GNB X-3 Battery Charger User Manual

GNB X-3 Battery Charger

Product Information

Specifications

• Model Number: FX3MMV48-
• Max Output Power: Maximum
• Output Amperage: 24V, 36V, 48V*

Fury X-3 Features and Benefits
The Fury X-3 charger is a multi-voltage modular design for industrial battery fleet applications. It uses Silicon Carbide MOSFET power technology to provide efficient high-frequency power conversion. This charger minimizes infrastructure costs, reduces your carbon footprint, and provides multi-shift standards, opportunity, and fast charging capabilities.

Features

• Capable of Opportunity and Fast charging (user programmable) in extended temperature industrial environments with auto finish and equalization.
• Modular and stackable design: The advanced 24/36/48V Multi-Voltage Modular design allows the charger to grow with your fleet. If more power is needed, more modules can be added. If one module fails, the others continue operation. Stackable with shelf, stand, and wall mounting options available.
• Intelligent charging technology: The charger analyzes battery historical performance and charge data to provide a rapid and efficient recharge while maximizing battery life. The charger’s diagnostic intelligence evaluates battery state and condition throughout the charging cycle.
• Silicon Carbide MOSFET power: Ultra high-frequency silicon carbide (SiC) MOSFET power conversion minimizes charger size and weight while maximizing efficiency and power factor.
• Fully programmable Intelligent battery module: The new advanced GNB battery module provides complete battery identification and operational history.
• Wireless communications: Wireless communication via Wi-Fi or Bluetooth allows both on-site and remote client configuration, programming, and data downloads using GNB Fleet Management software.
• Battery types: Lead Acid (Flooded, VRLA, AGM, Gel); Lithium capability coming soon. Fury X-3 chargers are field upgradeable to all capabilities as they are developed.

Benefits

• Efficient high-frequency power conversion
• Minimized infrastructure costs
• Reduced carbon footprint
• Multi-shift standard, opportunity, and fast charging capabilities
• Scalable design to grow with your fleet
• Intelligent charging technology for rapid and efficient recharge
• Maximized battery life through diagnostic intelligence
• Compact and lightweight design
• Complete battery identification and operational history
• Convenient wireless communication for configuration and data management

Product Usage Instructions

Installation
To install the Fury X-3 charger, follow the steps below:

Wall Mount Installation

1. Select a suitable location on the wall for mounting.
2. Use the provided mounting brackets to secure the charger to the wall.
3. Ensure the charger is securely attached to the wall.

Floor Stand Installation

1. Place the floor stand in the desired location.
2. Position the charger onto the floor stand and secure it in place.
3. Ensure the charger is stable on the floor stand.

Connection to Main Power
To connect the Fury X-3 charger to the main power:

1. Locate the main power supply connection on the charger.
2. Connect the appropriate power cables to the charger.
3. Ensure proper electrical connections and secure the cables.
4. Verify that the charger is receiving power.

Operating Instructions

Control Panel Features
The control panel of the Fury X-3 charger includes various features:

• Charger Operation: Controls for starting, stopping, and monitoring the charging process.
• Viewing Charger and Charging Information: Displays information about the charger and ongoing charging process.
• Main Menu: Access to different settings and options.
• Eq/Mix: Equalization and mixing settings for specific battery types.
• Actuals: Real-time charging data and statistics.
• Records Settings: Configuration options for charge records and information storage.
• Info (System Information): Provides detailed system information about the charger.
• USB Download Charge Records: Allows downloading of charge records via USB connection.
• Service and Troubleshooting: Provides information on addressing power module errors and system errors.
• Power Module Replacement: Instructions for replacing a faulty power module.

Charger Operation
To operate the Fury X-3 charger:

1. Ensure that the charger is properly installed and connected to the main power.
2. Access the control panel and select the desired charging settings.
3. Start the charging process.
4. Monitor the charging progress and adjust settings if necessary.
5. Stop the charging process once the batteries are fully charged.

