Enatel Motive Power Ltd.

Technical
Hardware
Manual
FS3, FS5 & FS9 Series Industrial Battery Charger
Version 3

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors exempt. Pictures
may be representative, actual products may differ.
Page | 1
 Table of Contents

1. Definition of Model Numbering ................................................................ 5

2. Introduction ............................................................................................... 6
3. Modular Charger Philosophy ................................................................... 7
Modular ........................................................................................ 7
Flexible ......................................................................................... 7
Redundancy ................................................................................. 7
4. Hardware Description ............................................................................... 8
Housing .................................................................................................... 8
FS3 ............................................................................................... 9
FS5, FS9 ...................................................................................... 9
Air Inlet Filter .......................................................................................... 10
AC Input Filter Board ............................................................................. 10
FS3LU, FS5, FS9 ....................................................................... 10
FS3LU only – Input Voltage Configuration ................................. 10
FS3xN, FS3xJ ............................................................................ 10
AC Input Terminal .................................................................................. 11
FS3xN, FS3xJ only..................................................................... 11
Charger Module Earth and AC Supply .................................................. 11
FS3LU, FS5 & FS9..................................................................... 11
FS3xN ........................................................................................ 11
FS3xJ ......................................................................................... 12
DC Output Bus Bars .............................................................................. 13
FS5, FS9 .................................................................................... 13
DC Output Connector ............................................................................ 14
FS3 ............................................................................................. 14
FS9L ........................................................................................... 14
FS5, FS9H .................................................................................. 14
Auxiliary Power Supply Unit (PSU) ........................................................ 14
FS3 ............................................................................................. 14
FS5, FS9 .................................................................................... 14
Backplane .............................................................................................. 14
FS3 ............................................................................................. 14
FS5, FS9 .................................................................................... 14
MPC35 / MPC37 Charge Controller ...................................................... 16
Blank Panel – Module Bay .................................................................... 16
Blank Panel – FS5/9 DC Output Connector .......................................... 16
Mounting Bracket ................................................................................... 16
FS3 ............................................................................................. 17
FS5/9 .......................................................................................... 17
Charger Modules ................................................................................... 18
Module Types ............................................................................. 18
Charger Module Front Panel ...................................................... 18
Charger Module LED Combination States: ................................ 19
Module Installation and Removal ............................................... 19
Orientation for Installation .......................................................... 19
Module Removal ........................................................................ 19
Electrical Interconnection....................................................................... 20
FS3 ............................................................................................. 20
FS5 & FS9 .................................................................................. 20

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 MPC Controller Circuitry............................................................. 21
5. Hardware Configuration – FS3 ............................................................... 22
Introduction ............................................................................................ 22
FS3xU: AC Input & Bus Bar Connection ............................................... 22
AC Supply Configuration Table .................................................. 22
Field Wiring Connections ........................................................... 23
AC Input Configurations ............................................................. 24
FS3LN: AC Input Terminal Block Configuration .................................... 25
Single Phase (MP13x modules) ................................................. 25
Three Phase (MP33x and 3xMP13x modules) .......................... 25
FS3xJ: AC Input Terminal Block for Japan RST Mains Supply............. 25
Surge Protection of MP130 & MP133 modules ......................... 26
Earthed S-Phase Configuration ................................................. 26
Current Limiting ..................................................................................... 27
Relay Configuration for External Applications ....................................... 28
6. Hardware Configuration – FS5, FS9 ...................................................... 29
Field Wiring Connections ....................................................................... 29
AC Input Configuration .......................................................................... 29
7. Charger Display Interface ....................................................................... 30
Equalise Next Cycle Option ................................................................... 30
Service Menu ......................................................................................... 30
Service Mode ......................................................................................... 30
8. Alarm Functions ...................................................................................... 31
Charger Alarms...................................................................................... 31
Charger Related Alarms ........................................................................ 31
Battery Related Alarms ......................................................................... 33
9. Self Test Process .................................................................................... 35
Introduction ............................................................................................ 35
Accessing Self Test ............................................................................... 35
Operating the Self Test Sequence ........................................................ 35
10. Maintenance, Service and Repair .......................................................... 37
Regular Maintenance ............................................................................. 37
Air Filter.................................................................................................. 37
Blown DC Fuse ...................................................................................... 37
Charger Module Fault ............................................................................ 37
Charger MPC Fault ................................................................................ 37
Backplane Replacement ........................................................................ 38
11. Troubleshooting ...................................................................................... 40
12. Spare Parts – Common to all models.................................................... 42
13. Spare Parts – FS3 Specific ..................................................................... 44
14. Spare Parts – FS5, FS9 Specific ............................................................ 46
15. Appendix .................................................................................................. 48
Interconnection – FS3LN/FS3HN .......................................................... 48
Interconnection – FS3LU/FS3H ............................................................. 49
AC Input Terminal Detail – FS3xN Standard ......................................... 50
AC Input Terminal Detail – FS3xJ (RST Mains) .................................... 51
Interconnection – FS5L/FS5H ............................................................... 52
Interconnection – FS9L/FS9H ............................................................... 53
Input Current by Output Current ............................................................ 54
Exploded Diagram – FS3LU .................................................................. 55
Exploded Diagram – FS5, FS9 .............................................................. 56
16. Glossary ................................................................................................... 57

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Page | 4
 1. Definition of Model Numbering

Model Number: eg. FS3LUV-532-US01

where

FS3 = Frame size, 3, 5 or 9 modules maximum

L = 24 – 65V DC output, H = 70 – 130V DC output
U = UL, N = Non-UL, J = Japan
V = branding: V=VForce, E=EcoCharge, H=Hawker
5 = Controller MPC35, 7 = MPC37
3 = module type, 1=MP130, 2=MP133, 3=MP330,
4=MP333
2 = number of modules fitted
US01 = internal manufacturer designation

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

This manual provides comprehensive technical information about all

aspects of the FSx series charger. It is intended for use by
technically skilled individuals responsible for second level support of
the chargers. It contains considerably more information than
required for a first level field service technician.
Distribution of this manual is to be restricted as the information
contained is not suitable for individuals who do not already have
some knowledge of the correct method to charge forklift batteries.
This information is commercial in confidence and is not to be
distributed to a third party without the express permission of Enatel
Motive Power.
An Operator/Installer manual is available for each charger and is
suitable for distribution to a wider audience.
A software manual is also available covering use of the Charger
Interface software to configure, troubleshoot and customize
operation of the FSx series charger.
It is expected that an individual responsible for the support of the
FSx series chargers will read and understand both the hardware
manual and the companion software manual.

Page | 6
 3. Modular Charger Philosophy

The modular charger concept represents a fundamentally different

approach to the way in which a forklift battery charger is designed.
Historically battery chargers have been designed to match a
specific battery type and rating. These uncontrolled chargers need
to be very closely matched to the intended battery. Due to the large
number of combinations of voltage, amp-hours, cell type and
recharge times, this results in a wide range of charger models being
required.

