Enerdrive EPI-2430 ePOWER Industrial Multi Stage Battery Charger Owner’s Manual

Ener drive EPI-2430 e POWER Industrial Multi Stage Battery Charger Owner’s Manual

PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE

For safe and optimum performance, the Ener drive e POWER Industrial Battery Charger must be used properly. Carefully read and follow all instructions and guidelines in this manual and give special attention to the CAUTION and WARNING statements.

Disclaimer L
While every precaution has been taken to ensure the accuracy of the contents of this guide, Ener drive assumes no rres ponsibilty for error or omissions. Note as well specifications and product functionality may change without notice.

Important
Please be sure to read and save the entire manual before using your Enerdrive ePOWER Industrial Battery Charger. Misuse may result in damage to the unit batteries and/or cause harm or serious injury. Read manua in its entirety before using the unit and save manual for future reference.

Product Numbers POWER Industrial Battery Charger Series

POWER Industrial Battery Charger Owner’s Manual 1.7. This manual applicable to all units with serial number prefix EPI.

Service Contact Information

Service Contact Information
Dometic Power & Control (Enerdrive) Pty Ltd
P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178
Ph: 1300 851 535 / Fax: 07 3390 6911
Email: sales@enerdrive.com.au
Web: www.enerdrive.com.au

NOTICE OF COPYRIGHT

Ener drive e POWER Industrial Battery Charger owner’s manual © 2021 Dometic Power & Control (Ener drive) Pty Ltd. All rights reserved. No part of this document may be reproduced in any form or disclosed to third parties without the express written permission of Dometic Power & Control (Enerdrive) Pty Ltd, P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178. Ener drive reserves the right to revise this document and to periodically make changes to the content hereof without obligationor organization of such revisions or changes, unless required to do so by prior arrangement.

Exclusions For Documentation And Product Usage
Unless specifically agreed to in writing, Enerdrive Pty Ltd: makes no warranty as to the accuracy, sufficiency or suitability of any technical or other information provided in its manuals or other documentation.

Assumes no responsibility or liability for losses, damages, costs or expenses, whether special, direct, indirect, consequential or incidental, which might arise out of the use of such information. The use of any such information will be entirely at the user’srisk.

Reminds you that if this manual is in any language other than English although steps have been taken to maintain the accuracy of the translation, the accuracy cannot be guaranteed.

Makes no warranty, either expressed or implied, including but not limited to any implied warranties of merchantability or Fitness for a particular purpose, regarding these Enerdrive products and makes such Enerdrive products available solely on an “as is” basis.

Shall in no event be liable to anyone for special, collateral, incidental, or consequential damages in connection with or arising out of purchase or use of these Enerdrive products. The sole and exclusive liability to Enerdrive, regardless of the form of action, shall not exceed the purchase price of the Enerdrive products described here in.

INTRODUCTION

Thank you for purchasing the Enerdrive ePOWER Industrial Battery Charger. With our state of the art, easy to use design, this product will offer you reliable service for providing a multistage battery charger to charge the different types of batteries you have installed in applications such as electric vehicles, fork lifts, floor cleaning machines, golf carts, and electric mobility scooters. This manual will explain how to use this unit safely and effectively. Please read and follow these instructions and precautions carefully.

IMPORTANT SAFETY INFORMATION:

This section contains important safety information for the Enerdrive e POWER Industrial Battery Charger. Each time, before using the Ener drive e POWER Industrial Battery Charger, READ ALL instructions and cautionary markings on or provided with the battery charger, and all appropriate sections of this guide. The Enerd rive e POWER Industrial Battery Charger contains no user serviceable parts. Opening up the charger will void product warranty. See Warranty section for how to handle product issues.

  WARNING
FIRE AND/OR CHEMICAL BURN HAZARD

• Do not cover or obstruct any cooling fins and / or install in a zero clearance compartment.

WARNING
SHOCK HAZARD. KEEP AWAY FROM CHILDREN!

• Avoid moisture ingress. Never expose the unit to snow, water, etc.

WARNING: EXPLOSION HAZARD!