Viewing Charger and Charging Information
To view information about the charger and ongoing charging process:

1. Access the control panel and navigate to the “Viewing Charger and Charging Information” section.
2. Review the displayed information, such as charging status, battery state, and charge data.
3. Use the provided controls to navigate between different information screens.

FAQ (Frequently Asked Questions)

• Q: Can the Fury X-3 charger be used for Lithium batteries?
  A: Currently, the Fury X-3 charger supports Lead Acid batteries (Flooded, VRLA, AGM, Gel). Lithium capability will be available in future upgrades.

• Q: Can I add more modules to increase the power of the charger?
  A: Yes, the Fury X-3 charger has a modular design that allows adding more modules to increase power output. This ensures scalability to meet the growing needs of your fleet.

• Q: How can I download charge records from the charger?
  A: Charge records can be downloaded from the Fury X-3 charger by connecting a USB device to the USB port on the charger and following the provided instructions.

NOTE This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are not present in all systems.

FEATURES AND BENEFITS

The Fury X-3 charger is a multi-voltage modular design for industrial battery fleet applications. It uses Silicon Carbide MOSFET (Metal Oxide Semiconductor Field-Effect Transistor) power technology to provide efficient high frequency power conversion to minimize infrastructure costs, reduce your carbon footprint and provide multi-shift standard, opportunity and fast charging capabilities.

programmable) in extended temperature industrial environments with auto finish and equalization.
Modular and stackable design| Advanced 24/36/48V Multi-Voltage Modular design allows the charger to grow with your fleet. If more power is needed, more modules can be added. If one module fails, the others continue operation. Stackable with shelf, stand and wall mounting options available.
Intelligent charging technology| Intelligent charging technology analyzes battery historical performance and charge data to provide a rapid and efficient recharge while maximizing battery life. The charger’s diagnostic intelligence evaluates battery state and condition throughout the charging cycle.
Silicon Carbide MOSFET power| Ultra high-frequency silicon carbide (SiC) MOSFET power conversion to minimize charger size and weight, while maximizing efficiency and power factor.
Fully programmable| Programmable via Wi-Fi or Bluetooth® to allow wireless client configuration. Large LCD graphics display allows for clear reading of battery and charger status
Intelligent battery module| New advanced GNB battery module provides complete battery identification and operational history.
Wireless communications| Wireless communication via Wi-Fi or Bluetooth allows both on-site and remote client configuration, programming and data downloads using GNB Fleet Management software.
Battery types| Lead Acid (Flooded, VRLA, AGM, Gel); Lithium capability coming soon

*Fury X-3 chargers are field upgradeable to all capabilities as they are developed.

TECHNICAL SPECIFICATIONS

Model Number| FX3M- MV48-| 0603| 0606| 0609| 0612| 0615| 0618| 1021| 1024| 1027| 1030
---|---|---|---|---|---|---|---|---|---|---|---
Max Output Power| 3kW| 6kW| 9kW| 12kW| 15kW| 18kW| 21kW| 24kW| 27kW| 30kW
Maximum Output Amperage| 24V| 64A| 128A| 192A| 256A| 320A| 384A| 448A| 512A| 576A| 640A
36V| 64A| 128A| 192A| 256A| 320A| 384A| 448A| 512A| 576A| 640A
48V| 52A| 104A| 156A| 208A| 260A| 312A| 364A| 416A| 468A| 520A
Number of Modules| 1| 2| 3| 4| 5| 6| 7| 8| 9| 10
Input Amps (480V 3Ph)| 4.2| 8.4| 12.6| 16.8| 21| 25.2| 29.4| 33.6| 37.8| 42
Min Circuit Breaker Size (A)| 6| 11| 16| 21| 27| 32| 37| 42| 48| 53
Max Circuit Breaker Size (A)| 10| 15| 20| 25| 35| 40| 45| 50| 60| 70
Min. AC Input Wire Size (AWG)| 16| 14| 12| 10| 10| 8| 6| 6| 4| 4
Min. DC Output Wire Size (AWG)| 1/0| 1/0| 2/0| 3/0| 4/0| 4/0| 3/0 (qty 2)| 3/0 (qty 2)| 4/0 (qty 2)| 4/0 (qty 2)
Cabinet Size| 6 Bay| 10 Bay
Dimensions (HxWxD)| 27”H x 18.6”W x 14.5”D| 39.5”H x 18.6”W x 14.5”D
Weight| 42 lbs + (# modules 9 lbs)| 65 lbs + (# modules 9 lbs)
Input Voltage| 480VAC ± 10% 3PH 60Hz
Efficiency and Power Factor| Efficiency = 0.94