Modular
The modular charger is based on the deployment of paralleled, high
frequency charger modules with microprocessor oversight
controlling the charge parameters. Modules can be easily added or
removed as required and the controller is configured via PC
software to set the charger’s particular rating.
Flexible
The modular charger series is capable of charging batteries of any
nominal voltage in the range of 24V - 80V and offer the choice to
operate on AC supply ranges of 208V single phase through to 480V
three phase. The modules can be paralleled to a maximum of three,
five or nine depending on the charger model.
Redundancy
Using parallel-connected charger modules also introduces the
capability to offer redundancy, which is a unique and desirable
feature for a forklift battery charger. Redundancy offers the
capability to complete a charge with backup modules should an
issue arise, albeit at a slower rate

Page | 7
 4. Hardware Description

Three base models make up the FSx modular charger series. For
each of the FS3, FS5 and FS9, a low and high output voltage model
cover the battery voltage range. Logical model name modifiers
allow differentiation, shown in the table below.

FS3 FS3LU Low voltage, UL Listed

FS3LN Low voltage, Non-UL

FS3HN High voltage, Non-UL

FS5 FS5LU Low voltage, UL Listed

FS5HN High voltage, Non-UL

FS9 FS9LU Low voltage, UL Listed

FS9HN High voltage, Non-UL

The FS5 and FS9 utilize a common larger chassis - only internal
components differ between the two - while the FS3 takes a more
compact form, suited to single-person handling.
The principal components of the FSx series comprise a number of
paralleled charger modules each monitored and controlled by a
system level microprocessor. The charger output characteristics are
controlled depending on the charge requirements, battery type and
state of charge.
The following sections describe the primary and auxiliary
components of the FSx series, including where relevant, detail on
model-specific features.
Housing
The FSx charger housings are 1.2 mm electro galvanized and
powder coated steel. An internal chassis provides support for
charger modules as well as primary and auxiliary circuitry. The
housing front contains the charger display, status LEDs, push-
buttons, and air filter assembly.
Access to internal charger circuitry for service is gained by
removing exterior panels.
Note: Before exterior housing panels are removed the charger
must be isolated from both the AC supply and battery.

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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 to the main serviceable internal areas of the FS3,
removable in that order.

FS5, FS9
These models share a common frame and external housing, the 5/9
designation is determined by internal hardware and circuitry with
the FS5 and FS9 supporting an operating maximum of five and nine
modules respectively.
Access to the module bays is via the air filter assembly on the front
face of the housing. Installed in the module bays, each charger
module is supported in a horizontal orientation by the internal
chassis.
The FS5 and some FS9 models require a single rather than double
DC output connectors. These models are fitted with a steel blanking
plate in place of the DC connector location.

Page | 9
 Air Inlet Filter

A stainless steel grille incorporating an electrostatic particulate air

filter ensures cooling air drawn through the charger modules is free
of dust and particulate matter.
The filter assembly is fastened to the front of the housing with
thumbscrews.
The Maintenance section of this document covers the air filter
cleaning procedure.

AC Input Filter Board

FS3LU, FS5, FS9
The AC Filter Board distributes AC supply to the modules and
auxiliary power supply while providing protection to these
components from surges in the supply voltage.
AC input cables are terminated onto the AC filter board input
terminal via a five way terminal strip.

FS3LU only – Input Voltage Configuration

Configuration possible for single and three phase, 208V-480V
supplies. Configurable bus bars provide AC input type selection and
two headers allow either 240V or 480V connection to the auxiliary
power supply.
FS3xN, FS3xJ
See AC Input Terminal

Page | 10
 AC Input Terminal

FS3xN, FS3xJ only

FS3 chargers not fitted with an AC input filter board instead utilize
an input terminal block providing AC supply to the charger modules
and the auxiliary power supply via their respective looms.
The terminal block is configurable for single and three phase supply
via jumpers fitted to the terminal block. Refer to the Hardware
Configuration section for details on terminal block configuration.

Charger Module Earth and AC Supply

AC is delivered to the backplane via the AC Loom consisting of
2.5mm² cable for each phase and neutral*.

Colour Notation

Red L1

White L2

Blue L3

Black* N*

Yellow/Green E

*FS3 option only

FS3LU, FS5 & FS9

Earth connections are grouped together, bolted to the chassis and
fed to the charger modules via the AC Loom. The chassis is
connected to the mains earth via a ground trace on the AC Filter
Board PCB, where a mounting screw provides connection.
FS3xN
Earth connections are grouped together, bolted to the chassis and
fed to the charger modules via the AC Loom. The chassis is
connected to the mains earth via 2.5mm² cable to the Input
Terminal earth block. See

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
FS3xJ
The FS3LJ and FS3HJ models are earthed the same as the FS3xN,
however, some models (Toyota specific) wired for Japan’s RST
mains feature an earthed S-Phase at the AC Input Terminal Block.
See the Appendix for wiring diagrams.

Page | 12
 DC Output Bus Bars
The DC output bus bars are solid copper bars mounted inside the
charger on the internal chassis frame. The bus bars provide DC
connectivity from the backplane to the output connector(s) at the
front of the charger.
Mounted on the bars are several key components of the charger
self-protection features. In all models, a crowbar diode and high
current fuses provide protection for the charger modules in the
event that a reverse polarity battery is connected to the charger.
Fuse status is monitored by the MPC controller using voltage sense
looms attached to the bus bars either side of the fuses.
FS3

FS5, FS9
Calibrated current shunts fitted to the output circuit allow
accurate current measurement at high amperages. These
shunts are fitted with voltage sense looms monitored by the
MPC controller.

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
 DC Output Connector
The DC output connector fitted to the FSx series is a high current
SB350 connector designed for low resistance connections.
FS3
A single SB350 connector mounted horizontally. Special
applications may require an SB175 connector fitted in place of the
SB350.
FS9L
Frame allows for two connectors to manage large output currents.
FS5, FS9H
A single DC output connector is fitted.
All models provide for fixing of the connecting battery cable by way
of the supplied threaded screws fastened through the cable
connector into the internal chassis.
Auxiliary Power Supply Unit (PSU)
The FSx series chargers contain a power supply unit to provide a
DC supply to the charger controller. A feed from this supply also
holds the charger modules in a default “standby” state, ready to
commence charging.
FS3
The auxiliary PSU is integrated into the backplane PCB and can be
configured at the AC filter board (UL models) or Input Terminal
block (Standard models) for 208VAC or 480VAC input voltages.
The FS3 PSU outputs a nominal 24VDC.

FS5, FS9
The auxiliary PSU is located on a dedicated PCB assembly
mounted on the side of the internal chassis frame above the
controller and bus bars.
The FS5-9 PSU provides a regulated 54VDC output from a 480VAC
supply.
Backplane
At the rear of the FSx housing is the backplane PCB providing
connectivity to the charger modules. The backplane features a
multi-pin connector in each supported module bay for connection
with an installed charger module. The connector passes AC from
the AC Loom and DC output into the backplane. The connectors
also contain a pin for communications between the modules and
the MPC controller.
FS3
The backplane also incorporates the auxiliary PSU circuitry and
three module connectors.
FS5, FS9
Backplanes each support five and nine module connectors
respectively.

