Power Designers PowerCharge iHF3 series Installation & Operation Manual Download

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MAN-230000-00 REV B

480 V Models

PCiHF-10kW-yyyA-zzV

Installation & Operation Manual

4005 Felland Road, Suite 116

Madison, WI 53718

USA

© Power Designers USA LLC

iHF3 Series

Summary of Contents for PowerCharge iHF3 series

Page 1: ...MAN 230000 00 REV B 480 V Models PCiHF 10kW yyyA zzV Installation Operation Manual 4005 Felland Road Suite 116 Madison WI 53718 USA Power Designers USA LLC iHF3 Series ...

Page 2: ...rted 18 Charger Main Menu 22 TROUBLESHOOTING 32 RETURN MATERIAL PROCESS 400 CHARGER PROGRAMMING 411 WARRANTY INFORMATION 59 SOFTWARE LICENSE AGREEMENT 621 APPENDIX A WALL MOUNT DIMENSIONS AND CLEARANCES 632 APPENDIX B POST STAND DIMENSIONS AND CLEARANCES 643 APPENDIX C SHELF STAND DIMENSIONS AND CLEARANCES 654 APPENDIX D RECOVERY CYCLE FOR SULFATED BATTERY CURRENT AND TIMER SETTINGS 665 APPENDIX E...

Page 3: ...hargers are the lightest and most efficient chargers available on the market The PowerCharge iHF3 chargers support standard opportunity and fast charge cycles iHF3 chargers also offer programmability All charger settings and features can be easily customized to match workloads and schedules Finish and equalize cycles may be automatically programmed to run on certain days of the week Additionally P...

Page 4: ...inals All tools should be adequately insulated to avoid the possibility of shorting connections Inspect cables often for damage to the insulation Replace cracked or worn cables immediately Improper Connections If the charger is incorrectly wired to input or output devices or wiring is not in accordance with local safety codes and standards the iHF3 charger and or its components are at risk of bein...

Page 5: ...ust be ensured Do not restrict fan inlets or exhaust outlets Do not mount the charger in a confined space or where the exhaust air will recirculate No User Serviceable Parts If service is required contact Power Designers USA LLC or its service representative These instructions assume a certain level of competence by the installer and or user The following practices and codes contain relevant infor...

Page 6: ... First Aid and Sanitation respectively applicable to electric storage battery charging and maintenance areas EMC Compliance This device complies with Part 15 section 103 of FCC Rules as a digital device used exclusively as a power system in public utilities or industrial plants Operation is subject to the following two conditions 1 This device may not cause harmful interference 2 This device must ...

Page 7: ...mbers PCiHF 10kW 250A 36V PCiHF 10kW 250A 48V PCiHF 10kW 120A 80V Figure 1 PowerCharge iHF3 10 kW Battery Charger features LCD keypa d Knockout for input wiring Strain reliefs for output cables Lift handles Lift handle s Air filter AC disconnect switch Optional Ethernet ...

Page 8: ...x 250 A max 120 A max Power 10 kW max 10 kW max 10 kW max Pk Pk Voltage Ripple 1 Efficiency Typical 92 at full load Protection Input Under voltage Over voltage transients Output Over current Over voltage Over temperature Battery reverse polarity protection Operating Conditions Ambient Temperature 0 40oC Humidity 10 90 RH noncondensing Interface Communication Isolated RS 232 Ethernet optional User ...

Page 9: ... keypad the AC disconnect switch or the DC cables If any damage is apparent contact the shipping carrier Do not install or operate the charger if it has any visible damage Ensure that the charging area is well ventilated dry and clean 1 Lifting the Charger Never lift the charger from the middle of the lower cover as this will damage the air filter Use the lift handles mounted on either side of the...

Page 10: ... option is used the air filter must be inspected and cleaned more frequently Do not restrict airflow to the air filter at the bottom of the charger or to the vents at the top of the charger There are three mounting options available for the iHF3 charger standard wall mount optional floor mounted post stand or shelf stand a Wall Mount Option i Dimensions and clearances for the wall mount option are...

Page 11: ...mounts to the stand using 1 4 20 hardware provided with the post stand It is also available with a pogo stick cable management system providing easy connection to the battery and keeping cables off the floor when not connected Dimensions and clearances are detailed in Appendix B page 64 of this manual Figure 4 Post stand ...