• DO NOT use the Ener drive e POWER Industrial Battery Charger in the vicinity of flammable fumes or gases (such as gas bottles or large engines).
• AVOID covering the cooling fins. Always operate unit in an open and well ventilated area.
• Prolonged contact to high heat or freezing temperatures will decrease the working life of the unit

  WARNING

FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH OR SERIOUS INJURY

• When working with electrical equipment or lead acid batteries, have someone nearby in case of an emergency.
• Study and follow all the battery manufacturer’s specific precautions when installing, using andc servicing the battery connected to the charger.
• Wear eye protection and gloves.
• Avoid touching your eyes while using this unit.
• Keep fresh water and soap on hand in the event battery acid comes in contact with eyes. If this occurs, cleanse right away with soap and water for a minimum of 15 minutes and seek medical attention.
• Batteries produce explosive gases. DO NOT smoke or have an open spark or fire near the system.
• Never attempt to re-charge a damaged, frozen or non-rechargeable battery.
• Keep unit away from moist or damp areas.
• Avoid dropping any metal tool or object on the battery. Doing so could create a spark or short circuit which goes through the battery or another electrical tool that may create an explosion.
• Battery charger must be plugged in to an earthed and Australian Standards compliant mains supply. If the units power cable is damaged, replace the cable immediately.

  LIMITATIONS OF USE

• Do not use in connection with life support systems or other medical equipment or devices.
• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision and instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

WARNING

• Enerdrive recommends that all wiring be done by a skilled technician to ensure adherence to the best practice standards for on-board DC electrical installations. Failure to follow these instructions can damage the unit and could also result in personal injury orloss of life.

  CAUTION

• Before Beginning Your Unit Installation, Please Consider The Following:
• The unit should be used or stored in an indoor area away from direct sunlight, heat, moisture or conductive contaminants. Do not install the ePOWER Industrial Battery Charger in corrosive environments.
• When placing the unit, allow a minimum of 75mm of space around the unit for optimal ventilation

PRODUCT DESCRIPTION

The Enerdrive ePOWER Industrial Battery Charger package includes the items listed below.

• ePOWER Industrial Battery Charger
• IEC 240Vac Power Lead
• Waterproofing grommet for power lead
• owner,s manual

INSTALLATION

• This charger is to be installed in a cool and well ventilated location.
• Although certain models are waterproof, it is recommended to install in a dry location.
• When using in a fixed installation use suitable fasteners (screws or bolts) to secure the charger to a solid surface that can handle the weight and forces when the vehicle is moving.

OPERATION ILLUSTRATION

LED Indicators and Fault Signals

LED Indicators during start up:

In order to find out the installed charging profile in the unit please follow the step below.

1. Make sure the DC cables are not connected to the battery.
2. Connect the AC input to the charger and switch on.
3. The charger LED display panel will

LED Indicators and Digital Display:

Charger will enter charging model when connecting to battery & AC input cable. Digital display on the front panel will show in turn: AC XXX (Current AC  in puvoltage), CPU X.XX (corresponding software version number), b**(Current charging profile code).

To change the charging profile, press & hold the Select button for 5 seconds, then press the Select button to choose the desired profile. Once selected, press & hold the Select key for 5 seconds, and the charging profile selection will be completed. To start EQ mode, press & hold the Select button for 10 seconds, and display will show EQ mode. The next charging cycle will go into EQ mode. If you want to quit the EQ mode, hold the Select button for 10 seconds. When display shows OFF, the charger will quit the EQ mode.

Common Mode (Default) & BMS Mode:

A : The charger enters BMS mode when being connected to lithium-ion battery through Can Bus;
B: For safety reason, the charger will fiash “bn S” if being reconnected to Lead-acid battery under a BMS mode;
C: The charger will only charge Lead-acid type battery again if we refresh the charger through USB port with the desired lead acid battery charging profile via USB drive.

Charging Status Indicator and Status Display

• % Capacity Percentage Indicator: Display shows charging percentage. e.g. 10 20 30…100 (%)
• V Charging Voltage Indicator: Display shows charging voltage. e.g. 24.0 (V)
• A Charging Current Indicator: Display shows charging voltage. e.g. 36.0 (V)

Additional Battery Voltmeter Function

• B Battery Voltage Indicator. To check battery voltage, disconnect charger AC input and press “Select” button for 1 second. Display shows battery voltage. e.g. 24.0 (V).

Battery Capacity Indicators:

LED will be showing Battery Charging Profile as below:

LED 1| LED 2 (100% Indicator)| LED 3 (75% Indicator)| LED 4 (50% Indicator)
---|---|---|---
Algorithm 30+| Algorithm 20+| Algorithm 10+| Algorithm 1 – 9

For example:

If the charging profile has been selected to 435, LED 1 will  be on to represent the charging profile is 30, and LED 4 will blink 5 times to indicate algorithm #35, while LED 2 and LED 3 will remain off. lithe charging profile has been selected to 418, LED 3 will be on to represent the charging profile is 10, and LED 4 will blink 8 times to indicate algorithm 418, while LED 1 and LED 2 will remain off.