Page | 14
Page | 15
 MPC35 / MPC37 Charge Controller
The MPC controller provides the monitoring and control functions of
the charger.
Operating on a 12-65VDC supply, the MPC35 controls the low
voltage MP130 & MP330 range of modules while the MPC37
operates at 65-150VDC controlling the high voltage MP133 &
MP333 modules.
The MPC allows the charger to be configured easily to charge
different battery types. The MPC can also be set to automatically
reconfigure when connected to a battery fitted with a battery module
(Automatic Profile Configuration – APC).
The MPC also features configurable relays for operation of optional
accessories such as battery auto-watering systems.

MPC35 MPC37

Operating Voltage 12-65VDC 65-150VDC

Module Compatibility MP130/MP330 MP133/MP333

The MPC indicates the charger configuration and status on an LCD

display, LED status lights, push button controls and a mini-USB port
located on the front panel of the charger.

Blank Panel – Module Bay

Unused charger module positions should be fitted with a blank
panel fixed to the housing metalwork. The blank panel prevents
high temperature exhaust air recirculating inside the charger
enclosure to the module air intake, ensuring the modules receive
cool externally-sourced air.
To fasten to the chassis, two self-tapping screws are required per
blank panel.

Blank Panel – FS5/9 DC Output Connector

The FS5-9 Output Blank Panel covers the lower output connector
opening in models where a second connector is not fitted.
The blank panel is fastened to the charger chassis with two M5
captured washer hex-head bolts.

Mounting Bracket
The charger mounting bracket enables the charger to be secured at
an elevated position and is recommended to protect the charger
against accidental physical damage from vehicles or other hazards.
Bracket fasteners should be appropriate for the wall construction
and material, and the wall should be capable of supporting the
weight of the charger.

Page | 16
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 mounted to an appropriate surface suitable for
the particular configuration of the charger.
An FS3 with three modules can weigh up to 21kg.
The charger incorporates two slots for locating the bracket and two
captured thumbscrews then secure the charger to the bracket.

FS5/9
The FS5/9 wall mounting bracket requires eight fasteners to secure
it to the supporting wall.
An FS9 with nine modules can weigh up to 90kg.
The charger can be positioned on and fixed to the bracket using M5
machine screws fastening into the charger base frame. The same
base mounting points may be used for a standard shelf, rack or
table-top. The base mounting measurements are as follows:
FS5-9 base screw spacing (mm, c-c): 333W x 275D

Page | 17
 Charger Modules
The primary function of the charger modules is to rectify AC mains
into DC suitable for battery charging.
Module Types
There are four module types available depending on the input and
output requirements of the charger. The module variants are
detailed in the table below.

Low Voltage Output High Voltage Output

MP130 MP330 MP133 MP333

Supply Single or 3 Single or 3

Phase 3 Phase only 3 Phase only
Phase Phase

Input Voltage
Range 208 - 240 380 - 480 208 - 240 380 - 480

Output
Voltage 25 - 65 70 - 143
Range

Nominal
Battery 24 / 36 / 48 72 / 80
Voltages

Faceplate
Color Yellow/Black Green Blue/Black Blue/Green

Charger
FS3L, FS5L, FS3H, FS5H,
Compatibility FS3L FS3H
FS9L FS9H

Charger Module Front Panel

Charger modules have a front panel with three LEDs to indicate
their basic operating state. The charger front panel display and LED
indicators typically provide any charger status information, however
the charger module LEDs are useful for understanding and
troubleshooting charger issues.
The module front panel LED indicators are as follows:

RED AMBER GREEN

No Output Current Limit Charging

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
Charger Module LED Combination States:

Charger State LED State

AC Power OFF No LEDs illuminated
Battery Disconnected
AC Power ON No LEDs illuminated
Battery Disconnected
AC Power ON Red LEDs illuminated
Battery Connected
AC Power OFF Red LEDs illuminated
Battery Connected
Charge Cycle Stage: Green & amber LEDs illuminated
Constant Current
Charge Cycle Stage: Green LEDs illuminated
Constant Voltage
Charge complete Red LEDs illuminated
Battery connected

NOTE: Charger alarm indicators are reset if the battery is

disconnected.

Module Installation and Removal

Ensure the charger is removed from AC supply before
installing or removing modules.
Modules are installed through the front of the charger housing. The
air filter assembly must first be removed to gain access to the
module bays.
Only a small amount of force is required to have the module
connect with the charger backplane. Once the module is fully
inserted, engage the locking tabs at each side of the module front
panel. A module removal tool is available combining the module
locking and removal requirements into one tool. A small pair of
needle-nosed pliers is a good alternative.
Orientation for Installation
It is important the module orientation be correct before installing a
module.
FS5, FS9
The module must be oriented horizontally with the front panel type
identification up-right and readable.
FS3
The modules must be installed vertically so that the rear blue
connector is at the top.
Module Removal
To remove a module, first unlock the green locking tabs and, using
either the module removal tool or needle-nosed pliers on the
module grille, draw the module forward from the housing.

Page | 19
 Electrical Interconnection
FS3
The FS3 electrical interconnection differs at the AC input stage of
the charger depending on the model. UL listed models feature the
AC Filter Board, while the standard non-UL models distribute AC
via a terminal block.
Aside from the AC supply filtering and distribution, the two variants
share the same internal circuitry.
FS5 & FS9 AC Filter Boards are non-configurable.
FS3xU AC Input: AC Filter Board - UL models only
Each phase of the AC input supply is connected to the charger
module bays via the AC Filter board, the AC Loom and a connector
on the backplane. Incoming earth is connected to the internal
chassis via a mounting screw on the AC Filter board.
The FS3 AC Filter board allows for re-configuration of the incoming
phases to allow for a number of AC input types, explained in detail
in the Hardware Configuration section.
The auxiliary power supply is connected via the AC Loom from
either J5 or J6 on the AC Filter board depending on the mains
supply configuration of the charger.
FS3xN, FS3xJ AC Input: Input Terminal Block –
Standard models only
Non-UL models distribute the AC phase and neutral to each of the
three module bays via a din rail mounted terminal block. The Input
Terminal Block also provides an AC supply to the Auxiliary Power
Supply Unit. Jumpers are required to be fitted correctly depending
on the AC supply type. See the Hardware Configuration section.
Incoming earth is tied to the earth stud on the internal chassis.
FS3 DC Output Circuitry: All Models
Individual DC outputs from each charger module are connected in
parallel with 9 mm² cables to the output bus bars. Fuses and a
crowbar diode mounted on the bus bar assembly provide reverse
polarity protection. Two voltage-sensing PCBs fitted either side of
the fuses enable the MPC to determine if the fuses are blown.
The final internal connections to the SB350 output connector are via
short lengths of 50 mm² cable.
FS5 & FS9
The FS5/9 input circuitry consists of a non-configurable AC Filter
board distributing each AC phase via dedicated looms to each of
the backplane and auxiliary power supply. No neutral is supplied to
the backplane.
Incoming earth is connected to the internal chassis via a mounting
screw on the AC Filter board ground plane, and the backplane loom
earth wires are all tied to a stud on the internal chassis.
DC output circuitry consists of copper bus bars carrying DC current
2
via fuses, current shunts and 70mm cable to the output
connector(s). Models with output capability exceeding 300A utilize
parallel output circuits terminating with two output connectors.
Fuses fitted in-line with the bus bars are each 180A and provide
reverse polarity protection with a 300A crowbar diode fitted across
the output.

