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

Hawker PTO MOD3 Owner's Manual

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PTO™ MOD3
Battery Charger
OWNER'S MANUAL
Model: PTO3
Skip to page 25 For Model:
PTOM1, PTOM3, and PTOM3C (Standard and Flex)
www.hawkerpowersource.com

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Summary of Contents for Hawker PTO MOD3

  • Page 1 PTO™ MOD3 Battery Charger OWNER’S MANUAL Model: PTO3 Skip to page 25 For Model: PTOM1, PTOM3, and PTOM3C (Standard and Flex) www.hawkerpowersource.com...

  • Page 2: Table Of Contents

    CONTENTS Features ..........3 Technical Information ....... 3 Important Safety Instructions ..6 Installation ........7 Glossary ..........8 Operating Instructions ....9 Menu Access ........10 Charging the Battery ......12 Charge ..........14 Equalization ........14 Options ..........15 RST Memo/Status ......

  • Page 3: Features

    • Fully programmable to unique fleet requirements • Unique profile for charging Thin Plate Pure Lead • Battery chemistry agnostic - TPPL, Flooded and (TPPL) Gel Lead Acid • Unique profiles for HAWKER FLEX battery ® charge applications. Technical Information Main nameplates (UL model number) vs.
  • Page 4 TECHNICAL INFORMATION Technical Information (cont.) Nameplate Label Definitions Item Description UL Model No UL recognized number that indicates the ratings of the cabinet at its full capacity. Provides date code. Serial Number Battery type L-A: Lead Acid; Li-ion: Lithium-ion. Maximum amp-hour capacity of this cabinet. Max Ah Number of battery cells this unit will charge.
  • Page 5 TECHNICAL INFORMATION Technical Information (cont.) Cabinet Size (number of modules available) AC Line Voltage and DC Cable Size Line Voltage(s) Frequency Standard Letter Code (volts rms) (Hertz) Comments Letter Module Cable Code Positions Gauge Comments 50/60 600 VAC only Four slot, 3.5 kW cabinet 208/220/240 50/60 208/220/240 VAC...

  • Page 6: Important Safety Instructions

    Ventilate well when the or grounded metal. battery is in an enclosed space. 12. For HAWKER FLEX batteries, use only ® 5. Unless charger is equipped with LM2 (Late HAWKER battery packs that include the ®...

  • Page 7: Installation

    INSTALLATION Installation Location AC Circuit Protection For safe operation, choose a location which The user must provide suitable branch circuit is free of excess moisture, dust, combustible protection and a disconnect method from the material, and corrosive fumes. Also, avoid high AC power supply to the charger to allow for safe temperatures (above 113ºF [45ºC]) or potential servicing.

  • Page 8: Glossary

    INSTALLATION Installation (cont.) DC Plug Polarity AC Amps (A) Description The charging cables are connected to the DC 1 - 12 output of the charger with the red cable to the positive bussbar, and the black cable to the 12.1 - 16 negative bussbar.

  • Page 9: Operating Instructions

    Glossary (cont.) Opportunity Profile (cont.) FXBLOC This charging profile allows the charging of Daily Charge HAWKER FLEX bloc batteries. ® When using the Opportunity Profile, the Daily Charge option can be set to add additional FXSTND charging time every day if the work schedule This charging profile allows the charging of allows.

  • Page 10: Menu Access

    MENU ACCESS Menu Access When the charger is idle, press and hold <ESC>, the Main Menu is then displayed. The main menu is automatically exited after 60 seconds of inactivity or can be exited voluntarily by pressing the <ESC> button. Figure 1 Main Menu All menus are accessed from Main Menu;...
  • Page 11 Save Settings: Save configuration settings from This is where the password is entered to gain a flash drive. access to service level menus by authorized Restore Settings: Restore configuration settings HAWKER service personnel. ® from a flash drive. Update MODULE: Update module firmware.