Power Factor = 0.95 max

Control| Manual and fully automatic control of charge, finish, and equalization
Environmental| 0º to +40ºC (32º to 104ºF), NEMA1
Display| 4.3” Backlit Color Graphic
Power Device| Silicon Carbide MOSFET
AC Line Disconnect| Yes, Contactor
**Certifications*| CSA Certified to UL1564, CSA 22.2, CEC
IoT Data Capability| Wireless configuration, communication, and control capabilities via Bluetooth®, Wi-Fi and PLC, USB port
Field Repair| Module Replacement
Installation**| Wall, stand, or shelf mounting options

• Stated output currents will require connectors and electrical cables of adequate capacity

SAFETY PRECAUTIONS

SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions.

This danger symbol indicates that personnel must practice safety procedures to prevent equipment damage, bodily injury, or death.

• CAUTION! Batteries can be dangerous.
  Batteries generate explosive gases during normal charging and usage. Do not smoke, use open flame or cause sparking near the battery. To reduce risk of battery explosion always follow charging instructions and those of the battery manufacturer.

• WARNING! Do not attempt to charge non-rechargeable batteries.
  Fast chargers are designated to be used only for charging rechargeable batteries. Attempting to charge a non-rechargeable battery could lead to possible injury or death from exploding batteries.

• WARNING! Risk of electrical shock that can cause serious injury or death.
  Do not touch un-insulated battery terminals, connectors or other live electrical parts. Always make sure the charger is OFF before disconnecting it from the battery. Disconnect the charger from input power and battery before servicing. Only qualified personnel should install, use, or service the charger.

• CAUTION! Never place the charger directly above or below the battery being charged.
  Never place the charger directly above or below the battery being charged; gases or fluids from the battery will corrode and damage the charger. Locate the charger as far away from the battery as DC cables permit.

INSTALLATION

Installation must only be carried out by suitably qualified personnel and by current local and national wiring regulations. Battery leads should not be altered without prior consultation with service personnel. The charger should be sited in a cool, dry, well-ventilated location away from corrosive fumes and humid atmospheres. Ambient temperature range must be maintained between 32°F-104°F. Ensure ventilation is not obstructed at the left air intake and right exhaust vents. The charger is for indoor use only.

Before installation, check that the charger has not sustained any damage during transit. Make sure the electrical ratings are suitable for both the intended AC input supply and the DC output current and voltage for the batteries to be charged. Also ensure that the connector polarity is correct and matches the polarity of the battery connector.

CAUTION – To reduce the risk of fire, use only on circuits provided with branch circuit protection consistent with the current indicated on the factory Charger Configuration label and by the National Electrical Code, ANSI/NFPA 70 or equivalent. The circuit breaker rating should be based on the charger’s maximum input current, as stated on the Factory Charger Configuration label. (See the Technical Specifications page for more details)

Wall Mount Installation
Wall mounting hangers with a pogo are available for installation. The figure illustrates the various parts for a typical wall mount charger installation:

• Step 1. Bolt the Wall Mount Hanger to the Wall
  Secure the wall mount hanger to the concrete wall through the pre-drilled holes in the hanger. Ensure the two fins are facing up. Mount to a solid concrete wall through holes using bolts into wall anchors – check with professional installation personnel to determine proper mounting techniques for all wall types.

