Hawker PTO MOD3 Owner's Manual
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Hawker PTO MOD3 Owner's Manual

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PTO™ MOD3
Battery Charger
Models: PTOM1 / PTOM3 / PTOM3C (Standard
For parts sales, call toll-free 1-800-409-8895 and for charger technical support,
troubleshooting, and service call 1-800-251-6560.
Model:
Installed by
Read and understand your user's manual before installing, operating, or servicing this product.
Owner's Manual
Owner's Manual
PTO™ MOD3
and Flex)
S/N:
IMPORTANT
DO NOT DESTROY THIS BOOK
AC Input Voltage
Date
1
AM-HPTOM3-OM
Rev AB February 2020
AM-HPTOM3-OM
Rev AB February 2020

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Summary of Contents for Hawker PTO MOD3

  • Page 1 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Battery Charger Owner’s Manual PTO™ MOD3 Models: PTOM1 / PTOM3 / PTOM3C (Standard and Flex) For parts sales, call toll-free 1-800-409-8895 and for charger technical support, troubleshooting, and service call 1-800-251-6560. AM-HPTOM3-OM Rev AB February 2020 Model:...

  • Page 2: Table Of Contents

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 TABLE OF CONTENTS Important Safety Instructions ........3 USB ................15 Technical Information ..........4 Memo Data ............15 Part Number ............4 Save Setup Params ..........15 Cabinet Size/Gauge Letter Codes ....4 Load Setup Params ..........

  • Page 3: Important Safety Instructions

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 IMPORTANT SAFETY INSTRUCTIONS WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE OPERATION. 1. This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, CAUTIONs and WARNINGs on the battery charger, the battery and the product using the battery.

  • Page 4: Technical Information

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 TECHNICAL INFORMATION There are two nameplates located on the outside of the charger and should be used to check the application before installation. The “Main” nameplate includes the UL Model number and the ratings of the cabinet at its full capacity, while the “Configured Ratings”...

  • Page 5: Ac Line Voltage Letter Codes

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 AC Line Voltage Letter Codes The following table describes the letter codes used in the charger part number to indicate the nominal AC line voltage(s) and frequency at which the charger is designed to operate. Line Letter Voltage(s)

  • Page 6: Hertz

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Hertz This is the frequency in cycles per second of the AC input voltage this charger is designed to operate on. Do not operate charger at a different frequency or from a generator with unstable frequency. Phase Number "1"...

  • Page 7: Installation

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 INSTALLATION WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE OPERATION Location For maximum trouble-free service, choose a location which is free of excess moisture, dust and corrosive fumes. Also, avoid locations where temperatures are high or where liquids will drip on the charger.

  • Page 8: Dc Plug Polarity

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 24.1 -28 28.1 - 32 32.1 - 36 36.1 - 40 40.1 - 48 48.1 - 56 56.1 - 64 64.1 - 72 72.1 - 80 80.1 - 88 88.1 - 100 DC Plug Polarity The charging cables are connected to the DC output of the charger with the red cable to the positive bus bar, and the black cable to the negative bus bar.

  • Page 9: Description Of Operation

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 DESCRIPTION OF OPERATION General The PTO™ MOD3 series of chargers are compatible with batteries at 24, 36, 48 volts or 72, 80 volts, depending on model. PTO™ MOD3 chargers are microprocessor-controlled. The processor calculates the battery’s capacity so that the charging profile can be automatically adapted to the battery’s actual state over a wide range of capacities.

  • Page 10: Glossary

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 GLOSSARY Charge Blockout This function prevents the charger from charging the battery during the block out time window. If a charge cycle has started before the block out window it is inhibited during the block out window and will automatically restart the charge cycle at the end of the block out window.

  • Page 11: Abbreviations And Acronyms

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 ABBREVIATIONS AND ACRONYMS Amperes-Hours American Wire Gauge AVAIL Available BBWC™ Battery Boss Wireless Communication California Energy Commission Depth of Discharge Ground Kilowatt Lead Acid Liquid Crystal Display Light Emitting Diode Thin Film Transistor Universal Serial Bus OPERATING INSTRUCTIONS The PTO™...

