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Flight Systems Xtender Operation Manual

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Operation Manual
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Summary of Contents for Flight Systems Xtender

  • Page 1 Operation Manual For more information or technical assistance, please call us toll-free 1-800-333-1194 or visit us online at shop.fsip.biz...
  • Page 2 • Safety instructions • Check list before operation • Safety instructions during operation • Machine model information • Accessories • Xtender Machines –Identification and Functions • Xtender Machines – Cable Connections 1. Start & Program • Start System • Program 2.

  • Page 3: Table Of Contents

    • ScrLock • Zoom 4. Upgrade of Xtender Machines • Latest Firmware Download • Software Update 5. Xtender Monitoring Program for PC • Program Installation • Operation of Equipment • Log Files - Viewing & Printing • Useful Program Functions 6.
  • Page 4  Key Characteristics of Xtender Machines The Xtender Regenerator is a newly developed device for the regeneration of Lead-Acid Batteries using electric properties with the new concept of IT convergence technology. The Xtender is an economic and eco-friendly “Green Energy” product...
  • Page 5  Safety Instruction for Xtender Machines Please be fully aware of safety instructions described in this manual to prevent any possible danger. Please note that we shall not take any responsibility or liability for any loss or damage occurred by improper operation of control. For your safety, you should read this manual before operation of this equipment.
  • Page 6 Before contact with interface ports, make sure that power supply is not connected. ④ Before inspecting the Xtender for maintenance or repair, first shut off power supply and wear safety gear in order to avoid risk of hazardous electric shock.
  • Page 7  Safety Instruction for Xtender Machines WARNING C A U T I O N ① Physical contact may result in death or serous injury because high voltage current flowing inside the units. While operating or while connected to power supply, any contact with internal parts is strictly prohibited.
  • Page 8  Safety Instruction for Xtender Machines CAUTION C A U T I O N ① Install the unit on a flat surface without any slope. Make sure to keep the unit fastened and fixed using the castors mounted on the bottom of the unit.
  • Page 9  Check List Before Xtender Operation When you connect the Xtender to the power supply, make sure that power cords follow the local safety regulations exactly. Always check the condition of batteries before performing a Restoration or Discharge. Cracked, damaged or frozen batteries are strictly prohibited to Restore or Discharge using the Xtender.
  • Page 10 Do not disassemble the unit. ② Only use it for its intended purpose. It is strictly prohibited to use the Xtender for any other purposes. ③ Avoid using in extremely high or low temperatures, dusty, dirty areas or in high humidity conditions.
  • Page 11 Due to the risk of explosion and physical damage caused by the sulfuric acid, children should be prohibited from entering the designated area the Xtender is used in. Please be fully aware of safety instructions of this manual to prevent any possible danger during operation.
  • Page 12 It could also cause the leaking of sulfuric acid which could result in a loss of eyesight or a skin burn or damage to the Xtender.  AVOID USING IN WET AREA Water can cause a fire as a result of a short circuit and high humidity can damage the battery.
  • Page 13  Emergency Treatment Recommendation  IN AN EMERGENCY If any accident happens with the electrolyte, it could lead to a fatal injury. If the electrolyte gets into your eyes, you should clean your eyes with water several times and visit an eye doctor. If it gets into your mouth, you should rinse your mouth out and brush your teeth several times.
  • Page 14 Line-Up 93-M1001 93-M1005 93-M1007 93-M1009...
  • Page 15  Xtender Accessories Xtender Photo Description Model 93-M1001 Output Cable 1 93-M1005 93-M1007 Output Cable 2 93-M1009 Output Cable 3 93-M1007 93-M1007 Output Cable 4 93-M1009 Output Cable 5 93-M1007 Output Cable 6 93-M1009 Accessories provided are subject to change without...
  • Page 16  Xtender Accessories – Popular Xtender Photo Description SPEC Model Temperature Sensor PT100/2.5m common Xtender to Serial Cable common Router Xtender Router common USB Cable Router to PC common Server Ant. 2.4GHz common Xtender Ant. 2.4GHz common SD Card common...