Page 12: ...and brackets Figure 6 are fastened to the inside of the base plate using the supplied 1 4 20 bolts and lock washers Finger tighten only at this time Again note the brackets are on the left and right sides of the installation Figure 6 Post stand bracket iv The upper section of the post stand can now be placed over the top of the base plate and brackets Note the mounting studs for the iHF3 charger a...

Page 13: ... post stand base c Shelf Stand Option i The shelf stand Figure 8 provides another convenient mounting option Complete dimensions and clearances are given in Appendix C page 65 of this manual ii The shelf stand is typically bolted to open shelving using the hole pattern Figure 9 The shelf stand base plate has six 0 31 inch diameter clearance holes for 1 4 20 mounting hardware ...

Page 14: ...MAN 230000 00 REV B 12 Figure 8 Shelf stand Figure 9 Shelf stand mounting bolt pattern NOTE Dimension A critical for open shelf mounting ...

Page 15: ...de of the charger and slide the filter out ATTENTION Before installing clean the filter using soap and water and dry thoroughly or blow out debris in the opposite direction of airflow with compressed air To reinstall slide the filter into the guides and push in until fully inserted Figure 10 Figure 10 Installing reinstalling the air filter ATTENTION When reinstalling the filter or installing a new...

Page 16: ...3 chargers require a 480 VAC 3 four wire Wye or Delta electrical supply with a separate ground Figure 11 Nominal 480 VAC current draw is 13 8 A circuit disconnect at 125 should be 20 A Figure 11 AC input wiring diagrams 2 Verify that the source circuit is locked and tagged out before connecting power to the charger 3 Verify that the AC disconnect switch on the charger is in the OFF position Figure...

Page 17: ...conduit or strain relief fittings per local and national codes 6 Crimp a 10 ring tongue terminal 12 10 American Wire Gauge AWG to the ground GND wire and connect it to the GND terminal Figure 13 Torque the nut to 20 in lb 7 Strip the conductors back 0 5 inch 12 mm and connect them to the disconnect switch where labeled 480 VAC 3 in Figure 13 Torque the terminal screws to 20 in lb NOTE The charger ...

Page 18: ...e source circuit and verify proper AC voltage at the line side of the charger switch All line to line voltages should be 400 480 VAC 10 and matched within 10 VAC De energize the source circuit 10 Verify that the source circuit is locked and tagged out Replace the top cover on the charger securing it with the four mounting screws THE CHARGER IS NOW READY FOR OPERATION AC knockout 480 VAC 3 GND ...

Page 19: ...gh each charger s front panel LCD keypad Figure 14 This is the main user interface for viewing and displaying operation and fault messages It also allows limited charger programming options For programming information see CHARGER PROGRAMMING page 42 of this manual Figure 14 User interface LCD keypad RS 232 port IR window LCD Function keys ...

Page 20: ...he LCD is not lit or if the message is not displayed cycle the switch to the OFF position and then return it to the ON position DANGEROUS VOLTAGES AND CURRENTS ARE PRESENT IN THE AC MAINS WHEN ENERGIZED ONLY TRAINED PERSONNEL SHOULD PERFORM THESE CHECKS USING PROPER EQUIPMENT AND PROCEDURES e If the charger still does not power up carefully verify the source circuit and wiring to the charger and c...

Page 21: ...YES the charger automatically starts the charge cycle and briefly displays a START CYCLE TIMER message S T A R T C Y C L E T I M E R 0 0 0 0 0 1 E X I T S T A R T If either this screen or this message is not displayed the battery has not been detected Make sure that the battery cables are connected properly and verify that the auxiliary contacts are properly connected NOTE If Cells Autodetect is s...

Page 22: ...qualize The screen also displays a charge timer upper right battery voltage V amperes A temperature T and returned amp hours AH The bottom of the screen displays the battery state of charge If a PowerTrac SP battery data logger is installed PT is displayed in the lower right corner d To stop the charge cycle select the STOP button A CHARGING STOPPED BY USER screen appears C H A R G I N G S T O P P...

Page 23: ...MAN 230000 00 REV B 21 C Y C L E H H M M C O M P L E T E D T E M P X X X F A H R S X X X X E X I T On this screen appears the elapsed charging time battery temperature and total returned amp hours ...