Connecting the Cables

1. Connect to the positive terminal of the battery
2. Connect to the negative terminal of the battery / BTS3. Connect to the BTS+

4,5,6: Interlock Cable (4,6: NO the interlock cables will form an open circuit with no voltage. 5,6: NC The interlock cable will form a short circuit with no voltage).
Connect CANBUS or LED light wire (optional function).

Warning: Assure the battery connection cable is well connected with the charger before it is connected to the battery. Otherwise, the battery short circuit may occur and cause personal injury or damage to the battery.

WARNING

• Please make sure the battery connection cables are correctly connected to the charger terminals before operating the charger
• Always connect the positive cable to the battery first, then the negative cable to the negative (chassis for B negative grounded vehicles) prior to connecting to supply mains.
• After charging, and when removing charger, always disconnect the battery charger from the supply mains, then disconnect the negative/chassis connection and then the positive connection.
• Supply mains wiring in fixed installs such as caravans or similar vehicles must be in accordance with the national wiring rules.
  

WARNING

• Please make sure the battery connection cables are correctly connected to the charger terminals before operating the charger
• Always connect the positive cable to the battery first, then the negative cable to the negative (chassis for negative grounded vehicles) prior to connecting to supply mains.
• After charging, and when remo vim charger, always disconnect the battery charger from the supply mains, then disconnect the negative/chassis connection and then the positive connection.
• Supply mains wiring in fixed installs such as caravans or similar vehicles must be in accordance with the national wiring.

Images on previous page refer to EPI-2430, EPI-3620, EPI-4815 & EPI-4835

1. Connect to the positive terminal of the battery

2. Connect to the negative terminal of the battery

3. Connect to the Battery Temp Sense (BTS)

4. Interlock Connection – the interlock cable connections provide a normally open or normally closed circuit with no voltage, which change state when the charger is operational.
   4a Normally open
   4b Normally closed
   4c Common

5. USB Terminal for Charge Profile settings

WARNING

• Please make sure the battery connection cables are correctly connected to the charger terminals before operating the charger
• Always connect the positive cable to the battery first, then the negative cable to the negative (chassis for negative grounded vehicles) prior to connecting to supply mains.
• After charging, and when removing charger, always disconnect the battery charger from the supply mains, then disconnect the negative/chassis connection and then the positive connection.
• Supply mains wiring in fixed installs such as caravans or similar vehicles must be in accordance with the national wiring rules.
  

Image refers to EPI-4860

1. AC Input
2. DC Battery Connection
3. Brake Switch Red = Positive Black = Negative White = Temp. Sens When AC has power – open circuit When AC has NO power – closed circuit
4. Charger Switch Open circuit – charger ON Closed circuit – charger OFF
5. Remote LED

MAINTENANCE INSTRUCTIONS

1. Do not expose the charger to oil, dirt, mud or direct heavy water spray when cleaning vehicle.
2. The enclosure of the charger has been tested successfully to EN60529, meeting IP66 compliance.
3. If the detachable AC input power supply cable is damaged, replace witha cable that is a detachable cable,3conductor,1.5 mm² minimum, and rated appropriate for usein the country of destination. ACinputtypetothechargeris,typeIEC60320C14plug.

FAULT INDICATION

WITH LED DISPLAY

When a fault occurs, LED2(100%)/LED3(75%)/LED4(50%)will blink at the same time.

1. Check battery connection is correct.
2. Check charger connection is correct.
3. Check each battery is good.

2.| Abnormal AC Power Input (Voltage)|

1. Check AC input cord is connected between charger and AC outlet.
2. Make sure AC plug is tightly inserted into AC outlet.

3.| Charger High Temperature Protection|

1. Charger shuts down and enters protection mode due to charger/environmental temperature is too high. Please place the charger in a well ventilated environment.
2. Disconnect the charger and wait for 15-20 mins before reconnecting for charging.

4.| Battery High Temperature Protection|

1. Charger will reduce output current and stop charging when the battery temperature exceeds 50°.
2. When the battery temperature drops, the charger will reset automatically.

5.| Output Current is too large| Return to the factory for repair.
6.| Battery Voltage is too high| Check and assure that the correct output battery voltageis connected.