  • Page 12: Charging The Battery

    CHARGING THE BATTERY Charging the Battery At this point, the charger should have been set up by a qualified service person. Charging can only begin with a battery of the proper type, capacity and voltage connected to the charger. Figure 1 With the charger in wait mode (no battery connected) and without pressing the Stop/Start button, the display will show the information...
  • Page 13 CHARGING THE BATTERY Charging the Battery (cont.) Manual Equalization Start Automatic Equalization Start 1. At the end of charge (GREEN charge complete If an equalization day has been programmed into indicator or flashing), press on the <EQUALIZE> the charger configurations, the equalization charge button.

  • Page 14: Charge

    CHARGE Charge Profile standard charge is intended to compensate for For selecting the right charging profile for the consumption by the truck electronics that are left application: OPP , COLD STORAGE, STDFLD, GEL, on when the truck is not used (typically AGV). The FXBLOC, or FXSTND.

  • Page 15: Options

    FAULT CODES Options Idle On/Off Options Test Enable or disable the screen saver. Turns on Battery Status (Red/Green) and Electrovalve output briefly to test operation. Power Supply To select AC power supply. Electrovalve Time Sets time on in seconds. RST Memo/Status Factory Reset Resets the memorizations and charge status Requires higher level password.
  • Page 16 FAULT CODES Fault Codes (cont.) Fault Critical Cause Solution Check that the fan(s) is (are) working correctly and/or that the ambient temperature is not too high, or whether there is poor 14.0/10.0 natural ventilation to the charger. If all modules are in thermal fault, a TH fault will follow.

  • Page 17: 3.5 Kw Technical Specifications

    TECHNICAL SPECIFICATIONS 3.5 kW Technical Specifications AC Input 208/220/240V 3PH. DC Output Opportunity/ Nominal Flex Bloc Charger 8 Hour Standard Capacity Charger Model Draw Modules/ Current Capacity Capacity Range Dimensions Cable Weight Cabinet Number Voltage Amps Phase # Bays Cells Range (Ah) Range (Ah) (Ah)
  • Page 18 TECHNICAL SPECIFICATIONS 3.5 kW Technical Specifications (cont.) AC Input 208/220/240V 3PH. DC Output Opportunity/ Nominal Flex Bloc Charger 8 Hour Standard Capacity Charger Model Draw Modules/ Current Capacity Capacity Range Dimensions Cable Weight Cabinet Number Voltage Amps Phase # Bays Cells Range (Ah) Range (Ah)
  • Page 19 TECHNICAL SPECIFICATIONS 3.5 kW Technical Specifications (cont.) AC Input 480V 3PH. DC Output Opportunity/ Nominal Flex Bloc Charger 8 Hour Standard Capacity Charger Model Draw Modules/ Current Capacity Capacity Range Dimensions Cable Weight Cabinet Number Voltage Amps Phase # Bays Cells Range (Ah) Range (Ah)
  • Page 20 TECHNICAL SPECIFICATIONS 3.5 kW Technical Specifications (cont.) AC Input 480V 3PH. DC Output Opportunity/ Nominal Flex Bloc Charger 8 Hour Standard Capacity Charger Model Draw Modules/ Current Capacity Capacity Range Dimensions Cable Weight Cabinet Number Voltage Amps Phase # Bays Cells Range (Ah) Range (Ah)
  • Page 21 TECHNICAL SPECIFICATIONS 3.5 kW Technical Specifications (cont.) AC Input 600V 3PH. DC Output Opportunity/ Nominal Flex Bloc Charger 8 Hour Standard Capacity Charger Model Draw Modules/ Current Capacity Capacity Range Dimensions Cable Weight Cabinet Number Voltage Amps Phase # Bays Cells Range (Ah) Range (Ah)
  • Page 22 TECHNICAL SPECIFICATIONS 3.5 kW Technical Specificationts (cont.) AC Input 600V 3PH. DC Output Opportunity/ Nominal Flex Bloc Charger 8 Hour Standard Capacity Charger Model Draw Modules/ Current Capacity Capacity Range Dimensions Cable Weight Cabinet Number Voltage Amps Phase # Bays Cells Range (Ah) Range (Ah)

  • Page 23: Maintenance And Service

    MAINTENANCE AND SERVICE Maintenance and Service Any data, descriptions or specifications set forth WARNING WARNING: THERE ARE herein are subject to change without notice. DANGEROUS VOLTAGES WITHIN THE BATTERY Before using the product(s), the user is advised CHARGER CABINET. ONLY A QUALIFIED PERSON and cautioned to make its own determination and SHOULD ATTEMPT TO ADJUST OR SERVICE THIS assessment of the suitability of the product(s) for...
  • Page 24 NOTES...