Page 24: ...s These screens may only be accessed when the charger is in idle mode i e when either the CONNECT BATTERY or the PUSH START TO BEGIN CYCLE screens are displayed Pushing the Function key F selects the charger MAIN MENU screens The up down arrow keys scroll between the various screens In any MAIN MENU screen selecting EXIT F returns to the IDLE MODE screen Selecting the F key or the ENTER key ENT on...

Page 25: ...r up to 200 charge cycles beginning with the most recent cycle Selecting allows scrolling through the stored charge cycles from the most recent cycle to the earliest Cycle 0 in descending order C H 1 9 9 0 4 1 5 1 1 0 4 2 0 V O L T 5 8 6 H R S 0 3 2 1 T E M P 9 8 F A H R S 1 6 2 This screen includes the following information CH199 Charge cycle number 04 15 11 Start date of charge cycle 04 20 Start...

Page 26: ...cycle ACTIVATED PROFILES lists the profiles activated during the charge cycle Trickle charge appears as TR constant current as CC constant voltage as CV finish as FI and equalize as EQ STATE indicates whether the cycle was completed successfully COMPLETED interrupted by the user STOPPED interrupted due to a power outage or disconnection TURNED OFF or interrupted due to a fault e g OV FAULT for an ...

Page 27: ...ith the two programmed charger profiles A C T I V E P R O F I L E P 0 P 0 T R C C C V P 1 T R C C C V F I E Q This screen shows all of the programmed charge modes for Profile 0 and Profile 1 Refer to the CHARGER PROGRAMMING section page 42 of this manual for further details on programming these profiles 3 Charger Lifetime Summary a While in MAIN MENU select until the LIFETIME SUMMARY screen appear...

Page 28: ... and total kW since installation This information may be used to compare usage on different chargers 4 Charger Model a While in MAIN MENU select until the CHARGER MODEL screen appears M A I N M E N U C H A R G E R M O D E L E X I T E N T E R b Select ENT to access the selected screen which lists the charger model number manufacturing ID manufacturing date and firmware revision for reference M O D ...

Page 29: ...0 amp hours b While in MAIN MENU select until the RECOVERY CYCLE FOR SULFATED BATTERY screen appears M A I N M E N U R E C O V E R Y C Y C L E F O R S U L F A T E D B A T T E R Y E X I T E N T E R c Select ENT to access the recovery cycle set up screens The first screen selects the appropriate battery voltage N O M I N A L B A T T E R Y V O L T A G E 4 8 V E X I T E N T E R Selecting toggles the b...

Page 30: ...RECOVERY CYCLE TIMER screen appears R E C O V E R Y C Y C L E T I M E R 1 2 0 0 E X I T E N T E R Selecting allows adjustment of the charge timer setting in 15 minute increments The charge timer setting must be less than 24 hours Select the desired value then select ENT The PUSH START TO BEGIN RECOVERY screen appears P U S H S T A R T T O B E G I N R E C O V E R Y E X I T e Push START to initiate ...

Page 31: ...B L E F I N I S H E Q O N N E X T C Y C L E N O E X I T E N T E R c Select to select YES or NO NOTE Finish equalization once activated remains active until an equalization cycle has completed 7 Network Settings NOTE Network settings are retrievable through the Main Menu only for chargers that have the TCP IP option a While in MAIN MENU select until the NETWORK SETTINGS screen appears M A I N M E N...

Page 32: ... 0 0 0 0 8 Language a While in MAIN MENU select until the LANGUAGE screen appears M A I N M E N U L A N G U A G E E X I T E N T E R b Select ENT to access the next screen S E L E C T L A N G U A G E E N G L I S H E X I T E N T E R Selecting toggles between language options English or Japanese Select ENT to implement the desired language option ...

Page 33: ...ICS screen appears M A I N M E N U R U N P O W E R T R A C D I A G N O S T I C S E X I T E N T E R b Select ENT to view the PowerTrac diagnostic information I O E X P A N D E R Y E S T E M P A D C 4 0 9 5 P T D E T E C T E D Y E S P T C O M M O K R E V 1 1 4 The above display indicates diagnostics have passed Except for the revision number if any other data is displayed please contact the dealer o...