  • Page 17  Xtender Accessories – Popular Xtender Photo Description Model Gloves common Apron common Arm Cover common Face Shield common Accessories provided are subject to change without prior notice for safety or inventory.
  • Page 18 SD Card & Display Monitor Serial Port Emergency Switch Key Switch Input Output AC 1PH Ventilation 3Wire 2Wire Holes Temp. Circuit Sensor Breaker (CP) Be careful not to allow sulfuric gases enter into the Xtender through the vent during restoration & discharge.
  • Page 19 Antenna Display Monitor Serial Port Power Led Key Switch Input Output AC 3PH Ventilation 3Wire 2Wire Holes Temp. Circuit Sensor Breaker (CP) Be careful not to allow sulfuric gases enter into the Xtender through the vent during restoration & discharge.
  • Page 20 SD Card & Touch Screen Serial Port Display Monitor Power Led Key Switch Ventilation Holes Input Output AC 3PH 3Wire 2Wire Temp. Fuse Sensor Be careful not to allow sulfuric gases enter into the Xtender through the vent during restoration & discharge.
  • Page 21 TEMP.SENSOR : Connect Temp. Sensor with Model PC-100 provided CIRCUIT BREAKER : Xtender Protection Device: It will automatically cut electricity off during the excessive current or a power failure. OUTPUT : Battery has a polarity of (+) & (-). Be sure that they are connected correctly.
  • Page 22 TEMP.SENSOR : Connect Temp. Sensor with Model PC-100 provided CIRCUIT BREAKER : Xtender Protection Device: It will automatically cut electricity off during the excessive current or a power failure. OUTPUT : Battery has polarity of (+) & (-). Be sure that they are connected correctly.
  • Page 23 Battery has polarity of (+) & (-). Be sure that they are connected correctly. GROUND : Xtender to Earth Ground  When connecting cables to the backside of Xtender, be sure to connect to the suitable position.  When connecting cables to OUTPUT, be cautious not to confuse...
  • Page 24  Wiring Instructions  93-M1009 : Cable Connection INPUT : Xtender Electricity / AC 3 Phases 220V or 400V / 50Hz or 60Hz / L1, L2 ,L3 3Wires TEMP.SENSOR : Connect Temp. Sensor with Model PC-100 provided Fuse : Xtender Protection Device: It will automatically cut electricity off when excessive ampere or power blackout.
  • Page 25 1. Start & Setting  SYSTEM START Turn the key of Xtender “ON”. System loading picture with Xtender logo will show in screen.  Each model shows on screen  93-M1001  93-M1005  93--M1007  93-M1009 [Main Screen] After booting up PC, main screen will show as above.
  • Page 26 ③ Touch : Touch Screen Calibration ④ Screen Lock : Setup screen lock password to prevent tampering. ⑤ Bluetooth : Bluetooth wireless communication between Xtender and integrated receiver. ⑥ Back light off : Automatically backlighting off, energy saving mode. ⑦ Language : Korean, English, Spanish and Japanese ⑧...
  • Page 27 1. Start & Setting  SETTING SCREEN – TOUCH CALIBRATION Touch Screen is for setting of coordinate location. You can select : Touch Calibration, Run for activation. When you activate, “+” will be shown up on the screen as under. Keep press “+”...
  • Page 28 1. Start & Setting  SETTING SCREEN – SCREEN LOCK Screen Lock can protect Xtender from unauthorized personnel changing settings or operational data. Any change without password will not be permitted. 2) Make Password with 6 letters from C,H,A, 1) Touch “Setting”...
  • Page 29 1. Start & Setting  SETTING SCREEN – SCREEN LOCK Screen Lock is in effect. • When you touch the Screen Lock, the picture will be shown as above and you can • release Screen Lock with your password.
  • Page 30 1. Start & Setting  SETTING SCREEN – BLUETOOTH Bluetooth wireless communication between Xtender and Integrated Receiver. Connected : Disconnected :  SETTING SCREEN – BACK LIGHT OFF For the life span of LCD & energy saving, LCD Back light will be automatically off after set time regardless of operation of Xtender.
  • Page 31 1. Start & Setting  SETTING SCREEN – LANGUAGE Xtender supports Korean, English, Spanish and Japanese. Other languages will be added to the list continuously.
  • Page 32  SETTING SCREEN – S/W UPGRADE Download the latest software to your SD Card from website for free. Then you can upgrade Xtender through this SD Card. Details of Upgrade will be explained in next page. Only use software files supplied by FSIP.