WITH DIGITAL DISPLAY

1. Check battery connection is correct.
2. Check charger connection is correct.
3. Check each battery is good.

**E02 AC| ** Abnormal AC Power Input (Voltage)|

1. Check AC input cord is connected between charger and AC outlet.
2. Make sure AC plug is tightly inserted into AC outlet.

**E03 Hot| ** Charger High Temperature Protection|

1. Charger shuts down and enters protection mode due to charger/environmental temperature is too high. Please place the charger in a well ventilated environment.
2. Disconnect the charger and wait for 15-20 mins before reconnecting for charging.

**E04 bAt| ** Battery High Temperature Protection|

1. Charger will reduce output current and stop charging when the battery temperature exceeds 50°.
2. When the battery temperature drops, the charger will reset automatically.

E05 Err| Internal error in product| Return to the factory for repair.
E06 bAt| Battery Voltage is too high| Check and assure that the correct output battery voltageis connected.

WATERPROOFING INSTALLATION

Waterproof ring installation of the AC input cable.

1. Slip waterproof ring or grommet over the AC input cable
2. Connect the AC input cable into the charger ensuring the waterproofing ring is seated correctly
3. Firmly tighten the waterproofing clamp using a Phillips head screw driver

NOTE: Take care to not overtighten the waterproof clamp.

SPECIFICATIONS

Model:| EPI-2430| EPI-3620| EPI-4815| EPI-4835| EPI-4860
---|---|---|---|---|---
DC Output
Voltage-nom (VDC)| 24V| 36V| 48V| 48V| 48V
Voltage-max (VDC)| 34V| 51V| 68V| 68V| 68V
Current-max (A)| 30A| 20A| 15A| 35A| 60A
Applicable to Battery| AGM, Flooded, GEL, Lithium
Reverse Polarity| Electronic Protection – auto – reset
Short Circuit| Electronic Protection – auto – reset
AC Input
Voltage Range (VAC)| 100 – 240AC| 180 – 240VAC| 220 – 240VAC
Frequency (Hz)| 50 – 60Hz| 50 – 60Hz
Power max (W)| 850W| 1985W| 3400W
Current max (A)| 8.5A| 10A| 15A
Dimensions| 20.7 x 18.0 x 16.0 cm| 19.5 x 18.0 x 19.5 cm| 35.9 x 28.0 x 10.7 cm
Weight| 4.6 kg| 5.2 kg| 10 kg
Operating Temperature| -20C ~ +50C| -20C ~ +50C| -20C ~ +50C
Storage Temperature| -40C ~ +70C| -40C ~ +70C| -40C ~ +70C

IP Rating: IP66 when AC input waterproof ring/grommet is used. See Page 12.

CHARGE PROFILE

Charge Profile Instructions:

Changing the Charge Profile on the Ener drive e POWER Industrial

Charger The e POWER Industrial charger has the ability to be programmed with a charge profile (algorithm) to suit any battery. The default charge profile that comes installed on the charger is b02. This charge profile is suited for Trojan T105 batteries. You can change the charge profile installed on the charger at any time via the USB port on the front of the charger.

NOTE: You will require a formatted (FAT32) USB memory stick with a capacity of 1024KB or larger.

Please carefully follow the steps below to change the charge profile:

1. 1. Download and save the Battery Algorithm Listing from the download link  www.enerdrive.com.au/Algorithm/ePOWER-algorithm.xlsx
2.  Listing” tab in this spreadsheet.
3. Make sure the charger is NOT connected to the battery or AC power.
4. Unscrew the round cap covering the USB port on the front of the charger and insert the USB memory stick.
5. Plug the AC power cord into the charger and switch ON AC power.
6. Please allow up to 1 min for programming. Programming is complete once USB status LED is “SOLID”.
7. Switch OFF AC power to the charger.
8. Remove USB memory stick and screw USB cap back on.

Charge Profile Table:

WARRANTY

5 Year Warranty

In the unlikely event that a technical issue arises with an Ener drive product, customers are encouraged to initially contact the Ener drive Support Team on 1300 851 535 or support@enerdrive.com.au for immediate and eficient expertise and first class product support.

DOMETIC POWER & CONTROL (ENERDRIVE) PTY LTD P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178
Ph: 1300 851 535 / Fax: 07 3390 6911
Email: support@enerdrive.com.au
Web: www.enerdrive.com.au

References

• Enerdrive Independent Power Solutions - ENERDRIVE | DOMETIC

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