Dc-power-technologies FS3 Version 3 - Technical Hardware Manual Manual de usuario Pagina 1

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

Page | 9 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

Page | 10 Air Inlet Filter A stainless steel grille incorporating an electrostatic particulate air filter ensures cooling air drawn through the charge

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

Page | 12 FS3xJ The FS3LJ and FS3HJ models are earthed the same as the FS3xN, however, some models (Toyota specific) wired for Japan’s RST mains featu

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

Page | 14 DC Output Connector The DC output connector fitted to the FSx series is a high current SB350 connector designed for low resistance conne

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Page | 16 MPC35 / MPC37 Charge Controller The MPC controller provides the monitoring and control functions of the charger. Operating on a 12-65VDC s

Page | 17 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 mount

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

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Page | 19 Charger Module LED Combination States: Charger State LED State AC Power OFF Battery Disconnected No LEDs illuminated AC Power ON Battery D

Page | 20 Electrical Interconnection FS3 The FS3 electrical interconnection differs at the AC input stage of the charger depending on the model. UL li

Page | 21 Up to two copper current measuring shunts are fitted in the DC output line, with current sense PCBs fitted to each shunt to allow sensing by

Page | 22 5. Hardware Configuration – FS3 Introduction The FS3 can be configured for a number of different AC supply voltages and phase configuration

Page | 23 * In single phase mode the output power will reduce to maintain maximum AC current draw. ** In three phase mode the adding of the third cha

Page | 24 AC Input Configurations The figures below show common industrial AC supply types and the appropriate wire connections to the input terminal

Page | 25 FS3LN: AC Input Terminal Block Configuration Standard FS3 models may be configured for single or three phase input, depending on the type an

Page | 26 Surge Protection of MP130 & MP133 modules Models fitted with 2 or more MP130 or MP133 charger modules must be fitted with MOVs across ph

Page | 27 Current Limiting A current limit may be required where the mains supply or input cable has reduced current capacity. Jumpers on the MPC con

Page | 28 Relay Configuration for External Applications The on-board relays fitted to the MPC controller allow control of external devices such as lig

Page | 2 Table of Contents 1. Definition of Model Numbering ... 52. Introduction ...

Page | 29 6. Hardware Configuration – FS5, FS9 The FS5 and FS9 require connection to a three phase 480V AC supply. AC supply wiring should meet or ex

Page | 30 7. Charger Display Interface By default the charger display provides the basic charge profile information and charger firmware version. The

Page | 31 8. Alarm Functions The FSx series charger includes comprehensive fault protection and alarm monitoring. Charger alarms are graded into urge

Page | 32 Charger is still operating but a charger module is not providing output. Redundancy has been lost and reduced power output and longer charge

Page | 33 For battery module equipped batteries, indicates the midpoint voltage varies from nominal by more than 0.5V. Battery module will schedule an

Page | 34 checked for correct polarity BEFORE plugging onto the lift truck or a charger. Minimum dV/dt - Non-urgent Details the change in battery vol

Page | 35 9. Self Test Process Introduction The self test process verifies the basic functions of the charger. A combination of button presses on the

Page | 36 In Green Led Test menu ensure that the Green Ready lamp is illuminated and the display reads Green Led Test. Press the button to pass

Page | 37 10. Maintenance, Service and Repair Regular Maintenance Cleaning the charger air filter is the only regular maintenance recommended. The ai

Page | 38 FS5, FS9: Replacement MPC boards for these models require Current Shunt Measurement to be enabled. Advanced User access to Charger Interface

Page | 3 MPC Controller Circuitry... 21 5. Hardware Configuration – FS3 ...

Page | 39 11. Remove 11 screws fastening the backplane to the backplane bracket. Refit Refit new backplane assembly following the above steps in reve

Page | 40 11. Troubleshooting Problem Possible Cause Remedy Main Switch Alarm Front panel switch in the STOP position Charge will start when the swit

Page | 41 Over Discharged Battery Battery is <1.9Vpc at connection but recovers within 30 seconds of charge Typically due to the battery being quic

Page | 42 12. Spare Parts – Common to all models Image Description MP130 Module MP330 Module MP133 Module MP333 Module DC Output plug retaining

Page | 43 Front Panel Red Indicator Front Panel Rocker Switch Module Bay Blanking Plate

Page | 44 13. Spare Parts – FS3 Specific Image Description FS3 Cabinet Mounting Bracket Backplane Assembly AC Filter and Voltage Selection Assem

Page | 45 Upper Gland Plate Lower Gland Plate Two Piece Filter Assembly Filter Element

Page | 46 14. Spare Parts – FS5, FS9 Specific Image Description 300A Current Shunt Current Sense Loom FS5/9 AC Filter Auxiliary PSU Stud Diode

Page | 47 Top Cover Side Panel DC Output Loom Handle Lower Gland Plate

Page | 48 15. Appendix Interconnection – FS3LN/FS3HN R1W1B1Module 1Module 2Module 3Mains Input HousingChassisInternal Module FusingOutput Fuse x2 18

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Page | 49 Interconnection – FS3LU/FS3H ABCNABCNABCNFS3 AC FilterModule 1Module 2Module 3L1L2L3NEMains Input TerminalsHousing ChassisJ5/J6Line 1Line 3I

Page | 50 AC Input Terminal Detail – FS3xN Standard

Page | 51 AC Input Terminal Detail – FS3xJ (RST Mains)

Page | 52 Interconnection – FS5L/FS5H HousingJ20Line 1Line 3Output Fuse x2 180A or 160A CP17x27 UR2Reverse Polarity DiodeSKN2404K74K7 4K7Output Connec

Page | 53 Interconnection – FS9L/FS9H ABCNEABCNEABCNEABCNEABCNEABCNEABCNEABCNEABCNEFS9 AC FilterModule 1Module 2Module 3Module 4Module 5Module 6Module

Page | 54 Input Current by Output Current

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

Page | 57 16. GlossaryADC Analogue to Digital Converter, internal controller hardware to convert measurements into digital signals for processing APC

Page | 58 LED Light emitting diode, a solid state light source that does not wear out micro controller Computer in a single chip motive Battery applic

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures may be representative, actual products

Page | 6 2. Introduction This manual provides comprehensive technical information about all aspects of the FSx series charger. It is intended for use

Page | 7 3. Modular Charger Philosophy The modular charger concept represents a fundamentally different approach to the way in which a forklift batte

Page | 8 4. Hardware DescriptionThree base models make up the FSx modular charger series. For each of the FS3, FS5 and FS9, a low and high output volt