OPERATION MANUAL, POWER MODULE-CHARGER SYSTEM. Man Occup. Machine Occup. Cycle Time Setup Time Batch Qty. Equipment Manufacturer Qty

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1 Rev Description Date ECO# Document Number: OPERATION MANUAL 3/24/ Form Instructions Title Operation Description Standards OPERATION MANUAL, POWER MODULE-CHARGER SYSTEM Power Module-Charger System Man Occup. Machine Occup. Cycle Time Setup Time Batch Qty Equipment List Equipment Manufacturer Qty Reference Docs Document # Description Document # Description Related Files RESP ENGR Kenneth Cao ALL TEXT AND GRAPHICS COMPUTER GENERATED, DO NOT REVISE MANUALLY T3MOTION, INC. PROPRIETARY INFORMATION This document is the sole property of T3MOTION, Inc. The release of data contained in this document and the reproduction of this document in whole or in part, without the written permission of T3MOTION, Inc. is prohibited. SHEET of Form xxx-xxxxx Rev

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3 Serious electrical shock can occur if precautions are not followed. T3MOTION VEHICLE ALWAYS TURN OFF POWER BREAKER IN GLOVE BOX BEFORE CHARGING OR REMOVING POWER MODULES. Power breaker in glove box Power modules ALWAYS SET THE PARKING BRAKE WHEN VEHICLE IS NOT IN USE. Parking brake 3

4 POWER MODULE WARNINGS DANGER! RISK OF POWER MODULE EXPLOSION MAY RESULT IN BLINDNESS, SERIOUS INJURY, PERMANENT DISFIGUREMENT AND SCARRING. Power modules can explode under abnormal conditions, such as short circuited, over charging, or malfunction of charger. In order to reduce the risk of these dangers and injury, it is of the utmost importance that each time before using your charger, you read and understand this manual, and any warnings and instructions by the power module manufacturer. Follow these instructions exactly. CAUTIONS:. Storage ALWAYS store power modules and chargers in ventilated dry room under specified temperature range. Be sure area around power module and charger are well ventilated during charging process. 2. Avoid Flames and Sparks DO NOT put flammable material on or under power module and charger. DO NOT use near gasoline vapors. ALWAYS plug charger into an electrical outlet AFTER all connections have been made. See OPERATING INSTRUCTIONS. If remove power modules from vehicle to charge, ALWAYS turn off main circuit breaker in the vehicle. 3. Follow Other Manufacturers' Recommendations Before using charger, read all instructions for, and caution markings on: () charger, (2) power module, and (3) related product using battery. Follow their recommended rate of charge. 4

5 ELECTRICAL WARNINGS DANGER! RISK OF ELECTRICAL AND FIRE HAZARD MAY RESULT IN DEATH, SERIOUS INJURY, SHOCK OR BURNS. This charger, like all electrical products, MUST be treated with respect. Follow these instructions to reduce electrical hazard risk. CAUTIONS:. Proper Grounding and AC Power Connection Charger MUST be grounded to reduce risk of electric shock. Charger is equipped with an electric cord having an equipment grounding conductor and a grounding plug. The plug MUST be plugged into an outlet that is properly installed and GROUNDED in accordance with all local codes and ordinances. 2. Avoid Charger Abuse To reduce risk of electric shock, unplug charger from outlet before attempting any maintenance or cleaning. DO NOT disassemble charger. Take it to a qualified service person when service or repair is required. Incorrect reassembly may result in a risk of electric shock or fire. DO NOT expose charger to rain, snow, water, gas, oil, etc. DO NOT block air flow in front and rear of charger. 4. Proper Use of Charger and Wiring An extension cord should not be used unless absolutely necessary. Use of improper extension cord could result in a risk of fire and electric shock. If extension cord must be used, use ONLY a grounded, 3-wire type cord. NEVER use a 2-wire cord and an adaptor! The cord MUST be plugged into a grounded outlet. Make sure it is properly wired, in good electrical condition, and wire size is large enough for AC ampere rating of charger as specified. AWG = American Wire Gauge 5

6 GENERAL INFORMATION The warnings are important. If you need these Safety Instructions, copy them from our web site, If you have any question or concern regarding safety or operation, contact T3 Motion service department at