  • Page 25: Battery Charger

    PTO™ MOD3 Battery Charger OWNER’S MANUAL Models: PTOM1, PTOM3, and PTOM3C (Standard and Flex) www.hawkerpowersource.com...
  • Page 26 CONTENTS Important Safety Instructions ....27 Technical Information ......27 Installation ..........30 Description of Operation .......31 Glossary ..........31 Abbreviations and Acronyms ....32 Operating Instructions ......33 Setting up the Charger ......34 Main Menu ..........34 Charge Prof. Config ........35 Configuration .........36 Charging the Battery ......37 Charger Information ......39 Fault Codes ..........41 Cabinet Mounting Dimensions ....42...

  • Page 27: Safety & Information

    SAFETY & INFORMATION Important Safety Instructions THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE OPERATION. WARNING 1. This manual contains important safety and 6. Lead-acid batteries contain sulfuric acid which operating instructions. Before using the battery causes burns. Do not get in eyes, on skin, or charger, read all instructions, CAUTIONs, and on clothing.
  • Page 28 TECHNICAL INFORMATION Technical Information (cont.) Single Display Cabinet: PTOM3 - 48F - 240YR Model type Phase (-) for Standard or (C) for CEC Max DC Volts Cabinet Size Max DC Current @ Max DC Volts Input Voltage Code Options Nameplate Labels Cabinet Size/Gauge Letter Codes The following table describes the letter codes to be used in charger part numbers to indicate the DC output voltage(s) of the charger.
  • Page 29 TECHNICAL INFORMATION Technical Information (cont.) Serial No. Config AC Amps This is the serial number that indicates complete This is the AC current that this charger will draw information about the charger. It must be supplied with the number of power modules shown in with the part number on any correspondence or Config Modules on the nameplate.

  • Page 30: Installation

    INSTALLATION Installation Breaker/Fuse Chart WARNING THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE OPERATION AC Amps (A) Breaker/Fuse size (A) Location 1–12 For maximum trouble-free service, choose a 12.1–16 location which is free of excess moisture, dust 16.1–20 and corrosive fumes.

  • Page 31: Description Of Operation

    AC Power Fail capacities. The charging coefficient is maintained If the AC power fails while the battery is connected absolutely on all types of batteries. HAWKER ® to the charger during a charge cycle, the charger PTO™ MOD3 chargers adapt to the battery’s will reset and start a new charge cycle when power capacity and its discharge level.

  • Page 32: Glossary & Abbreviations

    GLOSSARY & ABBREVIATIONS Glossary (cont.) Opportunity Profile Standard Flooded The OPPOR charge profile is used when The profile is an IEI (constant current, constant opportunity charging is desired. It has a start rate voltage, constant current) type with a number of of 25% of the batteries rated amp hour capacity, user-configurable parameters.

  • Page 33: Operating Instructions

    OPERATING INSTRUCTIONS Operating Instructions The HAWKER ® PTO™ MOD3 series of chargers are (Standard Flooded, Opportunity, Cold) based on compatible with batteries at 24, 36, 48 volts or 72, the configuration chosen by the operator. If the 80 volts (depending on the version supplied).

  • Page 34: Setting Up The Charger

    SETTING UP CHARGER Setting up the Charger 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 35: Charge Prof. Config

    HAWKER ® able to get into the charger settings anymore. Load Module FW: Enables the updating of the power modules internal firmware. Firmware updates will be provided by HAWKER ® Charge Prof. Config Battery Cells Battery Capacity...

  • Page 36: Configuration

    Cold profile, ranges allowed from 60°F to 149°F . 5. Firmware will automatically load at this point. If in Cold profile, range is 5°F to 50°F . Wait until it finishes and splashes the HAWKER ® startup screen before removing the flash drive.