  • Page 12: Charger Control Panel

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Charger Control Panel Ref Function Description Graphical LCD Display Display charger operation info/Menus USB Port Log charge data, and update firmware Navigate UP button Navigate menus/Change values Select menu items/Enter values/Stop and ENTER/STOP and START button restart battery charge Navigate RIGHT/EQUALIZE button...

  • Page 13: Setting Up Charger

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 SETTING UP CHARGER Idle Screen Display Start Menu Display Start Menu When the charger is idle, the display shows “CONNECT BATTERY”. To enter the Start Menu, press and hold <ESC>, the Start Menu is then displayed. The current menu is automatically exited after two minutes of inactivity or can be exited voluntarily by pressing the <ESC>...

  • Page 14: Time

    Display Contrast Adjusts the brightness of the LCD display. ENTER PASSWORD This is where the password is entered to gain access to service level menus by authorized Hawker service personnel. 1. Use the Up/Down buttons to select the correct alphanumeric character.

  • Page 15: Usb

    Hawker. Load Module FW Enables the updating of the power modules internal firmware. Firmware updates will be provided by Hawker. CHARGE PROF. CONFIG Battery Cells This allows the charger to be adjusted for the number of cells in the battery being charged.

  • Page 16: Battery Temperature

    4. Using the down arrow button, select firmware file from the list on screen and hit Select button. 5. Firmware will automatically load at this point. Wait until it finishes and splashes the Hawker startup screen before removing the flash drive. 6. Reenter password.

  • Page 17: Duration

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Duration Sets the equalization time from 00:05 to 23:59 (hh:mm). NOTE: If duration is set below 5 minutes the charge will default back to the factory setting for that profile. If not using this charger to equalize the battery, select no days of the week for equalize.

  • Page 18: Charger Config

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 CHARGER CONFIG Cabinet Bay Size This can only be accessed by entering the higher level password. Select cabinet size to match the actual cabinet size. Number of Modules This can only be accessed by entering the higher level password. Enter number of modules installed in charger.

  • Page 19: Charging The Battery

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 CHARGING THE BATTERY Once the charger is setup by a qualified service person, charging begins when a battery of the proper type, capacity and voltage is connected to the charger. With the charger in idle mode (No battery connected), the display will show the following information: Charger Idle Display Description Charger Type...

  • Page 20: Charge Display

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Charge Display A few moments into the effective charge, the display will begin alternating between the following charging information: Description Charger Type Firmware Version Charge Profile System Time and Date Volts Per Cell DC Amps AH Returned to Battery Charge Time...

  • Page 21: End Of Charge Display

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 End of Charge Display End of Charge without Equalization The green available LED comes on after proper end of charge. The green available LED is on and the display shows CHARGE COMPLETE.

  • Page 22: Charger Information

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 3. The battery will be available when the green LED comes back on and the display shows AVAIL. 4. The battery is now ready for use. If the battery remains plugged in and Refresh charge has been enabled, refreshes will occur to maintain an optimal charge.

  • Page 23: Status

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Status Status Description Connects Total number of times a battery was connected during the life of the charger. Comp Chg Total number of charges normally completed. Part Chg Total number of charges terminated before completion. Comp EQ Total number of equalizes normally completed.

  • Page 24: Memos

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Memos Memorization Access On the main Start Menu, select Memos and press <Enter>. Memorizations Display Screen The display lists memos in ascending order, one being the most recent charge cycle. Memos are stored for one year from the date recorded. Displaying a Charge Cycle Proceed as follows: 1.

  • Page 25: Fault Codes

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 FAULT CODES In case of a fault, one of the corresponding fault codes listed below will appear on the display. If it is a critical fault, charging will stop and the red Fault LED will be illuminated. Fault Cause Solution...

  • Page 26: Mounting Dimensions

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 3 Bay Mounting Dimensions All dimensions are in inches...
  • Page 27 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 All dimensions are in inches 6 Bay Mounting Dimensions...
  • Page 28 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 All dimensions are in inches...
  • Page 29 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 All dimensions are in inches...

  • Page 30: Maintenance And Service

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 MAINTENANCE AND SERVICE THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CAUTION: CHARGER CABINET. ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER. The charger requires a minimum of maintenance. Connections and terminals should be kept clean and tight.

