EG4 ELECTRONICS 100A 48VDC 5KW AC Charger User Manual
- October 30, 2023
- EG4 ELECTRONICS
Table of Contents
USER MANUAL
EG4 CHARGEVERTER
5KW AC CHARGER
100A 48VDC
Version 1.2.1 – Information subject to change without notice.
ABOUT THIS MANUAL
Purpose
This manual describes the assembly, installation, operation and
troubleshooting of this unit.
Please read this manual carefully before installation and operation.
Scope
This manual provides safety and installation guidelines as well as information
on tools and wiring.
SAFETY INSTRUCTIONS
WARNING: This section contains important safety and operating instructions. Read and keep this manual for future reference.
- Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all appropriate sections of this manual.
- CAUTION – To reduce risk of injury, charge only deep-cycle, lead acid, or Li-Ion type rechargeable batteries. Other types of batteries may burst, causing personal injury and damage.
- Do not disassemble the unit. When service or repair is required, take it to a qualified service center. Incorrect re-assembly may result in a risk of electric shock or fire.
- To reduce risk of electric shock, disconnect all wiring before attempting any maintenance or cleaning. Turning off the unit will not reduce this risk.
- CAUTION – Use extreme care when attaching this device to a battery.
- NEVER charge a frozen battery.
- Be very cautious when working with metal tools on or around batteries. A potential risk exists for a dropped tool to spark or short circuit batteries or other electrical parts causing a fire.
- Please strictly follow installation procedure when connecting or disconnecting DC terminals. Please refer to installation section of this manual for details.
- Breaker is required as overcurrent protection for the power supply.
- GROUNDING INSTRUCTIONS -This charger should be connected to a permanent grounded wiring system. Be sure to comply with local requirements and regulation when using this charger.
- NEVER short DC inputs.
- Warning!! Only qualified personnel are able to service this device. Please contact the tech department of the distributor where you purchased your product for assistance with any issues.
DISCLAIMER
EG4 reserves the right to make changes to the material herein at any time
without notice.
You may refer to the EG4 website at
www.eg4electronics.com for the most updated
version of our manual.
PRODUCT OVERVIEW
- Power indicator
- Charging indicator
- Function button – ESC
- Function button – UP
- Function button – DOWN
- Function button – ENTER
- LCD display
- Battery breaker
- Holding bracket
- AC line input
- Prewired 250V, 30A, twist-lock plug 11a. Plug pinout
- Positive battery cable input
- Negative battery cable input
Other Common 30A 120V Plug Pinouts
Warning!! Plug pinouts are provided as an example. Please seek guidance from a qualified professional before making any modifications.
INSTALLATION
Unpacking and Inspection
Before installation, please inspect the unit. Be sure that nothing inside the
package is damaged.
You should have received the following items inside of the package:
- The unit × 1
- User manual × 1
- Screws × 4
Mounting the Unit
Consider the following points before selecting where to install:
- Do not mount the charger on flammable construction materials.
- Mount on a solid surface
- Install this charger at eye level or a location that allows the LCD display to be easily viewed.
- The ambient temperature should be between 0°C and 55°C to ensure optimal operation.
- The recommended installation position is to be attached to the wall.
- Be sure to guarantee room for sufficient heat dissipation and to have enough space for wires.
**SUITABLE FOR MOUNTING ON CONCRETE OR OTHER NON-COMBUSTIBLE SURFACE ONLY.**
Install the unit by securing with four M4 screws.
Warning: Ensure battery breakers and/or battery on/off switches are in the off position and the charger is not plugged in while installing battery charging cables.
AC and DC Connections
- Connect battery cables to the battery terminals or bus bars using appropriate size bolts.
- Ensure charger cable ring terminals are attached to the battery terminals/bus bar of the proper polarity and tightened to the proper torque specifications.
- For 240V usage, plug the charger into a 250V 30A twist lock receptacle with a dedicated 30A breaker.
- For 120V usage, plug the charger into a 125V 30A receptacle with a dedicated 30A breaker.
An additional adapter cable (sold separately) will be required.
OPERATION
Power ON/OFF
- Ensure that the battery cables are securely connected.
- Plug the charger into an outlet of the proper voltage and amperage.
- Turn on battery breakers and/or battery on/off switches.
- Turn on the built-in battery breaker on the front of the unit.
- The unit will begin charging and work normally if properly connected.
Note: If battery voltages are zero, complete step 2 (plugging in the unit) after step 4, to ensure batteries do not go into fault mode.
Operation and Display Panel
The operation and display panel, shown in the chart below, is located on the
front panel of the AC charger. It includes two indicators, four function keys
and an LCD display, indicating the operating status and input/output power
information of the unit.
LED Indicator
| LED Indicator | Messages |
|---|---|
| POWER | Green |
| CHG | Green |
| Flashing | Battery is charging. |
Function Keys
| Function Key | Description |
|---|---|
| ESC | To exit setting mode |
| UP | To go to previous selection |
| DOWN | To go to next selection |
| ENTER | To confirm the selection in setting mode or enter setting mode |
LCD Setting
Press the “ENTER” button on the front of the unit to enter the settings mode.
Press “UP” or “DOWN” button to select setting programs. Press “ENTER” button
to confirm the selection or “ESC” button to exit.
Setting Programs:
| Program | Description | Selectable option |
|---|---|---|
| Program 1 | Charging voltage | Setting range is from 43V to 57V |
| Program 2 | Charging current | Setting range is from 0A to 100A |
SPECIFICATIONS
Charger Output Specifications
Battery Voltage| 48Vdc nominal
Charge Current (adjustable)| 0-100A (50A at 120V)
Charge Voltage (adjustable)| 43-S7dc (default 54Vdc)
Max Output Watts| 5120W at 24OVac, 3050W at 120Vac
Max Efficiency| 94% at 240Vac, 92% at 120Vac
AC Input Specifications
AC Input Voltage Range| 90-264Vac
AC Frequency| 50-60Hz
Maximum Input Amps| 26A at 24OVac, 28A at 120Vac
Environmental Specifications
Operating Temperature Range| 14°F to 131°F (-10°C to 55°C)
Storage Temperature Range| 5°F to 140°F (-15°C9‘,60°C)
Humidity| 5% to 95% relative humidity (non-condensing)
Rating| IP21
Operating Altitude| 01500 m (04921 ft.)
Physical Specifications
Dimensions HxWxD| 4.5 x 13.8 x 4.7 in. (11.5 x 35.0 x 12.0 cm)
Net Weight| 16.4 lbs. (7.4 kg)