Enerdrive Epower Industrial Battery Charger Owner's Manual

Operation & Owner’s Manual
24V, 36V & 48V Models
Rev: 1.6

PLEASE KEEP THIS MANUAL FOR FUTURE REFERENCE
For safe and optimum performance, the Enerdrive ePOWER 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
While every precaution has been taken to ensure the accuracy of the contents of this guide, Enerdrive assumes no
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 the manual in its entirety before using the unit and save the manual for future reference.

Product Numbers – ePOWER Industrial Battery Charger Series

ePOWER Industrial Battery Charger Owner’s Manual 1.6. This manual applies to all units with serial numbers prefix EPI.

Service Contact Information
ENERDRIVE PTY LTD
P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178
Ph: 1300 851 535 / Fax: 07 3390 6911
Email: [email protected] | Web: www.enerdrive.com.au

NOTICE OF COPYRIGHT

Enerdrive ePOWER Industrial Battery Charger owner’s manual © 2020 Enerdrive. 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 Enerdrive Pty Ltd, P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178. Enerdrive reserves the right to revise this document and to periodically make changes to the content hereof without obligation or 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’s risk

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 herein

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, forklifts, 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 ePOWER Industrial Battery Charger. Each time, before using the Enerdrive ePOWER Industrial Battery Charger, READ ALL instructions and cautionary markings on or provided with the battery charger, and all appropriate sections of this guide. The Enerdrive ePOWER Industrial Battery Charger contains no user-serviceable parts. Opening up the charger will void the product warranty. See the 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 Enerdrive ePOWER 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 the 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
• Study and follow all the battery manufacturer’s specific precautions when installing, using, and 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 the 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 into an earthed and Australian Standards compliant mains supply. If the unit’s 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.
• The charger is not to be used by persons with reduced physical or mental capabilities or lack of knowledge and experience. Not to be operated on or used by children.

WARNING

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

OPERATION ILLUSTRATION LED Indicators and Fault Signals

LED Indicators during startup:

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

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

LED Indicators and Digital Display:

Charger will enter charging model when connecting to battery & AC input cable. The digital display on the front panel will show in turn: AC XXX (Current AC input voltage), 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 the 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 the 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 the lithium-ion battery through Can Bus; B: For safety reasons, the charger will flash “bnS” if being reconnected to a Lead-acid battery under a BMS mode;

C: The charger will only charge the Lead-acid type battery again if we refresh the charger through a 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 the “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:

For example;

lithe charging profile has been selected to #35, 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.

if the charging profile has been selected to #18, LED 3 will be on to represent the charging profile is 10, and LED 4 will blink 8 times to indicate algorithm #18, 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 / BTS-
3. Connect to the BTS+
   4,5,6:        Interlock Cable (4,6: NO the interlock cables will form an open circuit withno voltage. 5,6: NC The interlock cable will form a short circuit with no voltage).

   7. 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

WARNING

• Please make sure the battery connection cables are correctly connected to the charger terminals before operating the charger

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

WARNING

• Please make sure the battery connection cables are correctly connected to the charger terminals before operating the charger

Image refers to EPI-4860

MAINTENANCE INSTRUCTIONS

1. Do not expose the charger to oil, dirt, mud, or direct heavy water spray when cleaning the 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 it with a cable that is a detachable cable, 3 conductors, 1.5 mm² minimum, and rated appropriate for use in the country of destination. AC input type to the charger is type IEC 60320 C14 plug. safety approved

FAULT INDICATION WITH LED DISPLAY

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

WITH DIGITAL DISPLAY

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 screwdriver

*NOTE: Take care to not overtighten the waterproof clamp.

SPECIFICATIONS

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

Note: Specifications are subject to change without notices.

CHARGE PROFILE

Charge Profile Instructions:

Changing the Charge Profile on the Enerdrive ePOWER Industrial Charger

The ePOWER 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 charging 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. Download and save the Battery Algorithm Listing from the download link www.enerdrive.com.au/Algorithm/ePOWER-algorithm.xlsx
2. Select a charge profile that matches the batteries you are using from the “Charge Profile Listing” tab in this spreadsheet.
3. Right-click on the selected Charge Profile in the “Charge Profile column and click “Copy”.
4. Now “Paste the copied charge profile to your formatted USB memory
5. Make sure the charger is NOT connected to the battery or AC power.
6. Unscrew the round cap covering the USB port on the front of the charger and insert the USB memory
7. Plug the AC power cord into the charger and switch ON AC
8. Please allow up to 1 min for Programming to be complete once the USB status LED is “SOLID”.
9. Switch OFF AC power to the \
10. Remove USB memory stick and screw USB cap back on.
11. Switch ON AC power to the charger and check the charge profile you selected has been installed. The charger will display the installed charge profile as a series of flashes of the Battery Capacity LED. See the user manual for the explanation.
12. Switch OFF AC power to the charger.
13. Connect the charger to the DC battery.
14. Switch ON the AC power to the charger to begin charging with the installed charge profile.

The ePOWER Industrial charger can also be programmed with a custom (user-defined) charge profile for batteries that are not listed. If you cannot find a suitable charge profile for your batteries please contact Enerdrive.

PLEASE NOTE: AU relevant battery charging specifications MUST be supplied in order for us to be able to create a custom charge profile for you. See the following page for the Charge Profile Table.

Charge Profile Table:

WARRANTY
5 Year Warranty

In the unlikely event that a technical issue arises with an Enerdrive product, customers are encouraged to initially contact the Enerdrive Support Team on 1300 851 535 or [email protected] for immediate and efficient expertise and first-class product support.

Important Note: Consumer Protections
If you have purchased your product in Australia, you should be aware that:
This warranty is provided in addition to other rights and remedies held by a consumer at law. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Enerdrive warrants that its Products will be free from defects in materials and workmanship (subject to limits, and in normal conditions, as described in the complete Enerdrive Warranty Policy) for up to 5 years from the date of purchase. For full terms, conditions, and claim process, refer to the Enerdrive website. https://enerdrive.com.au/warranty/

ENERDRIVE PTY LTD
P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178
Ph: 1300 851 535 / Fax: 07 3390 6911
Email: [email protected]
Web: www.enerdrive.com.au

Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)

References

• Enerdrive Independent Power Solutions - Enerdrive Independent Power Solutions
• Warranty Policy - Enerdrive Independent Power Solutions