  • Page 37: Charging The Battery

    CONFIGURATION Configuration (cont.) Post Charge Configuration Charger Options: • Select Options: choices are Remote, BSI or Cool-Down • Cool-Down On/Off: Sets this function ON or OFF . Electrovalve. If using one of these charger If enabled, the charger will not show available options, that option must be enabled.
  • Page 38 CHARGING THE BATTERY Charging the Battery (cont.) Starting a Charge Cycle The charger will start automatically when a battery is connected, or by pushing the ENTER/STOP & START button if the battery is already connected. Delayed Start If the charger is programmed for delayed start, charging will begin following that delay.

  • Page 39: Charger Information

    CHARGING THE BATTERY Charging the Battery (cont.) Manual Start Automatic Start 1. At the end of charge, press the Equalize If an equalization day has been programmed in navigation button. The equalize button can also Charger configurations, the equalization charge be pressed any time during the charge and an will start automatically on the programmed day of equalize charge will be started after charging is...
  • Page 40 CHARGER INFORMATION Charger Information (cont.) Status Status Description Total number of times a battery was connected Connects during the life of the charger. Comp Chg Total number of charges normally completed. Total number of charges terminated before Part Chg completion. Comp EQ Total number of equalizes normally completed.

  • Page 41: Fault Codes

    FAULT CODES 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 indicator will be illuminated. Fault Cause Solution Check input voltage and fuses.

  • Page 42: Cabinet Mounting Dimensions

    CABINET MOUNTING DIMENSIONS 3-Bay Mounting Dimensions Dimensions shown are in inches.

  • Page 43: 6-Bay Mounting Dimensions

    CABINET MOUNTING DIMENSIONS 6-Bay Mounting Dimensions Dimensions shown are in inches.

  • Page 44: Maintenance And Service

    MAINTENANCE & SERVICE Maintenance and Service CAUTION THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY 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 45: Component Locations

    COMPONENT LOCATIONS Component Locations Component Locations Inside View of 3-Bay Cabinet AC Input Backplane Fuses Module 1 Slot Module 2 Slot Module 3 Slot DC Output 20 in-lbs Inside View of 6-Bay Cabinet Backplane Fuses AC Input Module 1 Slot Module 6 Slot...

  • Page 46: Technical Specifications

    TECHNICAL SPECIFICATIONS Technical Specifications for 480V, 1 phase AC Input DC Output Nominal Rated Opportunity Charger Charger Model Draw Cabinet Modules/ Current 8 Hour Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in) (AWG)
  • Page 47 TECHNICAL SPECIFICATIONS Technical Specifications for 208/220/240V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)
  • Page 48 TECHNICAL SPECIFICATIONS Technical Specifications for 208/220/240V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)

  • Page 49: Technical Specifications For 440V, 3 Phase

    TECHNICAL SPECIFICATIONS Technical Specifications for 440V, 3 phase AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in) (AWG)
  • Page 50 TECHNICAL SPECIFICATIONS Technical Specifications for 440V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)
  • Page 51 TECHNICAL SPECIFICATIONS Technical Specifications for 440V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)
  • Page 52 TECHNICAL SPECIFICATIONS Technical Specifications for 440V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)

  • Page 53: Technical Specifications For 600V, 3 Phase

    TECHNICAL SPECIFICATIONS Technical Specifications for 440V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)
  • Page 54 TECHNICAL SPECIFICATIONS Technical Specifications for 600V, 3 phase (cont.) AC Input DC Output Charger Nominal Rated 8 Hour Opportunity Charger Model Amp Draw Cabinet Modules/ Current Capacity Capacity Range Dimensions Cable Cabinet Weight Number Voltage Amps Phase # Bays Cells Range (Ah) (Ah) H x W x D (in)
  • Page 55 NOTES...
  • Page 56 © 2024 Hawker Powersource, Inc., an EnerSys affiliate. All rights reserved. Trademarks and logos are the property of Hawker Powersource, Inc. and its affiliates, except BC, UL, Torx, Philips, Nomex, Molex, and OSHA trademarks, which are not the property of Hawker Powersource, Inc. Subject to revisions without prior notice.

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