Page | 20
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 the MPC.
FS5 and FS9H models: single bus bar, current shunt and DC
output connector.
FS9L models: dual bus bars, current shunts and DC output
connectors.
The FS5/9 Auxiliary PSU provides a nominal 54VDC. This is
supplied to the backplane via J4 enabling module-MPC
communications, and from J8 on the backplane via an RJ45 cable,
providing a power supply to the MPC.

MPC Controller Circuitry

With the exception of current sensing in FS5 & 9 models, charger-
MPC interconnections are fundamentally the same for all models of
MPC and charger.
The MPC has a number of connections on the main board to allow
control and monitoring functions. Digital signals to and from the
charger modules are via the RJ45 cable connected at J101.
Charger module shutdown control (RSD) is also via the RJ45
communications cable.
The Auxiliary power supply is fed to the MPC from the backplane
via J102 and J109. The large front panel mounted LEDs are
connected to J109 and the rocker switch input signals to J102.
A 10-way ribbon cable provides connectivity for the charger front
panel display, LEDs and push buttons, as well as USB
communications with a connected PC.
A communications transformer is fitted to the output circuit of the
FSx range and connects to J103, allowing communication with a
battery module (if fitted).
The MPC also features six available relay contacts to provide
switching for external functions such as auto watering systems.

Page | 21
 5. Hardware Configuration – FS3

Introduction
The FS3 can be configured for a number of different AC supply
voltages and phase configurations.
FS3 UL models (FS3xU) feature an AC Input PCB with
configurable link bars for various supply phases and
voltages.
Standard FS3 models (FS3xN) are configured with
jumper bars fitted to the AC input terminal block.
FS3xU: AC Input & Bus Bar Connection
Before AC is connected, the AC-select bus bars and auxiliary PSU
supply must be configured for the type of AC supply to be
connected.

Mounting posts for mains-select Headers for aux power supply

bus bars voltage selection. 240V – J5
480V – J6

Bus Bar Options

208-240V single phase 208-240V three phase 480V three phase

Unused bars are bolted to the internal chassis near the AC input
field wiring terminal inside the FS3 frame.
Bus bar screws should be torqued to 21in-lb (2.4 N.m) minimum.
AC Supply Configuration Table
The table below provides AC-configuration options for the various
AC supply and module configurations.

Page | 22
 * 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.
Field Wiring Connections
Field wiring connections should be made by a qualified
electrician.
A field wiring terminal strip on the input side of the AC Filter PCB
allows the connection of AC supply wiring to the unit.
Access into the frame should be gained through one of three
knockouts in the rear panel.
 A minimum of 2.5mm² multi strand cable per connection
should be used and cable-tied to the strain relief mount
provided.
 Wiring color should conform to standard practice for the
region of installation.

L1 L2 L3 Neutral Earth

Page | 23
AC Input Configurations
The figures below show common industrial AC supply types and the
appropriate wire connections to the input terminal strip.
Should connection to another type of supply be required, contact
the local distributor before connecting.

Note: It is common in the US that a fourth wire (neutral) be used in

a three phase circuit. If present, it should be attached to the “E”
(ground) terminal.

Page | 24
 FS3LN: AC Input Terminal Block Configuration
Standard FS3 models may be configured for single or three phase
input, depending on the type and number of charger modules
installed.
Single Phase (MP13x modules)
One 3-pole jumper and one 2-pole jumper required, fitted as shown.
Alternatively, two 2-pole jumpers may be used in place of the 3-
pole.

2-pole jumper location

3-pole jumper location

Three Phase (MP33x and 3xMP13x modules)

One 2-pole jumper required, fitted as shown:

2-pole jumper location

FS3xJ: AC Input Terminal Block for Japan RST

Mains Supply
The RST configuration does not require jumpers. Input wiring colour
standards vary across Japan, therefore input wiring colours shown
are indication only. See below for important surge protection
information for MP130 and MP133 modules.

Page | 25
Surge Protection of MP130 & MP133 modules
Models fitted with 2 or more MP130 or MP133 charger modules
must be fitted with MOVs across phases as follows:
 3 modules: 625VAC MOV fitted across S&T and T&R.
 2 modules: 625VAC MOV fitted across S&T.
 1 module: No MOV required.
MOVs may be fitted to the terminal blocks in conjunction with the
backplane loom wiring. MOV legs must be sufficient to
Earthed S-Phase Configuration
Some RST models required Earthed S phase, where an addition
earth link is made from the E terminal to the input S terminal.

Page | 26
 Current Limiting

A current limit may be required where the mains supply or input

cable has reduced current capacity. Jumpers on the MPC controller
enable the limiting of input current drawn by the charger.
A charger with current limit applied causes the Charger Interface
software to reject any configuration requiring more current than the
set limit. The software will alert the operator to any configuration
exceeding the current limit during the Charger Interface charger
configuration stage.

J119 and J120

current limiting
jumpers on the
MPC35

A position combination of jumpers J119 and J120 will limit the input
current to 10A,15A or 30A depending on the current limit
requirements.

Default setting

Page | 27
 Relay Configuration for External Applications
The on-board relays fitted to the MPC controller allow control of
external devices such as lights, indicators or Auto Watering.
Jumpers for each relay allow setting of the default state, NO
(Normally Open) or NC (Normally Closed).

Relay Function Notes

1 Charge BSI option must be enabled in

complete Controller Settings

2 Auto Watering Auto Watering must be enabled in

Configuration tab

3 Charge Active BSI option must be enabled in

Controller Settings

4 Alarm 1 Relay Alarm mode must be enabled in

Controller Settings

5 Alarm 2 Relay Alarm mode must be enabled in

Controller Settings

Page | 28
 6. Hardware Configuration – FS5,
FS9

The FS5 and FS9 require connection to a three phase 480V AC

supply.
AC supply wiring should meet or exceed the current draw
requirements of the specific charger model. See the rating label on
the charger for the input current requirements.
Field Wiring Connections
Field wiring connections should be made by a qualified
electrician.
A field wiring terminal strip on the input side of the AC Filter PCB
allows the connection of AC supply wiring to the unit. Access into
the frame should be gained through one of the two knockouts in the
rear panel.
Provision for securing the input cable jacket to the chassis with a
cable tie is located near the cable entry point.
Wiring color should conform to standard practice for the region of
installation.
FS5: Copper conductors required.
FS9: Copper conductors rated 75°C minimum required.
AC Input Configuration
Configuration No. 4 – 480V Three Phase

Note: It is common in the US that a fourth wire (neutral) be used in

a three phase circuit. If present, it should be attached to the “E”
(ground) terminal.

