106 Bradrock Dr. Des Plaines, IL 60018-19671 CPN 128964 Instruction Drawing Number: P25-LMXHF-1
Tel: 847 299 1188 Fax: 847 299 3061 Revision A00 Rev. Date: 03/14 ECN: 20355
La Marche Manufacturing Company
www.lamarchemfg.com
MXHF
MXHFMXHF
MXHF
Motive Power Battery Charger
Installation and Operation Manual
2
Important Safety Instructions
Before using this equipment read all manuals and other documents related to this unit and other equipment
connected to this unit. Always have a copy of a units manual on file nearby, in a safe place; if a replacement
copy of a manual is needed it can be found at the www.lamarchemfg.com.
Electrical Safety
WARNING:
Hazardous Voltages are present at the input of power systems. The output from
rectifiers and from batteries may be low in voltage, but can have a very high current capacity that
may cause severe or even fatal injury.
When working with any live battery or power system, follow these precautions:
• Never work alone on any live power system, someone should always be close enough to come to your aid
• Remove personal metal items such as rings, bracelets, necklaces, and watches.
• Wear complete eye protection (with side shields) and clothing protection.
• Always wear gloves and use insulated hand tools.
WARNING:
Lethal Voltages are present within the power system. Parts inside the unit may still be
energized even when the unit has been disconnected from the AC input power. Check with a meter
before proceeding. Do not touch any uninsulated parts.
• A licensed electrician should be used in the installation of any unit.
• Always disconnect the unit from the supply, batteries and loads before performing maintenance or cleaning.
• If the unit is hot-swappable, simply remove it from the shelf for any maintenance or cleaning.
• Always assume that an electrical connection is live and check the connection relative to ground.
• Be sure that neither liquids nor any wet material come in contact with any internal components.
• Do not operate this unit outside the input and output ratings listed on the unit nameplate.
• Do not use this unit for any purpose not described in the operation manual.
Mechanical Safety
• This unit or parts of the unit may get very hot during normal operation, use care when working nearby.
• Do not expose equipment to rain or snow. Always install in a clean, dry location.
• Do not operate equipment if it has received a sharp blow, been dropped, or otherwise damaged in any way.
• Do not disassemble this unit. Incorrect re-assembly may result in a risk of electric shock or fire.
Battery Safety
WARNING:
Follow all of the battery manufacturer’s safety recommendations when working with or
around battery systems. DO NOT smoke or introduce a spark or open flame in the vicinity of a
battery. Some batteries generate explosive gases during normal battery operation.
• To reduce risk of arc, connect and disconnect the battery only when the unit is off.
• If it is necessary to remove the battery connections, always remove the grounded terminal from the battery
first.
• Remove personal metal items such as rings, bracelets, necklaces, and watches.
• Always wear rubber gloves, safety glasses, and a rubber lined vest/apron when working near a battery.
• Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes.
• If the battery electrolyte contacts skin or clothing, wash immediately with soap and water.
• If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10)
minutes and seek medical attention immediately.
• Do not drop metal on a battery. A spark or short-circuit could occur and could cause an explosion.
3
Unit Location
• Allow at least 6 inches of free air on all vented surfaces for proper cooling
• Allow sufficient clearance to open the front panel for servicing.
• Do not operate this unit in a closed-in area or restrict ventilation in any way.
• Do not set any battery on top of this unit.
• Never allow battery electrolyte to drip on this unit when reading the specific gravity or filling the battery.
• Never place this unit directly above a standard flooded battery. Gases from the battery will corrode and
damage equipment.
• A sealed maintenance free or valve regulated lead acid (VRLA) battery may be placed below this equipment.
Check for Damages
Prior to unpacking the product, note any damage to the shipping container. Unpack the product and inspect the
exterior of product for damage. If any damage is observed, contact the carrier immediately. Continue the
inspection for any internal damage. In the unlikely event of internal damage, please inform the carrier and
contact La Marche for advice on the risk due to any damage before installing the product. Verify that you have
all the necessary parts per your order for proper assembly.
CAUTION:
Failure to properly file a claim for shipping damages, or provide a copy of the claim to La
Marche, may void warranty service for any physical damages reported for repair.
Returns for Service
Save the original shipping container. If the product needs to be returned for service, it should be packaged in its
original shipping container. If the original container is damaged/unavailable, make sure the product is packed
with at least three inches of shock-absorbing material to prevent shipping damage.
La Marche is not
responsible for damage caused by improper packaging of returned products.