Page 34: ...ower up carefully verify the source circuit and wiring to the charger and correct any problems Be sure to check that the fuses in the AC mains junction box on the wall are intact and also that the supply voltage for all three phases AC mains line to line is 400 480 V 10 and matches to 10 VAC or better DANGEROUS VOLTAGES AND CURRENTS ARE PRESENT IN THE AC MAINS WHEN ENERGIZED ONLY TRAINED PERSONNEL...

Page 35: ... outside of allowable limits 10 Fuse blown Internal input stage failure Troubleshooting a Select STOP to revert to the IDLE screen b Verify the AC connections to the charger c Restart the charge cycle by selecting START d If the fault persists contact the dealer or Power Designers USA LLC ...

Page 36: ...hile charging if thermistor disabled Troubleshooting a The OVER VOLTAGE FAULT screen automatically reverts to the IDLE MODE screen in 30 seconds b Select STOP to revert to the IDLE MODE screen c Verify that the output cables are in good working condition and are properly connected to the battery d Restart the charge cycle by selecting START e If the fault persists contact the dealer or Power Desig...

Page 37: ...iled cooling fan Room temperature above 104 F Troubleshooting a Select STOP to revert to the IDLE MODE screen b Allow the charger to cool down c Make sure there are no airflow restrictions at the front or the rear of the charger chassis d Check the air filter and clean if necessary e Restart the charge cycle by selecting START f If the fault persists contact the dealer or Power Designers USA LLC ...

Page 38: ...le Causes A primary over current fault produces this message with earlier versions of the firmware Troubleshooting a Select STOP to revert to the IDLE MODE screen b Restart the charge cycle by selecting START c If the fault persists contact the dealer or Power Designers USA LLC ...

Page 39: ...tacts are dirty or corroded Troubleshooting a If the battery was intentionally disconnected select STOP to clear the fault message b If the battery was not intentionally disconnected check the charger and battery cables as well as the charger and battery connectors contacts Fix clean or replace damaged or dirty contacts or cables c Select STOP to clear the fault message d Restart the charge cycle ...

Page 40: ... The charger repeats this sequence for up to three additional attempts to restart and complete the cycle allowing the battery to cool down by 8 C 14 4 F 9 C 16 2 F and 10 C 18 0 F for subsequent attempts d If the charger is unable to restart and complete the charge cycle successfully select STOP to revert to the IDLE MODE screen e Attempt to measure the battery case temperature If the battery case...

Page 41: ...creen b Start the PowerCharge User software provided for use with Palm Pocket PC PC or Netbook select the Charge Timers button and select the Scan button on the CHARGE TIMERS screen c Verify that the programmed timer values are correct If not reset as appropriate d Using the provided software start the PowerCharge User program select Charge Parameters and then select the Scan button on the CHARGE ...

Page 42: ...t be resolved in this manner a Return Material Authorization RMA form must be completed and submitted to Power Designers USA LLC Upon receipt of the completed RMA form Power Designers USA LLC will issue an RMA number for the return Based on the serial number of the specific charger s and the particular problem encountered Power Designers USA LLC will either repair or replace the defective componen...

Page 43: ...pical of the Palm PDA application Similarly organized screens with the same functionality are found on the Pocket PC and desktop applications To use the PowerCharge Palm software to program the charger go to the Palm Home desktop and select the PwrChargeU icon on the Palm desktop NOTE This icon appears as Start PowerChargeUser on the Pocket PC and PowerChargeUser on the desktop ...

Page 44: ...Select the appropriate battery voltage Battery Ahrs Input battery capacity in Ahrs in increments of 10 Ahrs Application Select Conventional to set automatically for charging at 17 of rated capacity 17 A 100 Ahrs Opportunity for 25 of rated capacity 25 A 100 Ahrs or Fast Charge for 40 of rated capacity 40 A 100 Ahrs Charge Rate Allows adjustment of the preset charge rate in amps 100 Ahr of battery ...

Page 45: ...e Programming Function Charger Settings Scan charger factory set designations and ratings Battery Settings Scan and set battery parameters Charger Profiles Scan and set charging profiles Profile 0 Operation Scan and set a custom finish charge operation Profile 1 Operation Scan and set the equalization charge operation System Settings Scan and set charger system options Charger Parameters Scan and ...