Page | 29
 7. Charger Display Interface

By default the charger display provides the basic charge profile

information and charger firmware version. The top of the display
indicates the current status of the charger.

Equalise Next Cycle Option

From the default menu, pressing either the
arrow buttons shows the Eq. Next Cycle
option to have the charger perform an equalize
charge following the next successful charge
completion.
Press Enter to adjust the option, use the arrow
buttons to select Enabled. The option will
reset to Disabled once an equalize charge is
achieved.
Service Menu
A service menu can be accessed by holding down together up and
down buttons on the charger front panel for a minimum of 16
seconds. The top of the display shows the first item in the Service
Menu: “Service Mode”.
The following items are available from the Service Menu:
Service Mode Allows the charger to operate at a
specified voltage current and duration.
Self-Test Executes a self-test of the charger’s
internal and external components.
Requires user input when prompted to
advance through each step.
Relay Test Manually activate each of the 6 relays on
the MPC mainboard.
APC Mode Enable or disable the charger to use
Automatic Profile Configuration when
connected to a battery fitted with a
battery module.
Desulphation Advanced battery service option. When
enabled the charger will perform a
desulphation service charge on a battery if
the voltage is measured to be below
1.5V/cell.

Service Mode
To access Service Mode from the Service Menu, press the Enter
button. Within the Service Mode menu, use the up or down buttons
to specify current, voltage and duration. Within each menu press
Enter to select the value, up or down to change the value. Press
Enter again and choose “Store” to save the value.

Page | 30
 8. Alarm Functions

The FSx series charger includes comprehensive fault protection

and alarm monitoring. Charger alarms are graded into urgent and
non-urgent alarms.
Urgent alarms indicate a serious condition, and the charger
will stop the charge cycle.
Non-urgent alarms are indicated on the front panel and
recorded in the alarm log, but will not interrupt a charge cycle.
Non-urgent alarms can be expected to occur from time to time due
to the varying charge characteristics of batteries. Should non-urgent
alarms consistently arise, further investigation should be made.
If an urgent alarm occurs mid-charge cycle the charger stops,
illuminates the red Alarm LED on the front panel display and
indicates an urgent alarm event by alternating both large green and
red LED lamps.
If a non-urgent alarm occurs mid-charge cycle amber Alarm LED on
the front panel display illuminates and the large red LED lamp
flashes.
In both cases the alarm is logged into the memory of the MPC in
the form of an alarm log that can be downloaded at a later date to
aid fault diagnosis. In the PC application the relevant alarm name
highlight changes from green to red.

Charger Alarms

Charger Related Alarms

Main Switch - Urgent
Shows the status of the front panel start/stop toggle switch.
Inlet Filter - Non-urgent
Provides a warning as to when the inlet filter needs
servicing. Not enabled by default.
Low Mains - Non-urgent
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 that a charger module is
being overloaded.
Mains Fail – Urgent
A mains loss situation and the charge cannot proceed.
Non-Urgent Rectifier Fail - Non-urgent

Page | 31
 Charger is still operating but a charger module is not
providing output. Redundancy has been lost and reduced
power output and longer charge time will result.
Urgent Rectifier Fail – Urgent
If the number of charger modules not providing output
equals or exceeds the setting for urgent module count in
the PC application monitor tab then the charger will stop. If
the urgent module count is set to one then the charger is
configured without redundancy and a single fault will stop
the charge.
Rectifier Over Temperature – Urgent
Normally related to a blocked filter, restricted exhaust air or
installation in an inappropriate location.
Configuration Error - Urgent
The charger cannot meet the target current required by the
controller even with all fitted charger modules operating.
The configuration does not meet the limits set for a 10A or
15A mains input hardware limited charger.
Output Fuse - Urgent
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 cells for a reversed cable connection, a
common problem with first charge of shift batteries that
have not been previously tested in a lift truck. After
replacing a battery or charger cable always check the
polarity before plugging the battery into the charger.
No Output Current – Urgent
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
The internal watchdog of the MPC micro-controller is
indicating a major fault and potential unpredictable behavior
if the charger is left running.
APC Communications Fail - Urgent
The battery module has failed to communicate with the
charger.
APC Incorrect Voltage - Urgent
The charger cannot produce the voltage required by the
battery module.
APC Unknown Charger - Urgent
The charger cannot find the required profile required by
battery module.
APC Water Level Low - Non-Urgent
For battery module equipped batteries, indicates the
electrolyte sensor has detected a low level of electrolyte.
APC Voltage Imbalance - Non-Urgent

Page | 32
 For battery module equipped batteries, indicates the
midpoint voltage varies from nominal by more than 0.5V.
Battery module will schedule an equalize charge to rectify
this variation.
Battery Related Alarms
Over Discharged Battery - Urgent
The battery is still under 1.9Vpc after 30 seconds of charge
and indicates a faulty battery that needs investigation.
Deeply Discharge Battery - Non-urgent
The battery initially is under 1.9Vpc but recovers within 30
seconds of the charge cycle start, this alarm normally
comes up when a battery is unplugged from the lift truck
and immediately plugged into the charger.
Sulphated Battery – Urgent
The battery fails to complete a de-sulphation profile applied
by the charger correctly and generally means that the
battery requires attention.
Incorrect Battery - Urgent
The battery is inappropriate for the configuration of the
charger and cannot be charged without reconfiguring the
charger to suit the battery.
Bulk Charge Timeout - Urgent
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.
Finishing Charge Timeout - Non-urgent
The battery has exceeded the maximum time allowed for
the finishing part of the charge cycle. Generally not a
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
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
A battery with its 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
chargers DC output fuse(s). Such a situation is not covered
by warranty as new batteries should always first be

Page | 33
 checked for correct polarity BEFORE plugging onto the lift
truck or a charger.
Minimum dV/dt - Non-urgent
Details the change in battery voltage over time. The alarm
occurs when the change in voltage exceeds the value set in
the profile settings. This alarm also indicates the
termination of a successful charge.
Maximum Cell Voltage - Non-urgent
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
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
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
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
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
Occurs when the time in a given stage of the equalize
profile exceeds the value set for that stage of the profile.
This alarm will terminate the equalize charge but is not
considered an urgent alarm.

Page | 34
 9. Self Test Process

Introduction
The self test process verifies the basic functions of the charger. A
combination of button presses on the charger front panel allows
access to the charger’s Service Mode menu. The self test can then
be selected from the menu.
Self test checks the ability to store data, start/stop switch function,
charge status indicators, audible buzzer test, charger module start-
up as well as the MPC controller’s internal real time clock and
memory.
At least one charger module is required to be fitted for the
self test to complete.