Inspection Checklist
Enclosure exterior and interior is not marred or dented.
There is no visible damage components.
All internal components are secure.
Printed circuit boards are firmly seated.
All hardware and connections are tight.
All wire terminations are secure.
All items on packing list have been included.
Handling
Equipment can be very heavy and/or top heavy. Use adequate manpower or equipment for handling. Until the
equipment is securely mounted, care must be used to prevent the equipment from being accidentally tipped
over.
4
Table of Contents
Important Safety Instructions .................................................................................................................. 2
Electrical Safety .................................................................................................................................. 2
Mechanical Safety ............................................................................................................................... 2
Battery Safety..................................................................................................................................... 2
Unit Location ...................................................................................................................................... 3
Check for Damages ............................................................................................................................. 3
Returns for Service.............................................................................................................................. 3
Inspection Checklist.......................................................................................................................... 3
Handling ............................................................................................................................................ 3
Table of Contents ................................................................................................................................... 4
Model Scope/General Description ............................................................................................................. 6
Understanding the Model Number ............................................................................................................ 6
1
Equipment Handling ......................................................................................................................... 7
1.1
Storing the MXHF........................................................................................................................ 7
1.2
Placement of the MXHF ............................................................................................................... 7
2
Installing the MXHF.......................................................................................................................... 8
2.1
Mounting the MXHF..................................................................................................................... 8
2.2
Making the AC Input Connections ................................................................................................. 9
2.2.1
Bus Bar Selection ................................................................................................................ 9
2.2.2
Auxiliary Power Supply Voltage Selection ..............................................................................10
2.2.3
AC Input Connections .........................................................................................................10
2.3
Relay Configuration....................................................................................................................11
2.4
Alarms......................................................................................................................................11
2.4
Alarms......................................................................................................................................12
2.4.1
Charger Related Alarms ......................................................................................................12
2.4.2
Battery Related Alarms .......................................................................................................13
3
Operation of the MXHF ....................................................................................................................14
3.1
Front View of the MXHF ..............................................................................................................14
3.2
Power Modules ..........................................................................................................................15
3.3
Optional Auto Profile Configuration (APC) Module ..........................................................................15
3.4
Normal Operation ......................................................................................................................15
3.4.1
Pre-Charge Checks .............................................................................................................15
3.4.2
Stop/Start Rocker Switch.....................................................................................................16
3.4.3
Charge Complete................................................................................................................16
3.4.4
Fault indicators ..................................................................................................................16
3.4.5
Equalize Next Cycle ............................................................................................................16
3.4.6
Battery Disconnection .........................................................................................................16
3.5
LCD Display...............................................................................................................................17
5
3.5.1
LCD View in the Resting State..............................................................................................17
3.5.2
LCD View in the Charging State ...........................................................................................17
3.5.3
LCD View in the Charge Complete State................................................................................18
3.6
MXHF Status Indication...............................................................................................................18
3.7
MPC35 Controller Module............................................................................................................19
3.8
Charger Interface Software .........................................................................................................19
3.8.1
System Requirements .........................................................................................................19
3.8.2
Installation ........................................................................................................................19
3.8.3
Operator Access Level Control .............................................................................................19
3.8.4
Charger Interface Tabs .......................................................................................................19
3.8.5
Charge Profile Factory Settings ............................................................................................20
3.8.6
Alarm Factory Settings ........................................................................................................22
4
Service...........................................................................................................................................23
4.1
Maintenance..............................................................................................................................23
4.2
Troubleshooting.........................................................................................................................24
Appendix A: Manufacturer’s Warranty ......................................................................................................26
Appendix B: MXHF Specifications.............................................................................................................27
Appendix C: AC Current Draw .................................................................................................................28
Appendix D: Glossary.............................................................................................................................29
Appendix E: Document Control and Revision History..................................................................................31
6
Model Scope/General Description
The La Marche model MXHF is a high frequency battery charger designed for use in industrial applications. The
MXHF is offered with DC output voltages of 24, 36 and 48VDC with output currents of 60, 120 and 180ADC.
These chargers may be powered with 208-240VAC single phase or three phase. For 380-480VAC three phase
only.
Understanding the Model Number
The MHHF model number is coded to describe the options that are included. Find the model number on the
nomenclature nameplate of the charger. Then follow the example below to determine the configuration of your
battery charger.
*Charger Type is not required for chargers equipped with APC Module
7
1 Equipment Handling
1.1 Storing the MXHF
If the MXHF is to be stored for more than a few days after delivery, it should be stored within its shipping
container. The location chosen for storage should be within an ambient temperature of -20°C to +70°C with
a non-condensing relative humidity of 5 to 95%.