  • Page 33 Temp : present Temperature • Freq. : input Frequency [Operation Screen] All set and measured data will be seen on the screen during operation of Xtender. When touching any part of the “2” area, it will show the running information by graph.
  • Page 34 ⑥ Zoom : Graphic mode for Zoom In/Out Signal of Serial communication Signal of Bluetooth communication Top menu of Operation is related to setup of each mode of Xtender operation. Bottom menu of the Screen is related to the operation of Xtender mode.
  • Page 35 2. Operation (Restoration & Discharge)  MANUAL MODE – SETTING VALUES  Click “Manual” on Top menu  Exit : Return to Operation Screen.  Calc : Calculator You can calculate total “Voltage” for Battery operation (Restoration & Discharge) Calculator works only to set “Voltage” ①...
  • Page 36 ② Click 1 & 5 on keypad  Wrong set values may a cause damage to ③ Click “Enter” on keypad Xtender machine and degradation of ④ 15 (A) will be shown as Ampere set value performance. in “1” area of the screen.
  • Page 37 2. Operation (Restoration & Discharge)  MANUAL MODE - OPERATION  Check Set values  Select either Restoration or Discharge from Xtender bottom menu to begin programmed manual cycle.  If manual mode is programmed to discharge battery select “Discharge”, if manual mode is programmed to regenerate battery select “Restoration.”...
  • Page 38 10% when temperature reaches over 50℃ (adjustable in Setup menu)  Install temperature sensor connected with back side of Xtender unit on the top or good place on batteries to check the temperature of battery. If connecting to a large multiple cell battery place the temperature sensor over the middle cell.
  • Page 39 2. Operation (Restoration & Discharge)  MANUAL MODE – DISCHARGE PROCESS  Manual Mode: Discharge is performed with Constant Ampere form. • This graph shows Discharge  Explanation for the Graph of Discharge ① Start Discharge with Set Ampere until it reaches Set Voltage (Final Voltage for Discharge) ②...
  • Page 40 2. Operation (Restoration & Discharge)  PROGRAM MODE – SETTING ( V = Voltage, A = Ampere, T = Time )  Operation Screen : Click “Program “ on top menus  Program Mode – Setting Screen  Operation will proceed automatically according to the set modes in order.
  • Page 41 2. Operation (Restoration & Discharge)  PROGRAM MODE – SETTING  Select MODE1  Setting Screen per MODE  Input Set Voltage  Input Set Amperage  Input Set Time  Enter Key must be pressed with each change of the above to save changes Caution C A U T I O N...
  • Page 42 2. Operation (Restoration & Discharge)  PROGRAM MODE – PULSE SCENARIOS  Restoration(regeneration charge) Method – Pulse Scenarios (Patterns) ( V = Voltage, A = Ampere, T = Time )  Restoration Pulse1 Scenario : Pulse 1 ① Start Charging with Set A. ②...
  • Page 43 2. Operation (Restoration & Discharge)  PROGRAM MODE – PULSE SCENARIOS  Restoration (regeneration charge) Method – Pulse Scenarios (Patterns) ( V = Voltage, A = Ampere, T = Time ) Restoration and Discharge Pulse 3  Restoration Pulse 3 scenario : are combined ①...
  • Page 44 2. Operation (Restoration & Discharge)  PROGRAM MODE – PULSE SCENARIOS  Restoration(regeneration charge) Method – Pulse Scenarios(Patterns) ( V = Voltage, A = Ampere, T = Time ) Pulse 5  Restoration Pulse 5 Scenario : ① Start Charging with Set A for 10 minutes . ▶Keep Zero (0) Ampere for 5 minutes.
  • Page 45 2. Operation (Restoration & Discharge)  PROGRAM MODE – PULSE SCENARIOS  Discharge Method - Pulse Scenarios (Patterns) ( V = Voltage, A = Ampere, T = Time ) Pulse 1  Discharge Pulse 1 Scenario : ① Start Discharging with Set A. ②...
  • Page 46 2a. Typical Operation Program Mode 1. A typical regeneration process includes the following steps, assuming the process begins with a fully charged battery to be regenerated. 1. Discharge Battery to 20% capacity while monitoring AH output 2. Mass charge battery 3.
  • Page 47 2b. Program mode setup cont’d Example program typical lead acid battery regeneration process: ALWAYS FOLLOW BATTERY MANUFACTURERS RECCOMENDATIONS! a. Select “MODE 1” and follow formula in the below chart. i. Number of Cells = ½ of nominal battery voltage. b. Select “MODE 2” c.
  • Page 48 2b. Program mode setup cont’d Functional explanation of previous sample program: MODE 1 Battery is discharged with a 74.8A load until either the actual voltage measures 30.6V (1.7Vpc 20%) or the timer reaches 10 hours. In effect Mode 1 is used to measure the beginning battery capacity.