Accessing Self Test

With mains power only applied to the charger ensure that the
LCD displays the start-up screen

Connect Battery
48V 1000AHr
V29
Flooded 100A
Hold down the UP and DOWN buttons simultaneously for 10
seconds until “Test Mode” is displayed as below.

Test Mode
Disabled

Press the down button to get to the Self-Test option, then press
the ENTER button.
Self Test Self Test
Disabled Disabled

Press the UP button to enable Self Test and press the ENTER
button. In the Cancel/Store menu press the ENTER button to
select Store.
Self Test Cancel Cancel
Enabled Store Store

Operating the Self Test Sequence

Press ENTER and in the Switch Test menu Toggle the On/Off
switch. Ensure that the Red Charging lamp in illuminated and
the display reads Red Led Test. Press the UP button to pass
the test.

Self Test Self Test

Switch Test Red Led Test
Toggle Switch ON - Push UP
OFF - Push DOWN

Page | 35
 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 the test.
Self Test
Green Led Test
ON - Push UP
OFF - Push DOWN

In the Buzzer Test menu ensure the buzzer is sounding, press

the UP button to pass the test. The next 3 tests are automated
and require no user intervention.
Self Test Self Test
Buzzer Test RTC Test
ON - Push UP
OFF - Push DOWN

Self Test Self Test

Rectifier Test Memory Test

On completion of the test “Test Succeeded” should be

displayed. If a fault occurs the test will stop at the point of
failure. Cycling the power returns the charger to normal
operation mode.

Self Test
Test Succeeded

(Enter to Exit)

Page | 36
 10. Maintenance, Service and Repair

Regular Maintenance
Cleaning the charger air filter is the only regular maintenance
recommended.
The air filter should be inspected for dust accumulation at a 6 month
interval, more frequently if the charger is in a particularly dusty
environment.
Air Filter
The air filter may be cleaned with compressed air from the reverse
side after removal from the charger. Extremely soiled filter material
can be washed with clean soapy water and allowed to fully air dry
before refitting to the charger.
Failure to ensure the air filter is clean can lead to excessive fan
operation in order to maintain the charger module cooling during
operation. If left to operate in this way for an extended period the
risk of module fan wear increases, and charging ability is reduced
as the charger modules may de-rate output to avoid overheating.
Modules damaged by overheating due to lack of filter maintenance
will not be covered by warranty.

Blown DC Fuse
A reverse connected battery will blow the DC output fuse(s) in the
charger. A fuse blown alarm will be indicated on the front panel
display and the charger alarm logs. Fuses should be replaced only
with the same fuse as specified in the Spare Parts list.
Fuse Replacement
1. Remove the charger side panel (FS5, FS9 also remove rear
grille) and identify fuses.
FS3: Two fuses on the positive output bus bar.
FS5: Two fuses on the rear bus bar, two on the
side bus bar.
FS9: Same as FS5, with an additional two fuses
on the side bus bar
2. Remove each fuse and check for continuity.
3. Replace any open circuit fuses with the same fuse type.

Charger Module Fault

Charger modules found to be faulty should be removed from the
housing and returned to the Distributor for factory repair. Never
attempt to open a charger module, there are no user serviceable
parts inside and any warranty will be voided.

Charger MPC Fault

If the MPC is found to be faulty or damaged, it should be removed
from the housing and returned via the Distributor for factory repair.
A replacement controller can be factory configured with the
installation site information (battery type, capacity and voltage),
taken to site and fitted.

Page | 37
FS5, FS9: Replacement MPC boards for these models require
Current Shunt Measurement to be enabled. Advanced User access
to Charger Interface is required to make this configuration.

Backplane Replacement
Should a fault or damage be traced to the backplane, the option to
remove and replace the backplane is available.
A scorpion connector pin removal tool is required to remove
the AC Loom from the back plane.
FS3
Removal
1. Remove any charger modules from the charger, and
remove the side panel.
2. Disconnect the two secondary circuit connectors from the
lower backplane. (RJ45 and Molex connectors)
3. Remove the backplane AC supply
4. Remove the AC Loom chassis earth nut, and rear panel
earth connector nut.
5. Remove the 4 nuts fastening the backplane bracket to the
chassis.
6. Remove the backplane bracket assembly from the chassis.
7. Using the connector pin tool, release the AC loom pins from
the three backplane connectors.
8. Cut any cable ties securing the loom to the backplane
bracket.
9. Remove 11 screws fastening the backplane to the
backplane bracket.
Refit
Refit new backplane assembly following the above steps in
reverse, re-securing wires with cable ties where
appropriate.

FS5, FS9
Removal
1. Remove any charger modules from the charger, and
remove the rear grille, and top and side panels.
2. Disconnect the two secondary circuit connectors from top of
the backplane. (RJ45 and Molex connectors)
3. Cut the cable ties securing the secondary circuit wires to
the backplane bracket
4. Release the AC Loom from the AC Filter terminal blocks.
5. Remove the AC Loom chassis earth nut, and rear panel
earth connector nut.
6. Remove bolts securing the backplane to the output bus
circuit.
7. Remove the 5 bolts fastening the backplane bracket to the
chassis.
8. Remove the backplane bracket assembly from the chassis.
9. Using the connector pin tool, release the AC loom pins from
the backplane connectors.
10. Cut any cable ties securing the loom to the backplane
bracket.

Page | 38
 11. Remove 11 screws fastening the backplane to the
backplane bracket.
Refit
Refit new backplane assembly following the above steps in
reverse, re-securing wires with cable ties where
appropriate.

Page | 39
 11. Troubleshooting

Problem Possible Cause Remedy

Main Switch Front panel switch in Charge will start when the
Alarm the STOP position switch is set to START

Inlet Filter Alarm Air inlet filter blocked Clean the filter

AC mains supply is low

Low Mains Check configuration of the
or charger modules
Alarm charger suits the application
may be overloaded

charger module not

Non-Urgent
providing output, there Replace the faulty charger
Rectifier Fail
is capacity to charge at module(s)
Alarm
a reduced rate

Faulty charger
modules are affecting
Urgent Rectifier Replace the faulty charger
the ability of the
Fail Alarm module(s)
charger to charge the
battery

Rectifier Fan Faulty charger module

Replace charger module
Fail fan

Check air inlet filter is not

blocked, check the charger is
Rectifier Over Charger module is
installed without any
Temperature overheating
obstructions to air inlet and
outlet

Check the controller

Charger cannot configuration matches the
Configuration
provide the target quantity of Charger modules
Error
output current installed, add charger
modules if necessary

Check battery polarity,

Output Fuse Blown output fuse
replace blown fuse

Battery unplugged Ensure battery has not been

during charge. unplugged before charge
No Output completion.
Current Charge profile allows Check that the charge profile
current to fall below is appropriate for the battery
0.7A. type.

Replace the MPC35

Monitor ADC Faulty MPC35 controller module ensuring
Fail controller module the replacement is correctly
configured

Low Output Only one battery cable Ensure two battery cables
Current connected (FS9). are connected to the FS9.

