Hawker PTO MOD3 Manual de usuario

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

Battery Charger

Owner’s Manual

PTO™

MOD3

Models: PTOM1 / PTOM3 / PTOM3C (Standard

and Flex)

For parts sales, call toll-free 1-800-409-8895 and for charger technical support,

troubleshooting, and service call 1-800-251-6560.

AM-HPTOM3-OM

Rev AB February 2020

Model:

S/N:

AC Input Voltage

Installed by

Date

IMPORTANT

Read and understand your user’s manual before installing, operating, or servicing this product.

DO NOT DESTROY THIS BOOK

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

TABLE OF CONTENTS

Important Safety Instructions .....................................3

Technical Information..................................................4

Part Number..........................................................4

Cabinet Size/Gauge Letter Codes..................4

AC Line Voltage Letter Codes........................5

Specialty Charger Options List.......................5

Serial No................................................................5

Battery Type..........................................................5

Max AH..................................................................5

No. Cells................................................................5

Max Modules .........................................................5

Config Modules......................................................5

Hertz......................................................................6

Phase....................................................................6

AC Volts.................................................................6

Config AC Amps....................................................6

Max AC Amps........................................................6

Max DC Amps........................................................6

DC Volts ................................................................6

Config DC Amps....................................................6

CEC.......................................................................6

cULus....................................................................6

Installation....................................................................7

Location.................................................................7

Wall/Floor Mount Cabinet Chargers.......................7

Electrical Connections ...........................................7

Connecting Input Power.........................................7

AC Circuit Protection..............................................7

Breaker/Fuse Chart …………………………………..7

DC Plug Polarity ....................................................8

Grounding the Charger ..........................................8

Description of Operation.............................................9

General..................................................................9

Auto Start Charge..................................................9

Charging Current ...................................................9

AC Power Fail........................................................9

Series Charging.....................................................9

Glossary.......................................................................10

Charge Blockout....................................................10

Charging Profile……………………………………….10

Cold Profile............................................................10

Thin Plate Pure Lead.............................................10

Flex Bloc Profile.....................................................10

Flex Standard Profile .............................................10

Equalization Charging............................................10

Opportunity Profile.................................................10

Standard Flooded..................................................10

Refresh Charging...................................................10

Abbreviations and Acronyms .....................................11

Operating Instructions ................................................11

Charger Control Panel.................................................12

Setting Up Charger......................................................13

Idle Screen Display................................................13

Start Menu Display.................................................13

Start Menu.............................................................13

Main Menu.............................................................13

System Setup...............................................................13

Date........................................................................13

Time .......................................................................14

DST (Daylight Savings Time)..................................14

Language................................................................14

Units.......................................................................14

Display Contrast......................................................14

Enter Password............................................................14

Change Password........................................................14

USB ..............................................................................15

Memo Data............................................................15

Save Setup Params...............................................15

Load Setup Params...............................................15

Load Control FW ...................................................15

Load Module FW...................................................15

Charger Prof. Config ...................................................15

Battery Cells..........................................................15

Battery Capacity....................................................15

Battery Temperature..............................................16

Profile....................................................................16

Charger Coefficient................................................16

Constant Current Configuration.................................16

Equalization Configuration.........................................16

Equalize Days........................................................16

Delay Time Aft Chg................................................16

Duration.................................................................17

Start Charge Configuration.........................................17

Charge Delay ........................................................17

Charge Blockout....................................................17

Cond Charge %.....................................................17

Daily Chg Countdown............................................17

Post Charge Configuration.........................................17

Cool Down.............................................................17

Refresh On/Off ......................................................17

Charger Config ............................................................18

Cabinet Bay Size...................................................18

Number of Modules ...............................................18

DC Cable Setup.....................................................18

Charger Options....................................................18

Serial Number........................................................18

Asset Number........................................................18

Reset Memos ........................................................18

Charging the Battery...................................................19

Charger Idle Display..............................................19

Starting a Charge Cycle.........................................19

Delayed Start.........................................................19

Count Down ..........................................................19

Charge Display......................................................20

End of Charge Display...........................................21

End of Charge without Equalization.......................21

End of Charge with Equalization............................21

Charger Information....................................................22

Version..................................................................22

Serial Number........................................................22

Asset Number........................................................22

Status....................................................................23

Modules.................................................................23

Modules LED Status..............................................23

Memos..........................................................................24