  • Page 49: Useful Additional Functions

    3. Useful Additional Functions  FILTER :  [Operation Screen] Click “Filter” on Top Menu [Operation Screen]  Select items what you want to show up on the Graphic Screen by ON/OFF .  Set Voltage :  Set Ampere : ...

  • Page 50: Log File

    SD Memory Card.  Active Log Files are created by the operation time of Xtender and saved as the title of Starting date & time of operation.  R: Restoration (Regeneration Charge), D: Discharge...
  • Page 51  SCREEN LOCK: Activation Non activation  ScrLock is the function that protects Xtender from changing Set Data by others except authorized operators.  Lock process : Activate according to following process. ① Click “ON” to Screen Lock in Setting Screen (Setting of Password was explained in page 29) ②...

  • Page 52: Zoom

    3. Useful Additional Functions  ZOOM :  Zoom : You can load graph on the screen during operation of xtender or from the log files saved in SD card.  Graph shows for the results of every 30/60/120 minutes or total hours through zoom function on the screen.

  • Page 53: Upgrade Of Xtender Machines

    4. Upgrade of Xtender Machines  SOFTWARE UPDATE:  Install Xtender SD card into USB adapter and insert into pc usb drive. Copy the downloaded files from your pc to the SD card. When copying firmware do not place it into subfolders.
  • Page 54 4. Upgrade of Xtender Machines  SOFTWARE UPDATE:  If you select Yes for update, Xtender will check files in SD card and give you the information of devices as shown in the picture. After checking devices, perform the upgrade.