1.2 Placement of the MXHF
The preferred installation is where the charger(s) can be located on a table or shelf, protected against
accidental contact with the lift truck or its forks. The MXHF has rubber feet on its base for simple placement on
a table or shelf.
With the MXHF on a shelf the risk of
damage to the charger or battery cables
is greatly reduced.
Avoid just placing the MXHF on the
floor next to the lift truck.
Figure
1
–
Placement of the MXHF
8
2 Installing the MXHF
2.1 Mounting the MXHF
There is an optional universal mounting bracket that can be fixed to the base, side and rear panels of the MXHF
charger. The bracket enables the charger to be screwed or bolted to the bench, wall or floor surface and helps
to protect the charger against physical damage.
Mounting Bracket
–
Base Mount
1. Fix the Mounting Bracket
to a bench using a type
of fastener that suits the
bench material.
2. Slot the base of the
MXHF onto the mounting
bracket.
3. When fitting the battery
cable ensure the locking
screw is installed.
Mounting Bracket
–
Side Mount
1. Fix the Mounting Bracket
to the wall using a type
of fastener that suits the
wall material.
2. Slot the side of the MXHF
onto the mounting
bracket.
3. When fitting the battery
cable ensure the locking
screw is installed.
Mounting Bracket
–
Rear Mount
1. Fix the Mounting Bracket
to the wall using a type
of fastener that suits the
wall material.
2. Slot the rear of the MXHF
onto the mounting
bracket.
3. When fitting the battery
cable ensure the locking
screw is installed.
Figure
2
–
Mounting the MXHF
9
2.2 Making the AC Input Connections
AC input configuration is done at the factory prior to delivery once a customer’s AC main has been verified. The
available inputs are listed in the table below.
The process has been simplified using the AC filter board which is mounted inside of the MXHF. Simply remove
the top cover to access the AC filter board, it includes mounting posts for bus bar selection and headers for
auxiliary power supply voltage selection. Follow three easy steps to verify or configure proper AC input for the
MXHF.
2.2.1 Bus Bar Selection
Configuring the Bus Bars on the AC filter board negates the need to rewire the AC inputs to the power modules.
Use an 8mm socket on the M5 hex head bolts to secure the Bus Bars in place. Unused Bus Bar connectors are
bolted to the internal rear of the MXHF cabinet.
AC Input Voltage Bus Bar Selection
208-240 Single Phase J14-J15-J16
J17-J18-J19-J20
208-240 Three Phase
J14-J18
J15-J19
J16-J20
480V Three Phase J17-J18-J19-J20
Figur
e
3
–
AC Filter Board
Mounting posts for Bus
Bar Selection (Step 1)
Headers for auxiliary power
supply voltage selection (Step 2)
10
2.2.2 Auxiliary Power Supply Voltage Selection
The auxiliary plug provides AC for the Auxiliary DC Power Supply that powers the MPC35 control PCB and its
associated display and indicators. Connect the plug to the appropriate header, refer to the table below.
AC Input Voltage Aux. Power Voltage
Selection Plug
208-240V J5
480V J6
2.2.3 AC Input Connections
The AC input cables are terminated onto the AC filter board via a five way terminal strip marked A, B, C for
phases 1, 2 and 3, D for neutral and E for earth. Four configurations are available and are listed below.
L1 A
N D
L1 D
L2 C
N E
L1 A
L2 B
L3 C
L1 A
L2 B
L3 C
Configuration 1: 208-240VAC
Single Phase
Configuration 2: 208-240VAC
Single Phase Split Leg
Configuration 3: 208-240VAC
Three Phase
Configuration 4: 480VAC
Three Phase
Figure
4
–
AC Input Terminal Block
11
2.3 Relay Configuration
All relay contacts are located on the MPC35 Controller module. To access relay connections, simply remove the
right side cover of the MXHF. Always be cautious when opening up the MXHF, make sure the power is not
coming into the unit.
Relay Function Contacts State
(Factory setting)
Contacts State
when condition
occurs
Connections
S-C
Jumper Conf.
(Factory
setting)
1 Charge Complete Normally Closed Open RY1 J104 (Pin 2-3)
2 Auto Watering Active Normally Closed Open RY2 J108 (Pin 2-3)
3 Charge Active Normally Closed Open RY3 J113 (Pin 2-3)
4 Alarm 1* Normally Open Closed RY4 J115 (Pin 2-3)
5 Alarm 2* Normally Open Closed RY5 J106 (Pin 2-3)
6 Not used - - RY6 J117 (Pin 2-3)
The relays can be configured for normally closed or normally open contacts by setting up the jumpers J104,
J108, J113, J115, and J106. Relay 6 is not used. Refer to the table below.
Relay Normally Closed Normally Open
1 J104 (Pin 2-3) J104 (Pin 1-2)
2 J108 (Pin 2-3) J108 (Pin 1-2)
3 J113 (Pin 2-3) J113 (Pin 1-2)
4 J115 (Pin 1-2) J115 (Pin 2-3)
5 J106 (Pin 1-2) J106 (Pin 2-3)
* Refer to section (3.8.6 Alarm Factory Settings) for more details
Figure
5
–
MPC35 Controller Module
Relays
Jumpers
Relay
Contacts
12
2.4 Alarms
The MXHF includes comprehensive protection and alarm monitoring. The alarms are graded into Urgent and
Non-urgent alarms. Urgent alarms indicate a dangerous condition that immediately stops the charge cycle.
Non-urgent alarms are indicated on the LCD and are logged in the alarm log but do not actually stop the
charge cycle.
2.4.1 Charger Related Alarms
Main Switch <Urgent> shows the status of the front panel start/stop toggle switch.
Inlet Filter <Non-urgent> can give a warning as to when the inlet filter needs servicing but is 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. It might also indicate that a Power Module is being
overloaded.
Mains Fail <Urgent> a mains loss situation and the charge cannot proceed.
Non-Urgent Rectifier Fail <Non-urgent> there is a power module that is not providing output, the Charger is
still operating but redundancy has been lost. Reduced power output and longer charge time as a result.
Urgent Rectifier Fail <Urgent> if the number of power 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 power 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 power module.
Monitor ADC Fail <Urgent> the internal watchdog of the MPC35s micro-controller is indicating a major fault
and potential unpredictable behavior if the Charger is left running.
13
2.4.2 Battery Related Alarms
Over discharged Battery <Urgent> the battery is still under 1.9 V/C after 30 seconds of charge and indicates
a faulty battery that needs investigation.
Deeply Discharge Battery <Non-urgent> the battery initially is under 1.9 V/C 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 Power 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 it’s plus and minus 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 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 2.7 V/C 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 an 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
14
3 Operation of the MXHF
3.1 Front View of the MXHF
1. LCD – displays charger parameters
2. LEDS – for status of the charger: Red, Amber and Green
3. Pushbuttons – Up, Enter and Down pushbuttons for setting manual equalize and self-test
4. QR Code – scanning the QR code brings up the MXHF product page
5. Mini USB socket – the USB port allows the PC application to talk to MPC35 controller
6. Inlet Filter – required for the power modules to be cooled with clean air
7. Stop/Start rocker Switch – the rocker switch is used to start and stop the charge cycle
8. LED Lamps – for status of the charger: Green (Ready) and Red (Charging)
9. SB350 Connector – for the DC output cables plugging the battery
Figure
6
–
Front View of the MXHF
1
2
3
4
5
9
6
7
8
15
3.2 Power Modules
The powerer modules are installed through the front of the housing and slide between steel guides. To access
the modules simply remove the inlet filter by removing to thumb screws holding the grill to the MXHF.
Each module is forced-cooled by two high-speed axial fans that are located behind the module’s plastic
faceplate. When installed in the charger, the modules draw ambient air through the front grill and filter and
force the warm exhaust air out the rear.
There are two type of power modules: Yellow module with AC input range of 175-300VAC single or three phase
and Green module with AC input range of 340-530VAC three phase only.
3.3 Optional Auto Profile Configuration (APC) Module
The Auto Profile Configuration Module (also called a battery module) stores configured information and
communicates with the MXHF through the battery cables. Once the battery is connected the APC module will
send the information to the MXHF charger. The MXHF will charge the battery using the information stored on
the APC module.
The APC mounts easily onto the top of the battery. This option gives
ability to charge different type of batteries using only one MXHF
charger. Each battery will require an APC module.
The APC module monitors battery voltage and temperature during
the charge process. A unique ID code can be assigned to the
module. An optional electrolyte can be fitted to the battery.
Rugged case construction resists impact, water and battery
electrolyte spills. Compact case size will not interfere with battery
watering, removal or lid closure.
3.4 Normal Operation
The following is a concise summary of knowledge necessary by the forklift user to correctly operate the charger.
The charger has been designed to require minimal set-up by the end-user and can be reconfigured only by
Authorized Representatives.
3.4.1 Pre-Charge Checks
Before plugging in a battery apply mains power to the charger, check that it is suitably configured for the
battery by checking the LCD display data and check that the battery and related cabling is in good condition. If
there is any exposed copper showing through the battery cable insulation or the insulation appears overheated
or burnt, DO NOT attempt to charge the battery.
Figure
7
–
Pow
er Modules
There are three status LEDs on the
faceplate:
• Red – No output
• Amber – Current limit
• Green – Operating
16
3.4.2 Stop/Start Rocker Switch
Connect the battery to the charger using the supplied cable and set the toggle switch to START, make sure the
big red LED lamp illuminates on the charger.
3.4.3 Charge Complete
A completed charge cycle is indicated by the big green LED lamp on the charger being illuminated.
3.4.4 Fault indicators
A flashing big red LED lamp indicates a non-urgent alarm has occurred during the charge cycle. No action is
required unless it happens on every charge cycle. When both the red and green LED lamps flash alternately an
urgent alarm has occurred, the charge has stopped mid cycle, be aware the battery may be only partially
charged or not charged at all.
3.4.5 Equalize Next Cycle
Before a charge is started it is possible to manually set the controller to perform an “Equalize Charge” at the
end of a normal charge cycle. The battery however will need to remain connected following the completion of
the normal charge until the equalize lockout time has expired, normally 4 hours. If the battery is unplugged
before the lockout expires the request for Equalize will be cleared.
To enable Equalize Charge for the next cycle, using the buttons on front panel of the charger perform the
following:
• Press the UP button twice to select the “Eq. Next Cycle” function
• Push ENTER to bring up “Disabled”
• Push UP to select “Enabled”
• Push ENTER to accept the change
• Push DOWN to select “Store”
• Push ENTER to store
• Push DOWN to return to “Connect Battery”
3.4.6 Battery Disconnection
Always set the rocker switch to STOP position before removing the connector during the charge cycle to avoid
damage to the poles of the connector and creating sparks in the vicinity of a gassing battery. The connector
should NEVER be unplugged during a charge cycle without setting the rocker switch to STOP position.
If the charge cycle is complete and the charger is not putting out heavy current the connector can simply be
unplugged without setting the rocker switch to STOP position. This will initiate an Auto Start option.
17
3.5 LCD Display
3.5.1 LCD View in the Resting State
During the resting state of the MXHF, either waiting
for the battery to be connected or the rocker switch to
be set to START position the LCD will display the
settings of the charger.
As show in figure 8, the LCD will display the following
settings: Battery Voltage, Battery Type, Battery Amp-
Hour, and Maximum Battery Current.
3.5.2 LCD View in the Charging State
While the battery is being charged the LCD will display the following parameters with the screens scrolling
through for about 3 seconds:
Figure
8
–
LCD View
Battery Voltage
Cell Voltage
Battery Current
Amp
-
Hours Returned
Total Charge Time
Charge State
18
3.5.3 LCD View in the Charge Complete State
When the charge cycle is completed the LCD will display the following parameters with the screens scrolling
through for about 3 seconds:
3.6 MXHF Status Indication
Green OK LED is illuminated at all times whenever AC or
DC power is present.
Charger Conditions:
• Charge active: Red LED illuminated, Red LED Lamp
illuminated
• Charge complete: Green LED Lamp illuminated
• Charge terminated by the user: No LEDs
illuminated
• Urgent alarm ON, charge terminated: Red and
Amber LEDs flashing, Red and Green LED Lamps
flashing
• Non-urgent alarm ON, charge not affected: Red
LED flashing, Red LED Lamp flashing
Figure
9
-
Status LEDs and LED Lamps
Time spent in Bulk
Charge stage
Time spent in Standard
Charge Cycle
Total time spent
charging (Standard
+ EQ/Refresh)
Total amp
-
hours
returned
Cell voltage when
charge cycle ended
Present battery voltage
Cell voltage when
charge cycle ended
EQ/Refresh stage has
timed out
Time spent in
EQ/Refresh stage
19
3.7 MPC35 Controller Module
The MPC35 controller module provides the overall intelligence of the MXHF. It is the job of the controller to tell
the power modules how to correctly charge a battery. The controller must be configured to match a certain
battery before the charger can be used.
To understand the software element of the MXHF it should be explained that there are two separate software
components to the charger. First there is a Firmware (FW) which is embedded code that is loaded into flash
memory in the micro-controller chip in the MPC35 controller module. FW controls all the functions of the
charger. Second is the PC software that runs on host Windows computer and communicates to the MPC35 via a
USB connection. The PC software is called “Charger Interface” and provides necessary interface to read the
configuration, status, alarm logs and charge logs of the MXHF. If Automatic Profile Configuration (APC) module
is used, the APC configuration can also be read by the software.
There is no need for loading the FW as this is done at the factory during final test of the controller. However
should there be the need to adjust the function or add new features to the MXHF, the Charger Interface
software can be used to “Bootload” new FW into the controller.
3.8 Charger Interface Software
Note: Charger Interface software is not required to be used in order for the MXHF to fully operate. The “Read-
Only” version of the software may be provided to the customer for analysis purposes upon request. It is
intended to be used by technicians for troubleshooting, monitoring and retrieving alarm and charge logs.
3.8.1 System Requirements
Charger Interface software has the following minimum system requirements:
• Microsoft XP (SP3) / Windows Vista / Windows 7 / Windows 8
• Microsoft .NET Framework
• USB 1.0/1.1/2.0
• Administrator privileges on the PC for installation
3.8.2 Installation
Ensure the minimum system requirements are met before installing the Charger Interface software. The
software installer may be supplied on a CD, USB flash drive or other method. Locate and run the software
installer file. Follow the installer prompts to complete the installation. After installation a desktop shortcut will be
created. Power on the MXHF and connect the charger to the PC with a USB cable.
3.8.3 Operator Access Level Control
An incorrectly configured charger can cause irreversible damage to the batteries. For this reason Charger
Interface software employs a three-level access control. The three levels are:
• Read Only Access (Customer)
Read charger status, charger configuration, start and delay times, and alarm and charger logs. Viewing the
configuration of an attached APC module is also available.
• Configuration Access (Authorized Representatives)
Charger configuration settings can be modified using pre-defined template settings. The settings include:
Battery voltage, battery type, amp-hours and battery module (APC) enabling option.
• Advanced Access (Factory only)
Allows advanced control over the charger and battery module functions.
3.8.4 Charger Interface Tabs
Charger Interface software displays various charger data in a series of tabs within the main window. Some tabs
such as the Monitoring Tab are undocked by default. These tabs may be docked to the main window by double-
clicking the tab title bar.
20
Charger Tabs Battery Module Tabs
Charger Status – View recent charge cycles for
insight into the health and usage of the battery. If
the charger is used to charge multiple batteries,
the battery ID can be selected. Also available on
this is the ten most recent alarms recorded.
Battery Module Monitoring – Monitors battery
status via a battery module. The monitoring
includes present battery voltage, mid-point voltage,
battery current and battery temperature.
Configuration – View the current configuration of
the charger, including battery type, equalize,
scheduled start, and start delay options. Changes
to these options require Configuration Access.
Battery Module Configuration – Configure battery
module for battery type and ratings as well as set
charge profile types and sequences for a battery
module.
Charge Log – Displays the charge cycle log for
saving to PC. Useful for determining usage trends
and battery health.
BMM Alarm Log – View and save the alarm log
from a BMM battery module.
Alarm Log – Displays all recorded charger and
battery alarms for analysis and saving to PC.
BMM Charge Log – View and save the charge log
from a battery module.
Monitoring – A live display of the present charge
cycle parameters including battery, power module
and alarm status.
BMM Data Log – View and save the data log from a
BMM battery module.
3.8.5 Charge Profile Factory Settings
Charge Profile Name:
Flooded
Charge Profile Type: IUI
Stage 1 Current: 16A / 100Ah (100%)
Stage 2 Voltage: 2.4 V/C
Stage 3 Current: 4A / 100Ah (25%)
Stage 3 Min dV/dt: 3mV/15min/cell
Stage 3 Max Cell Voltage: 2.7 V/C
Stage 1 Timeout: 390 minutes
Stage 2 Timeout: 330 minutes
Stage 3 Timeout: 0 minutes
EQ/Refresh Current: 1.92A / 100Ah (12%)
EQ/Refresh Duration: 120 minutes
EQ/Refresh Max Voltage: 2.7 V/C
Auto EQ/Refresh After: 30 hours
EQ/Refresh lockout: 4 hours
Auto EQ/Refresh Options**: None
EQ/Refresh Constant Voltage: No
Temp Comp factor: -3mV/degC/cell
Figure
10
–
Flooded Lead Acid Cell
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