Memorization Access.............................................24

Memorization Display Screen ................................24

Displaying a Charge Cycle.....................................24

Fault Codes..................................................................25

Mounting Dimensions.................................................26

3 Bay Mounting Dimensions ..................................26

6 Bay Mounting Dimensions ..................................26

Maintenance and Service............................................30

Component Locations.................................................31

Technical Specifications 480V, 1ph............................33

Technical Specifications 208/220/240V, 3ph..............34

Technical Specifications 440V, 3ph............................39

Technical Specifications 480V, 3ph............................43

Technical Specifications 600V, 3ph............................47

Maintenance Log.........................................................49

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

IMPORTANT SAFETY INSTRUCTIONS

WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE

OPERATION.

1. This manual contains important safety and operating instructions. Before using the battery charger, read all

instructions, CAUTIONs and WARNINGs on the battery charger, the battery and the product using the battery.

2. This battery charger is designed to charge flooded and sealed lead-acid batteries. Read and understand all setup

and operating instructions before using the battery charger to prevent damage to the battery and to the charger.

3. Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock.

4. During charge, batteries produce hydrogen gas which can explode if ignited. Never smoke, use an open flame, or

create sparks in the vicinity of the battery. Ventilate well when the battery is in an enclosed space.

5. Do not connect or disconnect the battery plug while the battery is charging. Doing so will cause arcing and burning

of the connector resulting in charger damage or battery explosion.

6. Lead-acid batteries contain sulfuric acid which causes burns. Do not get in eyes, on skin, or on clothing. In cases

of contact with eyes, flush immediately with clean water for 15 minutes. Seek medical attention immediately.

7. Only factory qualified personnel can service this equipment. De-energize all AC and DC power connections before

servicing the charger.

8. The charger is not for outdoor use.

9. Do not expose the charger to moisture. Operating conditions should be 32º to 113º F (0º to 45º C); 0 to 70% relative

humidity.

10. Do not operate the charger if it has been dropped, received a sharp hit, or otherwise damaged in any way.

11. For continued protection and to reduce the risk of fire, install chargers on a floor of non-combustible material such

as stone, brick, or grounded metal.

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

TECHNICAL INFORMATION

There are two nameplates located on the outside of the charger and should be used to check the

application before installation. The “Main” nameplate includes the UL Model number and the

ratings of the cabinet at its full capacity, while the “Configured Ratings” nameplate includes the

Part number and the ratings of the cabinet as configured. The Configured Ratings nameplate label

must be replaced when adding or removing modules permanently in the field.

Part Number and UL Model Number

The UL Model Number specifies the characteristics of a full cabinet charger, while the Part Number

specifies the characteristics of the cabinet as configured, plus all options. The Part Number is

required in any discussion or correspondence regarding this unit.

PTOM3-48F-240YR

Model type

Phase

(-) for Standard or (C) for CEC

Max DC Volts

Cabinet Size

Max DC Current @ Max DC Volts

Input Voltage Code

Options

Cabinet Size/Gauge Letter Codes

The following table describes the letter codes to be used in charger part numbers to indicate the

DC output voltage(s) of the charger.

Letter

Code

Module

Positions

Standard Cable

Gauge

Comments

2/0

Three slot, 3.5kW cabinet

3/0

Six slot, 3.5kW cabinet

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

AC Line Voltage Letter Codes

The following table describes the letter codes used in the charger part number to indicate the

nominal AC line voltage(s) and frequency at which the charger is designed to operate.

Letter

Code

Voltage(s)

(volts rms)

Line

Frequency

(Hertz)

Comments

600

50/60

600 VAC only

208/220/240

50/60

208/220/240 VAC

440

50/60

440 VAC only

480

50/60

480 VAC only

Specialty Charger Options List

Suffix

Description

15 Ft of DC cable.

20 Ft of DC cable.

25 Ft of DC cable.

30 Ft of DC cable.

LAN (Ethernet Compatible)

Red/Green Next Battery Capable –used in conjunction with BSI and BSS

Remote control capable ( order remote control separately)

PLC capable

Serial No.