Page | 40
 Typically due to the battery
being quickly unplugged from
Battery is <1.9Vpc at the truck and plugged onto
Over Discharged connection but the charger without allowing
Battery recovers within 30 the battery to recover.
seconds of charge Regular occurrences might
need investigation of work
practices

Deeply Battery is still <1.9Vpc

Discharged after 30 seconds of Check battery for faults
Battery charge

Check the configuration

matches the battery, check
Charger voltage does
Incorrect Battery the operator is not trying to
not match battery.
plug an incorrect battery type
onto the charger

Check the charger

The bulk charge part of
Bulk Charge configuration matches the
the cycle is longer than
Timeout battery, check the battery for
expected
problems

Check that the configuration

The finishing charge
Finishing matches the battery, regular
part of the cycle is
Charge Timeout timeouts may indicate a
longer than expected
problem with the battery

Remind the operator if there

Battery has been is a need to disconnect the
Battery
disconnected mid battery mid charge cycle they
Disconnected
charge cycle must first set the front panel
toggle switch to STOP

A reverse polarity
Correct the incorrect battery
Reversed battery has been
wiring and replace the blown
Battery connected to the
charger output fuse(s)
charger

Inability to set a
Charger is connected
36V
to a 10 Amp mains Upgrade the AC input circuit
configuration to
supply, current limit and remove the hardware AC
greater than 46A
configuration is in current limit function
or a 48V config
place.
greater than 35A

Page | 41
 12. Spare Parts – Common to all
models

Image Description

MP130 Module

MP330 Module

MP133 Module

MP333 Module

DC Output plug
retaining screw

USB Hole Plug

MPC35/37 Large
Display Assembly

Voltage Sense Tab

MPC35 Main Board

Assembly

MPC37 Main Board

Assembly

Fuse HRC180A
150VDC 240VAC
Front Control Panel
Membrane
Specify branding

Front Panel Green

Indicator

Page | 42
 Front Panel Red
Indicator

Front Panel Rocker

Switch

Module Bay
Blanking Plate

Page | 43
 13. Spare Parts – FS3 Specific

Image Description

FS3 Cabinet

Mounting Bracket

Backplane Assembly

AC Filter and Voltage

Selection Assembly
FS3LU models

AC Input Terminal Block

FS3xN models

AC Input Terminal Jumper Set

– 1x 2 pole, 1x 3 pole
FS3xN models

Stud Diode 150A 300V

Carry Handle

Case Foot

FS3 Lid

FS3 Side Panel

DC Output Loom

Blanking Plate Conduit

Page | 44
 Upper Gland Plate

Lower Gland Plate

Two Piece Filter Assembly

Filter Element

Page | 45
 14. Spare Parts – FS5, FS9 Specific

Image Description

300A Current Shunt

Current Sense Loom

FS5/9 AC Filter

Auxiliary PSU

Stud Diode 240A 400V

FS5/9 Cabinet

Welded Filter Assembly

Filter Element

Backplane Assembly – FS5

Backplane Assembly – FS9

Page | 46
 Top Cover

Side Panel

DC Output Loom

Handle

Lower Gland Plate

Page | 47
 15. Appendix

Interconnection – FS3LN/FS3HN
Internal Internal
7x2 Terminal block Module Module
Option 1 Option 2 Fusing Fusing
OR Module 1
(3 phase) (Single phase)
R1 +Ve -Ve
Mains Input
W1
B1 MP130/330
L1
N1 MP133/333
E1
Jumper

L2

Module 2
L3 R2
Jumper

W2
B2 MP130/330
N2
MP133/333
N E2
Jumper

Module 3
R3
E
W3
B3 MP130/330
Output Connector SB350
N3
MP133/333
E3
Housing Chassis

2x
Chassis
70mm2
Each
Output Fuse x2
180A or 160A
CP17x27 UR2

4K7
J7
Menu Enable

Fuse Monitor +Ve

(NC)
Reverse Polarity
White Line 1
Diode
SKN240

Black J10

Red Line 3
TFF-FS9COMMS-00

Backplane
MP301PB9
J8
J4

4K7

Fuse Monitor -Ve

Red Green

RJ45 Cable
Rocker Switch
ON/OFF

Display, J102 J109 J100 J110 J101

Pushbuttons
&USB
J103 J111

MPC35/37 Monitor
ESM31DSL
RY1

RY2

RY3

RY4

RY5

RY6
NO

NO

NO

NO

NO

NO
NC

NC

NC

NC

NC

NC

J124 J123
J105 J107

Page | 48
 Interconnection – FS3LU/FS3H
Internal Internal
Module Module
Fusing Fusing

+Ve -Ve
A

Module 1
B
C
MP130/330
N MP133/333
Mains Input
Terminals

L1
L2 A
L3
Module 2
B
C
MP130/330
N
E N MP133/333

FS3 AC Filter
A

Module 3
B
MP130/330
C Output Connector SB350
N MP133/333

Housing Chassis
Line 1

2x
Line 3

Chassis
FH1 Fuse 70mm2
1A/500V
J5/J6 Each

Output Fuse x2 180A

or 160A CP17x27
J5 – 240V AC supply UR2

J6 – 480V AC supply

4K7
J7

Menu Enable (NC)

Fuse Monitor +Ve

Reverse Polarity
Diode
Line 1 SKN240

J10

Line 3
TFF-FS9COMMS-00

Backplane
MP301PB9
J8
J4

4K7

Fuse Monitor -Ve

Red Green

RJ45 Cable
Rocker Switch
ON/OFF

Display, J102 J109 J100 J110 J101

Pushbuttons &USB
J103 J111

MPC35/37 Monitor
ESM31DSL
RY1

RY2

RY3

RY4

RY5

RY6
NO

NO

NO

NO

NO

NO
NC

NC

NC

NC

NC

NC

J124 J123
J105 J107

Page | 49
 AC Input Terminal Detail – FS3xN Standard

Page | 50
 AC Input Terminal Detail – FS3xJ (RST Mains)

Page | 51
 Interconnection – FS5L/FS5H
Output Connector SB350

Internal Internal
Module Module
Fusing Fusing
2x 70mm2
A +Ve -Ve Each

Module 1 C Output Fuse x2 180A or

N
MP330/333 160A CP17x27 UR2

E
Mains Input
Terminals

L1
A
L2
B 4K7
L3
Module 2 C
N
N
MP330/333
E

Fuse Monitor +Ve

E
Reverse Polarity
Diode
SKN240

Module 3 C
MP330/333 TFF-FS9COMMS-00
N

E Shunt 300A 50mV

A Output Fuse x2 180A or 4K7 4K7

160A CP17x27 UR2
B
Housing
Module 4 C

N
MP330/333
E 4K7

Fuse Monitor -Ve

A

Module 5 C

N MP330/333
E

FS5 AC Filter
Line 1

Line 3

J20
Backplane
MP301PB9
J8
J4

Red Green

RJ45 Cable
Rocker Switch
ON/OFF

J100
J101

Auxiliary PSU Display, Pushbuttons J102 J109 J101

&USB
J103 J103

MPC35/37 Monitor J124 J123

ESM31DSL

Page | 52
 Interconnection – FS9L/FS9H

Internal Internal
Module Module
Fusing Fusing

A +Ve -Ve
B
Module 1 C
N MP330/333
E
Mains Input
Terminals

L1
A
L2
B
L3
Module 2 C
N
N MP330/333
E
E

A
B
Module 3 C
N MP330/333 Output Connectors SB350 (x2)