7 OPERATING INSTRUCTIONS:.0 Unlock the latch and open the top lid. 2.0 Pull out charger cables and AC power cord. 3.0 Close the lid. 4.0 Remove power module CHARGER INPUT connector cap. Power Modules Remove CHARGER INPUT connector cap 5.0 Check the power module capacity by pushing STATUS SWITCH button. If none of the LED s turns on, see LOW POWER MODULE CHARGING INSTRUCTION. 6.0 Connect charger# cable to battery and charger#2 cable to battery 2. Make sure to align charger connector to the power module CHARGER INPUT connector by using guide channel. The charger has an auto enable mode, wherein the charger will sense the presence of the power module on the charger via serial communication and automatically turns on. 7

8 Power module charged connector Charger connector Guide channel Align the connectors by using guide channel 7.0 Plug the AC power cord to AC inlet of the charger. Make sure the AC switch in off position. 8

9 8.0 Plug the AC power cord to a wall outlet and turn on AC switch. 9.0 The charger will initially do LED s test by turning on each LED in sequence. If any LED doesn t turn on, see TROUBLESHOOTING INSTRUCTIONS. After LED testing, CHARGING LED turns on along with POWER LEVEL LED s to indicate power module capacity. Charger POWER LEVEL LED s condition should be the same as power module POWER LEVEL LED s. The CHARGING LED should be on. Now the charger should be on to charge. Initially test LED s by turning on each LED in sequence 9

10 Charger LED s indicator Power module and 2: POWER LEVEL should match with charger 0.0 During charging, charger and power module POWER LEVEL LED s keep updating until the battery is fully charged, 3 LED s on..0 Charging process takes approximately 4 hours to complete. Once CHARGE COMPLETE LED turns on, power modules are fully charged and ready to use. 2.0 Turn off AC switch. 3.0 Disconnect the charger cables. 0

11 LOW POWER MODULE CHARGING INSTRUCTIONS: 4.0 If the power modules have been stored for a long time, the capacity may be very low due to power module has discharged by itself. Check the capacity by pushing STATUS SWITCH button. If none of the LED s turns on that means the power module is completely drained. Push button to check capacity 5.0 Connect charger cable to the power module CHARGER INPUT connector. 6.0 Picture below shows POWER LEVEL 25% LED on that indicates no power module present. The charger can be activated by pushing button switch, and once activated, will normally continue until the power module is fully charged. Indicate no power module connecting to charger Manually enable charger by pushing button switch 7.0 The charger continues charging process until the power module is fully charged.

12 ALARM INSTRUCTIONS: 8.0 During charging process the charger monitors condition of the power modules and charger itself. If any conditions below occur, turn off charger and call service department. LED Display LED Conditions Problem Action POWER LEVEL LED 25% is on POWER LEVEL LED s are flashing Charger can t sense the presence of the power module. The power module may be completely drained or has bad control board. Power module has problem:. Over heating 2. Bad cell.check power module capacity by pushing STATUS SWITCH button. If none of LED is on, the power module is completely drained. 2.Activate the charger by pushing button switch. 3.If the charger still doesn t sense the power module that means the power module control board is bad. The power module needs to repair..turn off charger and disconnect the charger cable 2.The power module needs to repair or replace. CHARGING AND CHARGE COMPLETE LED are flashing Charger has problem:. Over voltage charge 2. Over heating 3. Malfunction.Disconnect the charger cable from the power module 2.Do not turn off the charger. The fan will cool down the charger if over heating occurred. 3.If the charger is latched that means the charger is bad. It needs to repair or replace. 4.If the charger comes back to normal operation that means the charger is momentary over heating or malfunction. 5.If this event repeats frequently, do not use the charger. It needs to repair or replace. 2

13 TROUBLESHOOTING INSTRUCTIONS: 9.0 No DC output or all LED s are not on. 9. Unplug the charger and make sure connections are secure. 9.2 Check for wall outlet for power. 9.3 Check fuse inside the AC inlet fuse box Fans are not on. 20. Clean and vacuum dust Look for any wire or object stuck inside Bad fan. 2.0 LED is not on 2. Bad LED 22.0 Other problems, contact T3 Motion service department at CHARGING POWER MODULES IN VEHICLE INSTRUCTIONS: 23.0 Turn off power breaker in glove box Use the same procedure as above to charge the power modules. See OPERATING INSTRUCTIONS. 3

14 Power modules in vehicle Setup charging in vehicle 25.0 If you have any problem, contact T3 Motion service department at