This is the serial number that indicates complete information about the charger. It must be supplied

with the part number on any correspondence or discussion regarding this charger.

Battery Type

The chemical content of the battery this charger is designed to charge:

L-A = Lead Acid.

Max AH

This number indicates the maximum Amperes-Hours (AH) capacity of this charger. Charging

batteries of AH capacities not specified here will cause the charger to deviate from the specifications.

No. Cells

This is the number of cells this charger is designed to charge.

Max Modules

This is the maximum number of power modules that can be installed into the charger cabinet.

Config Modules

This is the actual number of power modules installed in the charger cabinet.

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

Hertz

This is the frequency in cycles per second of the AC input voltage this charger is designed to operate

on. Do not operate charger at a different frequency or from a generator with unstable frequency.

Phase

Number "1" indicates a Single Phase Charger and number “3” indicates a Three Phase Charger.

AC Volts

This is the input voltage accommodated by this charger.

Failure to use the correct voltage will result in damage to the charger and/or the battery.

IMPORTANT: THE CHARGER WILL OPERATE ONLY ON NOMINAL AC LINE VOLTAGES

INDICATED ON THE NAMEPLATE.

Config AC Amps

This is the AC current that this charger will draw with the number of power modules shown in

Config Modules on the nameplate.

Max AC Amps

This is the Maximum AC current this charger will draw from AC power. This charger must be

connected to a branch circuit protection in accordance with the National Electrical Code NFPA70

and local codes. (AC breaker/fuse values can be found on a decal outside the charger.)

Max DC Amps

This is the maximum DC current that this charger cabinet will deliver to a discharged battery when

fully populated with power modules.

DC Volts

This is the rated DC output voltage of the charger.

Config DC Amps

This is the DC current that this charger will deliver to a discharged battery with the originally-furnished

(Config Modules) number of power modules.

CEC

This logo is applied to chargers that are certified with the California Energy Commission in

compliance with Appliance Efficiency Regulations:

cULus

This logo is applied to chargers that have been tested to applicable standards and requirements by

Underwriters Laboratories (UL) and the Canadian Standards Association (CSA):

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

INSTALLATION

WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE

OPERATION

Location

For maximum trouble-free service, choose a location which is free of excess moisture, dust and

corrosive fumes. Also, avoid locations where temperatures are high or where liquids will drip on the

charger. Follow charger warning label when mounting on or over a combustible surface. Do not

obstruct the ventilating openings.

Wall/Floor Mount Cabinet Chargers

The charger must be permanently mounted in a vertical position. The lower part of the charger must

be at least 12 inches from the charger below if installed above another charger, and the upper part

12 inches from the ceiling. The distance between two chargers must be no less than 12 inches. Use

the mounting kit supplied with the charger. See the Mounting Dimensions section at the end of this

manual for proper Wall and Floor mounting.

NOTE: Ambient temperature cannot exceed 113° F (45° C).

Electrical Connections

To prevent failure of the charger, be sure it is connected to the correct line voltage.

WARNING: MAKE SURE THE POWER TO THE CHARGER IS OFF AND THE BATTERY IS

DISCONNECTED BEFORE CONNECTING THE INPUT POWER TO THE TERMINALS OF

THE CHARGER.

Connecting Input Power

Connect the input power to the appropriate terminals, including ground. For screw type terminals,

torque to 15 in-lb. Follow your local and National Electric Code in making these connections.

AC Circuit Protection

The user must provide suitable branch circuit protection and a disconnect method from the AC power

supply to the charger to allow for safe servicing.

Breaker/Fuse Chart

AC Amps

(A)

Breaker/Fuse size

(A)

1 –12

12.1 –16

16.1 –20

20.1 –24

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

24.1 -28

28.1 - 32

32.1 - 36

36.1 - 40

40.1 - 48

48.1 - 56

56.1 - 64

64.1 - 72

72.1 - 80

100

80.1 - 88

110

88.1 - 100

125

DC Plug Polarity

The charging cables are connected to the DC output of the charger with the red cable to the positive

bus bar, and the black cable to the negative bus bar. The red cable is terminated into the “+” side of

the battery connector, and the black cable is terminated into the “-“side of the connector. The output

polarity of the charger must be observed when connecting to the battery (read warning above).