• Step 2. Hang the Charger on the Wall Mount
  Hang the charger on the wall mount hanger so that the two slits on the back of the charger line up with the two fins of the hanger.

• Step 3. Mount the Bottom Brace to the Charger and Wall

• Step 4. Mount the Pogo Wall Bracket to the Wall and Attach the Pogo

Floor Stand Installation
Floor stands with a pogo are also available for installation.

1. Step 1. Bolt the Stand to the Floor
   Secure the stand to the concrete floor through the pre-drilled holes in the stand base. Use ½ inch diameter anchor bolts as a minimum.

2. Step 2. Attach Pogo to the Pogo Bracket
   Attach the pogo to the pogo bracket with the bolts provided.

3. Step 3. Hang the Charger on the Stand
   Hang the charger on the floor mount hanger so that the two slits on the back of the charger line up with the two fins of the hanger.

4. Step 4. Mount the Bottom Brace to the Charger and Stand.

CONNECTION TO MAIN POWER

CAUTION! Electrical connections are to be made by a qualified electrician only! Make sure that the service AC input voltage is OFF before wiring charger.
CAUTION! Risk of Fire! Use on circuits provided with the following branch circuit protection in accordance with the National Electric Code, NFPA 70.

**Ensure AC wiring and AC plugs used meet NEC requirements. Refer to the technical specifications section of this manual to view AC input information.

• Step 1. Remove Top Panel of Charger
  Remove the top panel of the charger by removing the six screws shown:

• Step 2. Attach Shielded Input Cable or Conduit to Charger Use an NEC-approved conduit or AC input cable (such as type SOOW) to connect to the charger.
  Use appropriate minimum wire size or larger for maximum kilowatt rating of charger – See Technical Specification Table (page 2): Min. AC Input Wire Size (AWG). The hole located in the top left corner of the charger must be used for the AC service entrance. Place an appropriate cable or conduit clamp in this AC service entrance hole.

• Step 3. Connect 3-Phase AC Input Power Cables
  Ensure ground and power cables have been properly stripped (approximately a half inch of insulation from the ends). Loosen the securing screws in the AC input block and insert the stripped ends of the ground and power cables. Retighten the screws. The 3-phase input is not phase specific, so AC line input positions are interchangeable. Ensure cable or conduit clamp has been properly tightened.

• Step 4. Connect 3-Phase DC Output Power Cables
  Use an NEC-approved DC output cable (if not already equipped from the factory) such as type UL 3311, UL 3279, or CSA CL 905 – battery cable, with a polarized connector appropriate for battery charging (such as REMA or Anderson Power Products Euro, SBX, or SB connectors).

Use appropriate minimum wire size or larger for maximum kilowatt rating of charger – See Technical Specification Table (page 2): Min. DC Output Wire Size (AWG).
The panel located at the bottom left of the charger must be used for the DC power output cables. There are threaded studs for the attachment of cable terminals which must be crimped or soldered to the DC cable. The positive (red) cable is attached on the right and the negative (black) cable is attached on the left. The clamps(s) at bottom are provided to secure the DC output cables.
Example Cable: Cobra Brand Battery Cable Chart

