet

Dimensions (in / cm): 13.40W x 18.0D x 26.00H / 340W x 45.7D

x 66.0H

Weight (lbs / kg):

Empty: 71.0 / 32.2 (approx.) FS5 (5 modules) 95.4 / 43.3 FS9 (9 modules) 123.0 / 55.8

MP330 Modules

AC Input Three phase 480V Nominal Input Voltage: 380-480V AC Operating Voltage Range: 340-580V AC Frequency Range: 45-65Hz >0.92PF Typical Efﬁciency: 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

California Appliance Large Battery Efﬁciency Program: Charger Systems

Notes

Enatel Motive Power FS5, FS9 Operator And Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual