Enerdrive ePOWER DC2DC User manual

Owner’s Manual
Enerdrive ePOWER DC2DC Battery Charger Owner’s Manual (Rev. 2.02) February 2016

Table of Contents
1. INTRODUCTION 4
2. WARNINGS 6
3. PRODUCT DESCRIPTION 8
4. UNDERSTANDING THE UNIT 9
Multistage Charging Process 9
Smart Charging Feature 9
Battery Charger Voltage 10
Battery Bank Size Recommendation 11
5. INSTALLING THE CHARGER 12
Mounting The Charger 13
6. CONNECTING THE CHARGER 14
Chassis Grounding Connection 14
DC Output Wiring 14
DC2DC Battery Charger Connections 15
Recommended Cable Length, Size And Fuse Protection 16
Standard Temperature Sensor Connection 16
Optional Remote Display Connection 16
Battery Wiring: Connecting The Batteries The Right Way 17
7. UNIT OPERATION 18
Understanding The Charging Mechanism 18
Operating From An Alternator (CH3) 18
DC Input (CH2 - Solar / PV) 20
Enerdrive ePOWER DC2DC Battery Charger Owners Manual (Rev. 2.02)
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Understanding The Display And Function Keys During Normal Operation 21
Understanding The Function Key ‘MENU’, ‘SET’ And ‘SEL’ During Charger Setting 22
Digital Display 23
Button Functions 23
Automatic Override Function 24
Programming Your Charger 24
Understanding The Three-Stage (Mode 3) Charging 24
Understanding The Battery Temperature Functions 24
Procedure To Set Or View Charger Setting 25
Procedure To Equalise Flooded Batteries 26
Understanding The Protection Features 27
Charging A Dead Battery 27
Understanding The Display Codes 27
8. SPECIFICATIONS 30
9. WARRANTY 31
Two Year Limited Warranty 31
Return and/or Repair Policy 31
Limitations 31
10. Appendix A1 32
11. Appendix A2 34
12. Appendix A3 36
Notes (Record Your Serial Number) 38
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1. INTRODUCTION
Thank you for purchasing the Enerdrive ePOWER DC2DC Battery Charger. With our state
of the art, easy to use design, this product will oer you reliable service for providing a
multistage, multi-input battery charger to charge the dierent types of batteries you have
installed in either your home, boat, caravan, 4WD or commercial vehicle. This manual will
explain how to use this unit safely and eectively.
Please Keep This Manual For Future Reference
For safe and optimum performance, the Enerdrive ePOWER DC2DC 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 responsibility for errors or omissions. Note the specications and
product functionality may change without notice.
Important Note
Please be sure to read the entire manual before using your Enerdrive ePOWER DC2DC Battery
Charger. Misuse may result in damage to the unit and/or cause harm or serious injury. Read
manual in its entirety before using the unit and save manual for future reference.
Product Numbers
ePOWER DC2DC Battery Charger Series
Product Number Product Description
EN3DC30 ePOWER DC2DC Battery Charger 12V / 30Amp
*ePOWER DC2DC Battery Charger Owners Manual Rev. 2.02. This Manual applicable to all units with serial number
prex EN.
Service Contact Information
ENERDRIVE PTY LTD
Unit 11, 1029 Manly Road Tingalpa, Queensland, Australia 4173
Ph: 1300 851 535 / Fax: [phone]
Email: [e-mail]
Web: www.enerdrive.com.au
Enerdrive ePOWER DC2DC Battery Charger Owners Manual (Rev. 2.02)
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Notice of Copyright
Enerdrive ePOWER DC2DC Battery Charger owner’s manual © 2015 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, Unit 11, 1029 Manly Road
Tingalpa, Queensland, Australia 4173. 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 specically agreed to in writing, Enerdrive Pty Ltd: makes no warranty as to the
accuracy, suciency 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 tness 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
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2. WARNINGS
Please read and follow the instructions and precautions carefully.
This section contains important safety information for the Enerdrive ePOWER DC2DC Battery
Charger. Each time, before using the Enerdrive ePOWER DC2DC Battery Charger. READ ALL
instructions and cautionary markings on or provided with the DC2DC Battery Charger, and
all appropriate sections of this guide.
CAUTION
This unit is intended for indoor use ONLY. It is not suitable for installation in an under
bonnet vehicle application and such application will void warranty.
Battery Charger contains no user serviceable parts. See Warranty section for how to
handle product issues.
Do not install the Enerdrive ePOWER DC2DC battery charger in any vehicle engine bay
or conned area where heat build up may occur.
WARNING: Shock Hazard.
Keep Away From Children!
Avoid moisture ingress. Never expose the unit to snow, water, etc..
WARNING: Fire &/or Chemical Burn Hazard!
When charging batteries they can release explosive and corrosive gasses / chemicals.
Please wear safety glasses and protective clothing including gloves when working around
batteries
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 or used by children.
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WARNING
Explosion Hazard!
DO NOT use the Enerdrive ePOWER DC2DC Battery Charger in the vicinity of ammable
fumes or gases (such as gas bottles).
AVOID covering the ventilation openings. 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 May 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 specic 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 re near
the system.
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.
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3. PRODUCT DESCRIPTION
The Enerdrive ePOWER DC2DC Battery Charger is a multistage, multi-input battery charger
to charge dierent types of batteries commonly installed in either boat’s, caravan’s, 4WD’s
or commercial vehicle’s.
Enerdrive’s ePOWER DC2DC Battery Charger package includes the following items;
1 x ePOWER DC2DC Battery Charge
1 x Battery Temperature Sensor
7.5 Meter Cable)
1 x Owner’s manual Rev 1
Enerdrive ePOWER DC2DC Battery Charger Owners Manual (Rev. 2.02)
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4. UNDERSTANDING THE UNIT
The Enerdrive ePOWER DC2DC Battery Charger is a fully automatic multistage, multi input
battery charger with the ability to charge from either an alternator linked to a battery; or via
solar power with the in built Maximum Power Point Tracking (MPPT) Solar Controller. With two
inputs available, the house battery will be charged from either the engine while underway,
or via the solar panels when stationary. The process to choose either engine or solar is fully
automatic and both functions are controlled from within the unit itself without the need for
external relays.
During normal operation the ePOWER DC2DC Battery Charger will do a full charge cycle to
oat stage on the house battery bank with ability to choose either GEL, AGM, Flooded, Custom
Programmable or Lithium. Once oat stage is reached the charger transitions to a power supply
mode to support any on-board DC loads.
Multistage Charging Process
The ePOWER DC2DC Battery Charger is a fully automatic, set and forget charger. It is designed
to quickly and accurately recharge your deep cycle batteries utilising charger algorithms that
help to maximise the life of your specialised deep cycle batteries.
The ePOWER DC2DC Battery Charger features multistage smart charging technology that
enables the charger to be connected to your battery banks permanently. With the input of
multiple sources, you can be assured of charging your batteries whenever underway; or when
the sun is shining on your solar array.
As dictated by battery manufacturer’s recommendations, deep cycle batteries require a
multistage charge sequence for perfect, fast and accurate charging. The Enerdrive ePOWER
DC2DC smart charger delivers three primary charge stages.
Stage 1 – Bulk or Boost charge; The battery is charged at full rated output current of the
charger until the battery reaches its nal charging voltage, known as its absorption voltage.
In this step, around 80% of the battery is recovered as fast as possible.
Stage 2 – Absorption Charge; With the charger voltage held steady, the remaining 20% is
replaced with the charger allowing the current to taper o as the battery approaches full charge.
Stage 3 – Float; Finally, in the oat stage the charger voltage is lowered and held at a constant
and safe predetermined level. This prevents the battery from being overcharged, yet allows
the charger to supply enough current to make up for the self-discharge losses of the battery,
while supporting any additional loads connected to the battery (such as DC lighting and
refrigerators). This stage allows for the charger to be used as a DC power supply.
Smart Charging Feature
The ePOWER DC2DC Battery Charger will regulate its output based on the loads connected
to your battery banks. This function is important to maintain the life of your battery banks as
some battery chargers mistake loads for discharge and continue to keep the batteries in the
bulk or absorption stage for extended periods of time, which will damage the battery bank.
The ePOWER DC2DC Battery Charger has two methods of load based regulation to ensure
your battery charger transitions to oat when it should do so.
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ePOWER charger algorithm
Battery Charging Curve For GEL, AGM, Flooded & Program Batteries:
CHARGE
CURRENT
V out ≥ V abs
for 1 min
V out ≥ V abs
for 1 min I out < 10% I rating
for 1 min
If V out < 12.5 Vdc
for 15 min
BULK
CV ABS timeout 5 hr
Total ABS timeout 8 hr
FLOAT BULK
TIME
CC
ABS CV ABS
Battery Charging Curve (Current) Battery Charging Curve (Voltage)
Note: Actual voltages depend on chosen algorithm.
Battery Charger Voltage
Battery Type Absorption Float Equalisation
GEL 14.4 V 13.7 V N.A.
AGM 14.7 V 13.6 V N.A.
Flooded 14.4 V 13.3 V 15.5 V (See Note1)
Lithium Constant 14.2 V, 14.3 V, 14.4 V (See Note2) N.A
Program (Custom
Settings) 13.8V-14.8 (0.1V Step) 13.0V-13.8 (0.1V Step) N.A
* For Concorde™ branded batteries (lifeline, sun xtender) use ooded setting and consult battery
supplier for equalisation recommendations.
Note 1: Equalisation setting can only be used on ooded battery type selection only. See
more details on Procedure to Equalise the Flooded Battery.
Note 2: Charger will terminate charging when charging current drops to below the set
charger termination value.
(Battery
recharge in Bulk
mode)
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Note 3: Charger is acting as a power supply with selected constant output voltage and
preset maximum output current.
NOTE: The equalisation function although included in the ePOWER DC2DC will rarely be
used. To activate the battery bank must be in oat, and manually activated. A typical drive
will not be long enough for the DC2DC function to complete the process. The MPPT Solar
function may provide enough time for Equalisation, but the best recommendation will be
an AC powered battery charger.
Battery Bank Size Recommendation
The battery charging current rating is based on the battery size. The battery bank should
meet the minimum Ah rating as shown. If a smaller size battery bank is used, set the current
rating to a lower value to match with the battery bank size. Normally, the minimum battery
bank capacity is based on a C5 rating of the battery for charging.
EN3DC30
Current Setting 5A 10A 20A 30A
Battery Capacity Min 25Ah Min 50Ah Min 100Ah Min 150Ah
EN3DC30 (Current Setting)
Bulk 30A 20A 10A 5A
ABS-Float 1.5A/ 3A/ 6A 1.0A / 2A / 4A 0.5A/ 1A/ 2A 0.3A/ 0.5A/ 1A
Note: Use the above table to set the Bulk and its related Absorption (ABS) to Float Charge Current.
Unit Setting for Lithium Type Battery (Voltage and Current):
Lithium Voltage Setting : 13.9 – 14.4 (0.1V Step) - EN3DC30 (Current Setting)
Charge Current 30A 20A 10A 5A
Terminate Current 1.5A/ 3A/ 6A 1.0A / 2A / 4A 0.5A/ 1A/ 2A 0.3A/ 0.5A/ 1A
Note: The return to charge voltage setting for Lithium Type battery is set to 13.3Vdc
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5. INSTALLING THE CHARGER
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 or loss
of life.
CAUTION
Before Installing The Unit Consider The Following:
This unit is designed ONLY for internal mounting and should be used or stored in an
indoor area away from direct sunlight, heat, moisture or conductive contaminants.
DO NOT INSTALL IN VEHICLE ENGINE BAY
This is an electronic device cooled by a fan, and will prematurely fail if installed in corrosive
/ moisture rich environments.
When placing the unit, allow a minimum of 75mm of space around the unit for optimal
ventilation.
NOTE
The Enerdrive ePOWER DC2DC Battery Charger is designed to be permanently mounted.
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Mounting The Charger
• Choose an appropriate mounting location.
• For installing in an indoor location, the unit should be mounted vertically (with the
battery terminals facing downwards). This provides the best thermal performance and
drip protection. The unit should NOT be mounted upside down.
• For installing in a boat or marine environment, the unit should only be mounted vertically
(Battery Terminals facing downwards only) to provide adequate drip protection.
• Use the base of the charger as a mounting template to mark the positions of the xing
screws.
• Drill the 4 xing holes and place the Charger in position and fasten the unit to the mounting
surface.
119 mm 55mm
160mm
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6. CONNECTING THE CHARGER
Chassis Grounding Connection
NOTE
This Charger SHOULD BE CORRECTLY GROUNDED.
The unit chassis has a stud point on it for grounding. Connect the unit’s chassis ground to
the common ground point through the ground stud located near one of the unit mounting
slots. (Battery DC negative is the best ground reference point in your installation) .
Failure to do so may result in poor charger performance or possible injury.
DC Output Wiring
WARNING: Correct DC Wiring Is Required
The DC wiring used must be of appropriate size.
An individual fuse or breaker is required to be installed within 20cm of the both the start
battery and house battery bank.
A DC isolator or fuse is also recommended for the solar input.
All devices must be rated for DC voltage and current.
The solar input fuse or breaker must be able to withstand the short circuit current rating
stated on the solar panel array.
All wiring must conform or exceed the recommendations stated in this manual (page 16).
This is a Dual Input device. Dierent cable sizes are required for the alternator input,
solar array input and the DC2DC charger to battery connection.
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DC2DC Battery Charger Connections
SOLAR INPUT SOLAR INPUTBATTERY INPUT BATTERY INPUT BATTERY OUTPUT BATTERY OUTPUTIGNITION
Battery
Temperature
Sensor Port
Unit Ground
Remote Display
Port
(Remote Display
Sold Separately)
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Start Battery House BatterySolar Array
CH2 CH1CH3

Recommended Cable Length, Size and Fuse Protection.
DC2DC Connection
Inputs
Require Length & Battery Cable Size
< 1.5 Meters 2) 2 Meters to 5
Meters 3)
Up to 10
Meters 3)
Greater than
10 Meters 3)
From Alternator Battery 10mm2 @ 12vdc
/ 6mm2 @ 24vdc
10mm2 @ 12vdc
/ 6mm2 @ 24vdc
16mm2 @ 12vdc
/ 8mm2 @ 24vdc
25mm2 @ 12vdc
/ 16mm2 @
24vdc
From Solar Panels 1) 4mm2 per solar
panel installed
4mm2 per solar
panel installed
4mm2 per solar
panel installed
4mm2 per solar
panel installed
Primary Battery
Connection 2) 10mm2 16mm2 Not Recommended
Not
Recommended
Note: Cable size quoted is one way from battery to device, however suggested cable size is calculated with return run.
1) Note: If solar panels are wired in Series (increased voltage), then typically 1 x 4mm2 cable run per series string
is suitable.
2) Based on 3% voltage drop.
3) Based on 10% voltage drop.
Recommended Fuse Protection
From Alternator Battery 50amp Maxi Fuse or Circuit Breaker no greater than 20cm from source
battery.
From Solar Panels
Fusing recommended no greater than 20cm from input to DC2DC
Charger. Typically 15amps per solar panel (consult your panel
specications for further details).
Primary Battery
Connection 40amp Maxi Fuse or Circuit Breaker.
Standard Temperature Sensor Connection
• To install the temperature sensor, simply connect the RJ12 plug from the sensor to the
RJ12 Temperature Sensor Port located next to the Remote Port.
• On the temperature sensor end, simply connect the ring terminals to the negative terminal
of the main house battery bank.
Optional Remote Display Connection
To install the optional Remote Display in a specic location, a 6 pin standard RJ12 cable
(maximum length 7.5 meters) is required.
• Install the standard RJ12 cable in your desired location.
• Connect one end of the RJ12 cable to the Remote Port and the other end of the cable to
the Display Panel. Please note polarity.
• The Remote Display is now ready for use.
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Battery Wiring: Connecting The Batteries The Right Way
(Optional Ignition - On)
VSO
(Voltage Sense Override)
Optional Remote Display
(Sold Separately)
Remote Cable
(Sold Separately)
Anderson Plug (Optional)
MPPT Solar Panel Input
Max: 500w / 45VOC
(For xed or portable panels)
Start / Vehicle Battery
12V or 24V
Fuse / Breaker
12V - 50A
24V - 25A
Fuse Size 1A
Fuse / Breaker Fuse / Breaker
40A
Temp Sensor Cable
(Included)
12V House Battery Bank
This diagram is for a referance only. No cables, fuse/breakers, batteries or solar panels are supplied with this unit.
Local rules and regulations should be followed when installing this unit.
POSITIVE WIRE NEGATIVE WIRE TEMPERATURE SENSOR
CABLE (INCLUDED)
REMOTE CABLE
(SOLD SEPARATELY)
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7. UNIT OPERATION
Understanding The Charging Mechanism
Note 1: The Charger is powered by the battery connected to DC Output (CH1) and also
supplied by CH2 or CH3 if available. The display will turn o to save power when Input
Channel CH2 and CH3 are out of operating range.
Operating from a Start Battery / Alternator (CH3)
Normal Operation: Input Battery / Source
12V Input 24V Input
Input Voltage Range 10.5V – 16.0V 21.0– 32.0V
Normal Start-Up Voltage (Note A) > 13.2V > 26.4V
Normal Under Voltage Recovery Voltage (Note A) > 12.8V > 25.6V
Ignition Start Terminal
> 10.5V forces Ch3 input to the Low
Start-Up and Low-Under Voltage
recovery settings.
Low Start-Up Voltage (using Ignition Start Terminal or
using Manual Over-ride setting) (Note B) > 12.3V > 24.6V
Low Under Voltage Recovery Voltage (Note B) > 12.0V > 24.0V
De-Rated Voltage (with load) (Note C) 11. 5V 23.0V
Under Voltage Shutdown (with load) 10.5V 21.0V
Over Voltage Shutdown 16.0V 32.0V
Over Voltage Recovery 15.5V 31.0V
Input Battery System Reset Voltage (NoteC) < 7V < 7V
Maximum Input Current - EN3DC30 30A 30A
Note A:
When the battery is charging through CH3 with normal operation (not through Ignition
or override setting), the charger will charge for 3 minutes, it will then rest for 5 seconds to
verify the Input voltage.
During the 5 seconds rest period, if the measured voltage is > Normal Under Voltage Recovery
Voltage (> 12.8Vdc on a 12V system or > 25.6Vdc on a 24V system), the unit will continue the
charging cycle through CH3.
Or if the measured voltage is < Normal Under Voltage Recovery Voltage (< 12.8Vdc on a 12V
system or < 25.6Vdc on a 24V system), the unit will switch back to charge from CH2 (PV) until
CH3 returns to Normal Start-Up Voltage (13.2V on a 12V System and 26.4V on a 24V system).
Also, during the 3 minutes charging process, if the measured terminal voltage drops below
Enerdrive ePOWER DC2DC Battery Charger Owners Manual (Rev. 2.02)
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the Under Voltage de-rated voltage (11.5V for a 12V system, 23V for a 24V system), the charger
will start to derate the output current. This function is used to compensate the use of long
or thin wire between the Input Battery System and the unit terminals. If the input voltage
continues to drop below the Under Voltage Shutdown Voltage (10.5V for a 12V system and
21V for a 24V system), the charging process will terminate and the unit will switch back to
charge from CH2 (PV). It will only switch back to CH3 if the CH3 voltage returns to 13.2V on
a 12V system or 26.4V on a 24V system.
Note B:
When the unit has activated the battery charging process using the Ignition Start terminal
or using the Manual Override through the unit setting, the input voltage specication is
reduced. It has the same charging process but with the Low Start-Up Voltage set to > 12.3V
(from 13.2V) on a 12V system and > 24.6V (from 26.4V) on a 24V system. The Low Under
Voltage Recovery Voltage is set to > 12V (from 12.8V) on a 12V system and > 24V (from 26.4V)
on a 24V system. During the 5 second rest period, if the input voltage returns above 12V/24V,
it will continue the charging process and if the input voltage did not return to > 12V/24V, it
will switch back to charge from the Solar - CH2 until the Start - CH3 input has returned to
the Low Start-Up voltage of 12.3V on a 12V system and 24.6V on a 24V system..
Also, during the 3 minutes charging process, if the measured terminal voltage drops to
below the Under Voltage de-rated limit (11.5V for a 12V system, 23V for a 24V system), the
charger will start to de-rated the charger current, this function is used to compensate the
use of long or thin wire between the Input Battery System and the unit terminals. If the
voltage continues to drop, and drops to below the Under Voltage Shutdown limit of (10.5V
for a 12V system and 21V for a 24V system), the charging process will terminate and the unit
will switch back to charge from CH2 (PV). It will only switch back to CH3 if the CH3 voltage
returns to 12.3V on a 12V system and 24.6V on a 24V system.
Note C:
The CH3 DC Input (Battery Input) can accept a 12V or 24V battery with an alternator system.
When the unit is rst connected, the unit will measure the input voltage. If the voltage is >
17V, it will assume it is connected to a 24V Input Battery/Alternator system. If the voltage
detect is < 17V, it will assume it is connected to a 12V Input Battery/Alternator system. Once
detected, it will store this into the microprocessor and it will only be erased if it is Input
battery is disconnected or if the measured Input Voltage drops to < 7Vdc.
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DC Input (CH2 – Solar / PV):
PV Input Voltage Range 14.5 - 45V
PV Input Under Voltage Shutdown 14.5V
PV Input Under Voltage Recovery 15.0V
PV Input Over Voltage Shutdown 45V
PV Input Over Voltage Recovery 44V
PV Charging Mechanism MPPT type ( approx. 97% eciency)
Maximum Input 500W *See note
*Note: The recommended maximum solar wattage input for the DC2DC Charger is 500w.
You can however “overdrive” the MPPT controller. Please note that doing this is partially
an economic decision. You can install more power than the controller can use and this will
contribute to better power availability. Enerdrive suggest a total maximum overdrive of
20% (total 600w). On cloudy (or intermittent sunny) days there will be little or no power
shaving and the extra power will serve the battery well with more energy harvest earlier
and later in the day.
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