Cobra Part Number| Size (AWG)| Stranding| Insulation Thickness (mils)| Nominal OD (in)| UL Style| CSA| Amps| Cable Weight (lbs/MFT)
---|---|---|---|---|---|---|---|---
*** 90ºC| **** 105ºC
C9908B| 8| 133 x 29| 0.060| 0.29| UL 3311 & UL 3279| CL 905| 83| 92| 84
C9906B| 6| 259 x 30| 0.080| 0.375| UL 3311 & UL 3279| CL 905| 105| 118| 136
C9904B| 4| 420 x 30| 0.080| 0.43| UL 3311 & UL 3279| CL 905| 140| 157| 189
C9902B| 2| 665 x 30| 0.080| 0.495| UL 3311 & UL 3279| CL 905| 190| 213| 288
C9901B| 1| 836 x 30| 0.095| 0.565| UL 3311 & UL 3279| CL 905| 220| 246| 348
C9910B| 1/0| 1064 x 30| 0.095| 0.615| UL 3311 & UL 3279| CL 905| 260| 291| 444
C9920B| 2/0| 1330 x 30| 0.095| 0.664| UL 3311 & UL 3279| CL 905| 300| 336| 551
C9930B| 3/0| 1672 x 30| 0.095| 0.719| UL 3311 & UL 3279| CL 905| 350| 392| 663
C9940B| 4/0| 2109 x 30| 0.095| 0.785| UL 3311 & UL 3279| CL 905| 405| 454| 820
C4925B| 250 MCM| 2451 x 30| 0.095| 0.806| UL 3311 only| CL 905| 455| 510| 970

Example Polarized Connector: Anderson Power Products Battery Charging Connectors Selection Guide

OPERATING INSTRUCTIONS

Control Panel Features

1. 4.3″ Backlit Color Graphic Display
2. USB Port for Updates and Data Transfer
3. Navigation Buttons
4. Start/Stop Button

Charger Operation

• Connect Battery:
  If a battery is not connected, the Connect Battery Screen is displayed. To start a charge cycle, attach charger cables to the battery. The charger will initialize the battery and be ready to start charging.

Start Charging

• Start Charging:
  If a battery is connected, the Press Start Screen is displayed. Press the START/STOP button to begin charging. If AutoStart is enabled, the charger will begin charging automatically after a 10 second countdown when a battery is connected to the unit.

Viewing Charging Information: After a charge has been started, the charger will display the following information:

1. Amp-hours Returned to Battery
2. Charge Mode (CC, CV, FN, EQ, TK)
3. SOC Progress Bar
4. Battery ID
5. Drawer Error Warning (When Flashing)
6. Battery Temperature
7. Charge Voltage
8. Charge Current
9. Active Power Drawers Indicator
10. State of Charge
11. Time, WiFi, and Bluetooth

• Stop Charging:
  To stop charging, press the START/STOP button during a charge. If a charge cycle is stopped by pressing the START/STOP button, the User Stopped Screen is displayed.
  Note: If the connection between charger and battery is disconnected while a charge cycle is underway, the charger will automatically stop.

• Charge Complete:
  When the charger completes a charge cycle, the Charge Complete Screen is displayed. The complete screen displays the battery’s state of charge along with its initial state of charge. There is also the option to view charge details by pressing the down arrow. The details screen provides the same information as the record detail screen.

VIEWING CHARGER AND CHARGING INFORMATION

• Main Menu
  Press the center or right arrow to access the Main Menu from the idle or charging screen. All other menus are accessed from the Main Menu. Use the arrow keys to navigate and the center key to select options. Main Menu options include:

  • Eq/Mix – Manually select equalization or mix to occur
    ( Note: If this feature is enabled, it is only accessible when a battery is connected)

  • Actuals – View Actuals Menu

  • Records – Browse charge records stored on the charger Settings – View the Settings Menu

  • Info – View system information

• Eq/Mix

  • Eq/Mix Menu:
    If this menu is enabled, it allows a user to manually run equalization or a mixing cycle on the currently connected battery. The selected option is indicated by a checkmark. Only one option can be selected at a time. By default, the charger will follow the user-defined schedule for finish and equalize. To manually begin an equalize cycle, navigate to the Main Menu and select the Eq Menu. Select the Equalize option. A check next to Equalize indicates a finish and equalize cycle will occur after the regular charge cycle.

  • Use Schedule – The charger will follow its programmed schedule for equalization and mixing.

  • Equalize – The charger will finish and equalize the currently connected battery once it’s fully charged.