A 4x
70mm2
B Each
Module 4 C
N
MP330/333 Output Fuse x4 180A or
160A CP17x27 UR2
E

A
B
Module 5 C 4K7
N MP330/333
E

Fuse Monitor +Ve

FS9 AC Filter Reverse Polarity
Diode
SKN240
A
B
Module 6 C
N MP330/333 TFF-FS9COMMS-00
E
Shunt 300A 50mV

A
Shunt
B 4K7 4K7 300A
50mV
Module 7 C
Housing
N MP330/333
E
4K7 4K7
4K7

Fuse Monitor -Ve

B
Module 8 C
N
MP330/333
E

A
B
Module 9 C
N MP330/333
E
Line 1

Line 3

J20
Backplane
MP301PB9
J8
J4

Red Green

RJ45 Cable
Rocker Switch
ON/OFF

J100
J101

Auxiliary PSU Display, J102 J109 J101

Pushbuttons &USB
J103 J103

EMPC35/37 Monitor J124 J123

ESM31DSL

Page | 53
 Input Current by Output Current

Page | 54
 Exploded Diagram – FS3LU

© 2014 Enatel Motive Power Ltd. Specifications subject to change without prior notice. Errors
exempt. Pictures may be representative, actual products may differ.
 Exploded Diagram – FS5, FS9

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

Analogue to Digital Converter, internal controller hardware to

ADC
convert measurements into digital signals for processing
Automatic Profile Configuration, a charger state where the
APC
charge profile is read from a battery module.
Battery module providing battery ID, charge profile, electrolyte,
APC Module temperature and voltage imbalance monitoring. Also known as
BMID.
Auxiliary transformer used to provide power to the MPC35
Aux TX
controller when no battery is connected to the charger
Printed circuit board with connectors and components to
backplane
connect the charger modules to the charger housing
A battery mounted module for battery-to-charger charge profile
battery module
identification and other functions. See APC, BMM, BMID.
Battery Monitoring Identification Device. Provides battery ID,
BMID charge profile, electrolyte, temperature and voltage imbalance
monitoring. Also known as APC Module.
Battery Monitoring Module, provides same functions as
BMM BMID/APC with additional discharge current monitoring and
logging features.
Setting a microprocessor in a condition where you can load or
bootload
update its firmware
The first stage of a charge cycle where the charging outputting
bulk charge maximum current to recharge to battery as quickly as possible,
must stop when the voltage reaches a certain point which
generally equates to 75-80% state of charge
PC software application required to communicate with the
Charger Interface
MPC35/37 controller
The core module that converts AC power into DC power
charger module
suitable for charging a battery
Setting the necessary adjustments of the MPC35 Controller to
configuration
suit the battery and charging application
CSV file containing the information for configuring the charger
Data.csv
to suit a battery, must be in the same directory as the MMPC
Interface application
Clip on mounting method for fixing electrical components to
din rail
metalwork
diode Electronic component that only passes current in no direction
Depth of discharge, measure of the battery discharge
DOD
condition, 100% is totally discharged
Rate of change of voltage, slope of the change in voltage
dv/dt
against time
Ratio of output power to input power of an electrical device,
efficiency
the higher the efficiency the less energy is lost as heat
Maintenance function using a low constant current charge to
equalize
ensure all cells in the battery have similar voltages
Timer to prevent an equalize charge starting after a normal
equalize lockout
charge until the battery has had time to cool down
The stage(s) that follow the bulk charge to return the battery
finishing charge
from 80 to 100% state of charge which must be done more
slowly than the bulk charge stage
firmware Computer code that is embedded in a microprocessor
Process where the firmware is written into the
flash
microprocessor’s FLASH memory
Batteries that have liquid electrolyte that can freely vent, also
flooded cell
referred to as wet batteries
FS3 Frame Size 3 modular charger that can accommodate up
FS3
to 3 charger modules
FS5 Frame Size 5 modular charger that can accommodate up
FS5
to 5 charger modules
FS9 Frame Size 9 modular charger that can accommodate up
FS9
to 9 charger modules
Easily replaced device that internally melts during an electrical
fuse
fault to prevent damage to other components
FW FW Abbreviation for Firmware
Battery that the electrolyte is trapped in a silica gel, fitted with
GEL
a pressure relief value so it only vents under unusual
circumstances
Higher frequency components being multiple of the 50hz AC
harmonics
power that may damage or degrade the performance of
electrical equipment
High frequency, a generic term for switch mode battery
HF
chargers used in motive power applications

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 Light emitting diode, a solid state light source that does not
LED
wear out
micro controller Computer in a single chip
Battery application used in moving plant and being regularly
motive
used and then recharged by connecting to a battery charger
MP130 – MP330 3kW Motive low voltage charger modules
MP133 – MP333 3kW high voltage charger modules
MPC35/37 Motive Power Controller type 35/37
neutral The fifth wire in a three phase supply
Printed circuit board used to mount and connect together
PCB
electronic components
Identification of the 3 lines of electrical power that make a
phase
3phase supply, referred to as A,B,C or 1,2,3
A measure of the effectiveness of an electrical device to
power factor
convert volt-amperes to watts, PF=1 is best
The core module that converts AC power into DC power
charger module
suitable for charging a battery
rectifier Another name for the charger module
Battery application where the batteries are generally on float
reserve
charge, only being discharged during AC power outages
Battery/charger must be connected positive/positive and
reversed battery
negative/negative, reversed connection will blow the fuses
8 pin modular connector used for the control cabling between
RJ45
the MPC31 controller and the backplane
SB350/SC350 350A Anderson Power connector type SB/SC
State of charge, measure of the battery charge condition,
SOC
100% is fully charged
Measure of the cross sectional area of an electrical cable,
sq mm or mm²
large enough to carry the required current without overheating
Battery plates have built up a hard sulphate layer which
sulphated
prevents the battery charging and discharging properly
Power conversion process using rapid turning on and off of a
switched mode
regulating device to achieve high efficiency and small size
Temperature compensation where the charging voltage is
temp comp
adjusted for the ambient temperature operating conditions
termination When the charge cycle completes
timeout Timer used to protect against abnormal conditions
txt text file format
Alarms that stops a charge from completing, battery may not
urgent alarm
be charged, battery cannot be used
Universal Serial Bus driver necessary to allow the host
USB driver
computer to communicate with the controller
Voltage per cell, total battery voltage divided by the number of
Vpc
cells

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