Improper connection will open the DC fuses in the power modules.

DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC

SHOCK. Follow local and National Electric Code for ground wire sizing.

Grounding the Charger

Connect incoming grounding conductor to the ground lug provided on the charger support panel.

Torque the Ground wire to 15 in-lb. This lug is marked as shown:

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

DESCRIPTION OF OPERATION

General

The PTO™MOD3 series of chargers are compatible with batteries at 24, 36, 48 volts or 72, 80 volts,

depending on model.

PTO™MOD3 chargers are microprocessor-controlled. The processor calculates the battery’s

capacity so that the charging profile can be automatically adapted to the battery’s actual state over

a wide range of capacities. The charging coefficient is maintained absolutely on all types of batteries.

PTO™MOD3 chargers adapt to the battery’s capacity and its discharge level.

PTO™MOD3 chargers can easily be set to charge flooded batteries used in cold or freezer storage

applications, standard flooded or opportunity profiles. This battery charger is also designed to charge

flooded and sealed lead-acid storage batteries within the range of the cell and amp-hour rating as

marked on the nameplate.

Auto Start Charge

When a battery is connected to the charger, the control board senses the voltage and after a 20

second delay, the charger starts charging the battery automatically.

Charging Current

Charging current is determined by the charger based on battery voltage and its state of charge.

Charging current declines automatically as battery voltage rises during the charge. As the battery

charges, the graphical LCD display will output various charge parameters including the charging

current.

AC Power Fail

If the AC power fails while the battery is connected to the charger during a charge cycle, the charger

will reset and start a new charge cycle when power is restored. All charger settings as well as the

time and date are preserved.

Series Charging

In series charging, the voltages of both batteries add up and must match charger’s nameplate DC

Volts rating. The charger’s amp-hour rating must be equal to each of the batteries’ AH rating. Charge

cycle will not start unless both batteries are connected.

PTO™MOD3

Owner’s Manual

AM-HPTOM3-OM

Rev AB February 2020

GLOSSARY

Charge Blockout

This function prevents the charger from charging the battery during the block out time window. If a charge

cycle has started before the block out window it is inhibited during the block out window and will automatically

restart the charge cycle at the end of the block out window.

Charging Profile

The charging profile defines the rate of current charge over time. The charger adapts to the battery’s condition

and level of discharge.

Cold Profile

This is a charging profile that allows the configuration of the charger for use with batteries in cold storage

application. The profile is an IEI (constant current, constant voltage, constant current) type with a number of

user configurable parameters.

Thin Plate Pure Lead (TPPL)

This is an advanced lead acid battery design used in FLEX batteries. TPPL technology provides longer

service life, higher power density, longer shelf life and fast recharge capabilities.

Flex Bloc Profile

This charging profile allows charging of Flex bloc batteries at rates up to 0.7C.

Flex Standard Profile

This charging profile allows charging of FLEX 2v cell batteries at rates up to 0.25C.

Equalization Charging

Equalization charging, performed after normal charging, balances the electrolyte densities in the battery’s

cells.

Opportunity Profile

The OPPOR charge profile is used when opportunity charging is desired. It has a start rate of 25% of the

batteries rated amp hour capacity, requires one complete recharge in every 24 hours of service and must

have an equalize charge done once a week which is programmed to run automatically.

Operation:

During opportunity charging the user can plug the battery in and charge it during breaks, lunch or any

work stoppage time. One time per day the battery must receive a full standard recharge. The complete

charge must be programmed for a delay that’s long enough so that the complete charge will not occur

during normal operation. Sufficient time should be scheduled after the full charge to allow the battery

to completely cool to ambient temperatures before use.

Note: The user must configure the charger for the day of the week that the equalize charge will take

place.

Standard Flooded

The profile is an IEI (constant current, constant voltage, constant current) type with a number of user

configurable parameters.

Refresh Charging

Refresh or maintenance charging enables the battery to be maintained at maximum charge all the time that

it is connected to the charger. Refresh charge is applied at a predetermined intervals after charge is complete

and battery remains connected to charger.

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