• Actuals

  • Actuals Menu: This menu has options to view data for each of the power modules and battery information for a connected battery.
  • Controller – Displays information about the management controller.
  • Modules – Displays status information for each power module in the charger.
  • Battery – Displays information about the currently connected battery.

• Records

  • Records Menu:
    This menu holds records of the 100 most recent charges always starting with the most recent. Select a record by using the Up and Down arrow keys. To view a selected record details, press the center key. Use the left arrow key to go back to the previous screen.

Record Detail

Settings

• Settings Menu: This menu allows a user to browse current user settings for the charger.
• User Settings: Displays the currently configured user settings. Schedule: Displays the Finish/Eq, Mix, and Finish Makeup schedules.
• Max Amps: Displays the max ampere settings for various battery sizes.
• Set Date: Allows a user to set the date on the display.
• Set Time: Allows a user to set the time on the display.

Set Date and Time
From the Settings Menu, select Set Date or Set Time. Use the left and right arrows to highlight a property and the up and down arrows to change that property. Note: the Set Time Menu uses a 24-hour clock.

Info (System Information)
This screen displays the following information about the charger:

• Type: Kilowatt rating
• Serial number: Max output current
• Application version: Max output current
• Drawer quantity: Voltage setting

USB

• Download Charge Records
  A charger can transfer its charge records to a USB drive. For instructions on transferring data, contact your local sales representative.

• Update Software
  A USB stick can be used to update the charger’s software. If you need assistance with updating charger software, please contact your local sales representative.

SERVICE AND TROUBLESHOOTING

• Power Module Error
  If an error occurs and the charger can keep charging, the red warning symbol will flash in the bottom-left of the screen. This error indicates one or more modules has an error.

• System Error
  If an error occurs that restricts the charger from running properly, the following screen will be displayed: To find more information on the error, press the down arrow on the navigator to access the Error Details screen.

For service, please contact your local sales representative.

POWER MODULE REPLACEMENT

IMPORTANT! Make sure the charger is completely POWERED OFF and NO BATTERY CONNECTED before opening the charger’s door and replacing a power module. Power module replacement should only be performed by qualified personnel.

Required Tools

1. Flat Head Screwdriver
2. 7mm Socket Wrench

• Step 1. Open Charger Door
  Using the flat head screw driver, turn the latch on the side of the charger clockwise to unlock the door and open it.

• Step 2. Disconnect Power Cables
  Disconnect the 3-phase AC input and the DC output cables from the power module you intend to replace by squeezing the clamp releases and pulling. Use a 7mm socket wrench to disconnect the ground cable.

• Step 3. Disconnect Power Module Communication Cable(s)
  There are two possible configurations for power module communications. Directions for disconnecting each type are shown:

  • Single Cable Connection
    For a single cable connection, start by disconnecting the end of the cable from the termination block located at the very bottom of the charger. Then, unplug the communications starting from the bottom power module until you have disconnected the module you are replacing.

  • Multi-Cable Connection
    For a multi-cable connection, you only need to disconnect the communication cables from the module you are replacing.

• Step 4. Loosen Mounting Screws and Remove Power Module
  Using a flat head screwdriver, turn each mounting screw counterclockwise until the spring ejects and releases the screw from the nut. Carefully pull the power module out.

• Step 5. Insert Replacement Module and Set Module Position Selector
  Insert the replacement power module. Use a flat head screwdriver to tighten the mounting screws by pushing in and turning clockwise.
  Using a flat head screw driver, adjust the module position selector to match the modules position. The power module positions are 1 through 6 starting at the top of the charger as shown in the following table:

• Step 6. Reconnect Communication and Power Cables
  Reconnect all communication cables that were disconnected in step 3. Reconnect ground , DC output, and AC input cables. Close charger door and use flat head screwdriver to turn the latch counter-clockwise to lock.

Fury X-3 Installation and Operating Instructions
©2018 Exide Technologies Exide Technologies Milton, GA 30004. GB5080 08/18

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