Page 46: ...lowing charger parameters These parameters are not field programmable Parameter Description 1 Charger Model Charger model number 2 Factory ID Factory programmed serial number 3 Voltage Rating Factory programmed voltage rating 4 Current Rating Factory programmed current rating 5 Power Rating Factory programmed power rating 6 Cable R mOhms Charger cable resistance used to correct for cable voltage d...

Page 47: ...ears as Start PowerChargeUser on the Pocket PC and PowerChargeUser on the desktop Select the Detailed Programming button and then the Charger Settings button Align the Palm with the IR window on the LCD keypad Select the Scan button to view the charger settings PCiHF10kw 48V 2311010001 60 250 10000 1 5 Standalone ...

Page 48: ...tion coefficient in mV C VPC This is activated if the battery temperature exceeds the High Comp Temp limit Range 0 10 mV C VPC 4 mV C VPC 5 High Comp Temp F The temperature at which the high temperature compensation is activated Range 32 165 F 125 F 6 Battery Max Temp F Maximum allowable battery temperature A charger fault is generated if the battery temperature exceeds this limit Range 32 165 F 1...

Page 49: ...w the programmed values To change Battery Settings Type the desired values into the respective fields Align the Palm with the IR window on the LCD keypad Select the Save button to apply the new settings NOTE Keep the Palm aligned until a confirmation screen appears Charge Profiles Screen The CHARGE PROFILES screen is used to view and program the charging modes for the two charging profiles a Profi...

Page 50: ...arge cycle To view Charge Profile settings On the Palm desktop select the PwrChargeU icon NOTE This icon appears as Start PowerChargeUser on the Pocket PC and PowerChargeUser on the desktop Select the Detailed Programming button and then the Charge Profiles button Align the Palm with the IR port on the LCD keypad Select the Scan button to view the programmed values To activate deactivate charge mo...

Page 51: ...e various charge modes for a typical charge cycle Figure 14 Typical charge cycle charge modes t VB CC Ich VB Trickle CC CV Finish Equal CV Trickle current Trickle voltage CC finish current Ich Equalization current Finish voltage Equalization voltage ...

Page 52: ...me is 1 00 1 00 am and the default duration is 22 00 hours NOTE All times are 24 hour clock times To view or program a Profile 0 Custom Finish charge operation On the Palm desktop select the PwrChargeU icon NOTE This icon appears as Start PowerChargeUser on the Pocket PC and PowerChargeUser on the desktop Select the Detailed Programming button and then the Profile0 Operation button Align the Palm ...

Page 53: ... When the duration times out the charger will return to the default profile NOTE In order for the charger to automatically switch between profiles the Profile Auto Switch setting must be enabled see System Settings Screens page 53 To view or program Profile 1 settings On the Palm desktop select the PwrChargeU icon NOTE This icon appears as Start PowerChargeUser on the Pocket PC and PowerChargeUser...

Page 54: ...ive Profile Default profile to be activated Profile 0 or Profile 1 Profile 0 8 Profile Autoswitch Automatically switch between Profile 0 and Profile 1 once the start day and time of Profile 1 are reached YES or NO YES Second screen 1 Precharge High The high voltage limit of the precharge function Range 12 0 60 0 V 50V 2 Precharge Low The low voltage limit of the precharge function Range 12 0 60 0 ...

Page 55: ... upon connection to a battery 3 Use PT Params should be selected YES when charging batteries equipped with the PowerTrac monitor and when charging batteries of different voltages or amp hour capacities using the same charger 4 The Delay Start Timer is used in conventional charging to allow battery cool down prior to starting a charge cycle Enter the desired time delay in minutes Default is 0 minut...

Page 56: ...rogramming button and then the System Settings button Align the Palm with the IR port on the LCD keypad Select the Scan button to view the programmed values Select the Next button to go to the second screen select Back to return to the first screen To program System Settings Select type in desired settings in the respective fields Align the Palm with the IR port on the LCD Keypad Select the Save b...