  • Page 31: Component Locations

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 COMPONENT LOCATIONS AC INPUT BACKPLANE FUSES MODULE 1 SLOT MODULE 2 SLOT MODULE 3 SLOT 20 in-lb DC OUTPUT 20 in-lb...
  • Page 32 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Inside View of Cabinet BACKPLANE AC INPUT FUSES Inside View of a 6-Bay Cabinet MODULE 6 SLOT MODULE 1 SLOT...

  • Page 33: Technical Specifications 480V, 1Ph

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 TECHNICAL SPECIFICATIONS Technical Specifications for 480V, 1 phase: 8 hour Opportunity Dimensions Charger Weight AC Input DC Output Capacity Capacity H x W x D Cable (lbs) Cabinet Range Range (inch) Model Number Type Nominal...

  • Page 34: Technical Specifications 208/220/240V, 3Ph

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 8 hour Opportunity Dimensions Charger Weight AC Input DC Output Capacity Capacity H x W x D Cable (lbs) Cabinet Range Range (inch) Model Number Type Nominal (AH) (AH) (AWG) Rated Current Voltage Phase...
  • Page 35 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportunity AC Input Output 8 hour Capacity Range Dimensions Charger Cabinet Weight Model Number H x W x D Cable Capacity Type (lbs) # Modules / (AH) (inch) (AWG) Nominal Amp Range Voltage Phase...
  • Page 36 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportunity AC Input Output 8 hour Capacity Range Dimensions Charger Cabinet Weight Model Number H x W x D Cable Capacity Type (lbs) # Modules/ (AH) (inch) (AWG) Nominal Amp Range Voltage Phase Cells...
  • Page 37 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportunity AC Input Output 8 hour Capacity Range Charger Dimensions H Cabinet Weight Model Number Cable Capacity x W x D (inch) Type (lbs) (AH) (AWG) Nominal Amp Modules/ Range Voltage Phase Cells Current...
  • Page 38 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportunity AC Input Output 8 hour Capacity Range Dimensions Charger Cabinet Weight Model Number H x W x D Cable Capacity Type (lbs) (AH) (inch) (AWG) Nominal Amp Modules/ Range Voltage Phase Cells Current...

  • Page 39: Technical Specifications 440V, 3Ph

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Technical Specifications for 440V, 3 phase: Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) Nominal # Modules/ (AH)
  • Page 40 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) Nominal # Modules/ (AH) Range Voltage Phase Cells Current...
  • Page 41 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportunity AC Input Output 8 hour Capacity Range Dimensions Charger Cabinet Weight Model Number H x W x D Cable Type (lbs) Capacity Nominal (inch) (AWG) # Modules/ (AH) Range Voltage Phase Cells Current...
  • Page 42 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportunity AC Input Output 8 hour Capacity Range Dimensions Charger Cabinet Weight Model Number H x W x D Cable Capacity Type (lbs) Nominal # Modules/ (AH) (inch) (AWG) Range Voltage Phase Cells Current...

  • Page 43: Technical Specifications 480V, 3Ph

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Technical Specifications for 480V, 3 phase: Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) # Modules/ (AH) Nominal...
  • Page 44 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) # Modules/ (AH) Nominal Range Voltage Phase Cells Current...
  • Page 45 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) # Modules/ (AH) Nominal Range Voltage Phase Cells Current...
  • Page 46 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) # Modules/ (AH) Nominal Range Voltage Phase Cells Current...

  • Page 47: Technical Specifications 600V, 3Ph

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Technical Specifications for 600V, 3 phase: Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) # Modules/ (AH) Nominal...
  • Page 48 PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 Opportuni AC Input Output 8 hour Capacity Charger Range Dimensions H x Cabinet Weight Model Number Cable W x D (inch) Type (lbs) Capacity (AWG) # Modules/ (AH) Nominal Max Current Range Voltage Phase...

  • Page 49: Maintenance Log

    PTO™ MOD3 Owner’s Manual AM-HPTOM3-OM Rev AB February 2020 MAINTENANCE LOG 1. Modifications to Factory Settings Date Variable Change Service Technician 2. Service Date Description Service Technician...
  • Page 50 AM-HPTOM3-OM Rev AB February 2020 © 2020 Hawker. All rights reserved. Trademarks and logos are the property of Hawker except for the BL and UL logos, which are not the property of Hawker. Subject to revisions without prior notice, E. & O.E.

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