  • Page 55: Xtender Monitoring Program For Pc

    5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM FOR PC Integrated Monitoring program for PC can control the Xtender and manage the operation data easily  by using integrated router.  BMS (Battery Monitoring System) can be synchronized with the Xtender through this program.
  • Page 56 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – PROGRAM INSTALLATION  Integrated Monitoring program for PC can control the Xtender and manage the operation data easily by using integrated server.  BMS (Battery Monitoring System) can be synchronized with the Xtender through this program.
  • Page 57 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – PROGRAM INSTALLATION  Install the program in your PC using Setup.exe file from the CD-ROM supplied.  Integrated Monitoring shortcut will be generated on the desktop of your PC.
  • Page 58  Double click the generated icon of Integrated Monitoring Program on the wallpaper to activate program as above picture.  Connect your PC with “Integration Router” using USB Cable supplied with Xtender.  COM PORT will be set automatically.  Integrated Monitoring program can perform following functions.
  • Page 59 (will be shows as MCS-serial number) ③ Serial No. of the units will be shown as above ④ Select one unit on the list and “double click” it or click “connect” for activation Integrated receiver will be connected with Xtender one to one (1:1)
  • Page 60  INTEGRATED MONITORING PROGRAM FOR EQUIPMENT CONTROL [Xtender only] ⑤ Select equipment you want to operate.  MCS : Xtender only  BMS : BMS only  MCS+BMS : Xtender + BMS synchronized Synchronization only possible during manual discharge [BMS only] [Xtender + BMS synchronized]...
  • Page 61 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – Xtender CONTROL ⑥ Select MCS only for Xtender only. ⑦ You can select the communication method from options below.  Wireless : Bluetooth 2.4GHz  Fixed-Line : Serial communication by cable (Serial cable should be connected between Xtender and Router.)
  • Page 62 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – Xtender CONTROL ⑩ Pop-up window for setting  Click “start” after input setting data [(Manual-Restoration Setting] [Folder for saving Log file] [Tip] “Tag” will help you find log files saved.
  • Page 63 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – Xtender CONTROL [Graph in progress ]...
  • Page 64 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – Xtender CONTROL  Operation Mode : Top Menus Change of set value Stop Pause Synchronizing (Extender (MCS) + BMS) Print “Test Report” Reconnect of equipments Extender (MCS)<-> BMS switchable ...
  • Page 65 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – Xtender CONTROL When you change Set values during Xtender operation, Select and revise set value. After revising set values, click “Resetting” button to apply new values.
  • Page 66 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – BMS CONTROL ① Select “BMS” ② Process of connection with BMS. BMS Server Setting  Set ID  Channel  The num of BMS cell BMS Voltage Setting  Full Battery Voltage : Full charging voltage ...
  • Page 67 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – BMS CONTROL ④ BMS is in progress ⑤ BMS proceed during Set Time When you change Set values during BMS operation, Select to revise set values.
  • Page 68 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – Xtender+BMS CONTROL USED TO MONITOR MANUAL DISCHARGE CYCLE ONLY ① Select “MCS+BMS” ② Process of connecting with MCS+BMS ③ Click ④ Click button to synchronize MCS of MCS on the left and BMS.
  • Page 69  “Log file” saved in SD memory card or in PC shows the details of operation in a short time.  “Test Report” can be printed for customers.  We can review Xtender use history data through reviewing Log Files.
  • Page 70 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING ① Click Log button on the top menu  Select item on the list (MCS(Xtender), BMS. or Program Use)  Log Files will be pop-up on the screen.
  • Page 71 5. Xtender Monitor Program for PC  INTEGRATED MONITOR PROGRAM – LOG FILE VIEWING & PRINTING  Example : Xtender Log file on the Screen Information of Xtender operation...
  • Page 72 • To step : return to previous range list to show up as per your choice. If you leave any messages by using the Comment Function during operation of Xtender or BMS, you can read it when you activate the Log file saved.
  • Page 73 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING  Xtender Log file : Top Menu Copy the Chart . Print “Test Report”. Adjust pixel of X. Y. Save or copy the chart as the graphic file.
  • Page 74 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING  Example : BMS Log file on Screen Information of BMS operation...
  • Page 75 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING  BMS Log file : Bottom Menu – Table Chart 1. Type 3. Back Color [Table] If you set default value of Voltage for Good (Green Color) and Bad (Red Color) status, Table data will be shown with 2.
  • Page 76 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING  BMS Log file : Bottom Menus – Line 1. Line [Line Graph] 2. Click Point 3. Y axis You can change minimum or maximum value of the Set If you select a line graph on the screen, it will show the time Voltage for Y axis.
  • Page 77 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING  BMS Log file : Bottom Menus – Column 1. Column [Column Graph Example] 2. Vision 3. Y axis Select Voltage from the list to output.
  • Page 78 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – LOG FILE VIEWING & PRINTING  Top Menus Copy the Chart Print “ Test Report” Adjust pixel of X. Y, Save or copy the chart as graphic file Input the information and make “Preview” for printing Test Report.
  • Page 79 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM - OPTIONS  [℃] Use Celsius at Set Temperature Axis of Chart  [℉] Use Fahrenheit at Set Temperature Axis of Chart  [yyyy-MM-dd] Expression style of date for inner clock or Log file name (Year-Month-Day) ...
  • Page 80 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – USEFUL FUNCTIONS  Tag  Log File is saved in the name of “Date and Time” of operation hour. Example) 2012_02_16_115429_R_noTag.csv : (2012.02.16, 11:54:29 Restoration) * If you have any difficulties searching the Log File of a specific operation, please use the Tag...
  • Page 81 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – USEFUL FUNCTIONS  Tag  Save the log files with Tag (specific name or title)  Special characters won’t be input.
  • Page 82 5. Xtender Monitoring Program for PC  INTEGRATED MONITORING PROGRAM – USEFUL FUNCTIONS  Comment  If you enter any notes in the Comment field during the operation of Xtender or BMS, you can review it when you activate the Log files.
  • Page 83  [Manual] Operation manual of Xtender & BMS  [Contact us] e-mail address for your inquiry  [Visit our website] website address for firmware update or other information  [Check for update] it will check and upgrade your Xtender automatically.