Page 57: ... Current 3 A 100 Ahrs Range 1 600 A 15 A 2 Trickle Voltage 1 75 1 95 VPC Range 1 80 2 10 V 1 85 VPC 3 CC Current 40 50 A 100 Ahrs Range 1 600 A 200 A 4 CV Voltage 2 37 2 45 VPC Range 2 00 2 60 V 2 42 VPC 5 CV Finish Current 12 15 A 100 Ahrs Range 1 600 A 75 A 6 Finish Current 5 A 100 Ahrs Range 1 600 A 25 A 7 Finish Voltage 2 55 2 60 VPC Range 2 00 2 70 V 2 55 VPC 8 Equalize Current 3 A 100 Ahrs R...

Page 58: ...e Detailed Programming button and then the Charge Parameters button Align the Palm with the IR port on the LCD keypad Select the Scan button to view the programmed values To program Charge Parameters Type in desired settings in the respective fields Align the Palm with the IR port on the LCD keypad Select the Save button to program new values NOTE Keep the Palm aligned until a confirmation screen ...

Page 59: ...constant voltage timer sets the maximum duration of a constant voltage charge phase Range 0 12 00 hrs 3 00 hrs 5 Finish dV Sets dV in mV cell for the finish termination condition If the VPC does not change by this amount in the specified dt time the finish mode will be terminated Range 1 200 mV 5 mV cell 6 Finish dt Sets dt in minutes for the finish termination condition Range 1 120 min 25 min 7 F...

Page 60: ...V B 58 Figure 15 Finish charge termination criteria t VB Finish dt Finish charge When Volts Per Cell rises by less than Finish dV value within time interval Finish dt finish charging automatically terminates Finish dV ...

Page 61: ...ect the Detailed Programming button and then the Charge Timers button Align the Palm with the IR port on the LCD keypad Select the Scan button to view the programmed values To program Timers Type in desired durations in the respective fields Align the Palm with the IR port on the LCD keypad Select the Save button to program new values NOTE Keep the Palm aligned until a confirmation screen appears ...

Page 62: ...urly rate for the technician s services b Service during the Remaining Term of the Limited Warranty Period During the remaining term of the Limited Warranty Period you must contact the PD Service Group at 608 216 9295 for service A PD service technician will determine if the unit qualifies for limited warranty repairs Once the determination is made to be defective in material or workmanship the Co...

Page 63: ...Buyer harmless from and against any claim demand or cause of action including expenses costs and damages related to the same each a Claim in an amount not to exceed the Aggregate Limit brought against Buyer by any third party to the extent the Claim is based on the allegation that the Products infringe or violate the intellectual property rights of any third party provided that 1 Buyer promptly no...

Page 64: ...gs or free from viruses To the maximum extent permitted by applicable law the software and documentation are provided as is and the licensor disclaims all other warranties and conditions expressed or implied including but not limited to implied warranties of merchantability fitness for a particular purpose conformance with description title and non infringement of third party rights To the maximum...

Page 65: ...MAN 230000 00 REV B 63 APPENDIX A WALL MOUNT DIMENSIONS AND CLEARANCES ...

Page 66: ...MAN 230000 00 REV B 64 APPENDIX B POST STAND DIMENSIONS AND CLEARANCES ...

Page 67: ...MAN 230000 00 REV B 65 APPENDIX C SHELF STAND DIMENSIONS AND CLEARANCES ...

Page 68: ...s 100 Ahrs x 5 A 2 If necessary round up the current ONLY to the next highest current in increments of 5 A For capacities over 1200 Ahrs select 60 A the maximum value allowed 3 Time battery capacity in Ahrs current 4 If necessary round the time to the nearest increment of 15 minutes For capacities over 1200 Ahrs select 24 hours 24 00 5 If the time calculated is greater than 24 hours the maximum ti...

Page 69: ...werCharge iHF3 fast charger implements two temperature compensation coefficients 1 The low battery compensation coefficient Batt Low Temp Comp is activated when the battery temperature is different than 77 F but lower than the high compensation temperature limit High Comp Temp Figure E1 2 The battery high compensation coefficient Batt High Temp Comp is activated when the battery temperature is hig...

Page 70: ...powerdesigners com service powerdesigners com Main Office Phone 608 231 0450 Main Office Fax 608 231 9979 Service Department 608 216 9295 Phones are answered between 9 a m and 5 p m Monday through Friday Central Time After hours calls are answered by voice mail and returned on the next business day Questions and comments can also be submitted via fax or email ...

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