  • Page 84: Important Information

    1.2V ~ 75V 93-M1009 0A ~ 300A  Battery is not well connected to Xtender for operation (contact failure, low voltage under 5V). When any error messages show up on screen during operation, please address as indicated. For additional assistance, please contact FSIP.
  • Page 85 6. Important Information  Xtender : ERROR MESSAGES  Active Voltage exceeds Max. Voltage  Active current exceeds Max. Ampere during operation. during operation. Max. Voltage per Xtender Model Max. Current per Xtender Model Model Max. Active Voltage Model Max. Active Ampere...
  • Page 86 6. Important Information  Xtender : ERROR MESSAGES  Active Frequency is different from  Active time exceeded possible operating the Set Frequency of Xtender. Set time in program mode.  You are requested to confirm your local frequency before Xtender operation.
  • Page 87  Communication problem in controlling of  No files are in SD memory Card for S/W the inner devices of Xtender. upgrade of Xtender.  Files for Xtender operation do not exist on SD memory Card, or SD Card does not work properly.
  • Page 88 6. Important Information  Xtender : ERROR MESSAGES  The problem with electric fan in the  Actual temperature of inner Xtender is over Xtender. the set temperature.  Stop Xtender operation When any Error messages show up on screen during operation, please make proper...

  • Page 89: Xtender Alarm Messages

    6. Important Information  Xtender : ALARM MESSAGES  Program Mode is completed  In Manual mode, Discharge is completed  In Manual mode, Restoration is completed...

  • Page 90: Trouble Shooting

    Booting is not completed on 2. Check the switch to be electric power “On” LCD monitor. 3. Check the emergency switch “Off” 1. Check CP terminal (Circuit Breaker) of Xtender unit to be Active Voltage or Active “On” Ampere are not displayed.

  • Page 91: Met Certificates

    8. MET CERTIFICATE  Copies of MET certification can be requested by contacting FSIP.  Posted on machine identification label. For more information or technical assistance, please call us toll-free 1-800-333-1194 shop.fsip.biz or visit us online at...

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