Enerdrive ePOWER Series User manual

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

Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (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 followallinstructions and guidelines in this manual and give special attention totheCAUTION and WARNINGstatements.
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 manual in its entirety before using the
unit and save manual for future reference.
Product Numbers - ePOWER Industrial Battery Charger Series
EPI-2430 ePOWER Industrial Battery Charger 24V / 30Amp
EPI-3620 ePOWER Industrial Battery Charger 36V / 20Amp
EPI-4815 ePOWER Industrial Battery Charger 48V / 15Amp
EPI-4835 ePOWER Industrial Battery Charger 48V / 35Amp
EPI-4860 ePOWER Industrial Battery Charger 48V / 60Amp
Service Contact Information
ENERDRIVE PTY LTD
P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178
Ph: 1300 851 535 / Fax: [phone]
Email: [e-mail] | Web: www.enerdrive.com.au
ePOWER Industrial Battery Charger Owner’s Manual 1.6. This manual applicable to all units with serial number prex EPI.
Page 2

NOTICE OF COPYRIGHT
Enerdrive ePOWER Industrial Battery Charger owner’smanual©2020Enerdrive. All rights reserved.No part ofthisdocument
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
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
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
www.enerdrive.com.au Page 3

Table of Contents
1. INTRODUCTION: 5
IMPORTANT SAFETY INFORMATION: 5
2. PRODUCT DESCRIPTION: 7
3. OPERATION ILLUSTRATION: 7
LED INDICATORS DURING START UP: 7
BATTERY CAPACITY INDICATORS: 9
4. CABLE CONNECTIONS:
5. MAINTENANCE INSTRUCTIONS:
11
13
5. FAULT INDICATOR: 14
6. WATERPROOFING INSTALLATION: 16
7. SPECIFICATIONS: 17
8. CHARGE PROFILE: 18
CHARGE PROFILE INSTRUCTIONS: 18
CHARGE PROFILE TABLE: 19
9. WARRANTY: 20
5 YEAR LIMITED WARRANTY: 20
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)Page 4

1. INTRODUCTION
Thank you for purchasing the Enerdrive ePOWER Industrial Battery Charger. With our state
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 product warranty. See
Warranty section for how to handle product issues.
WARNING
FIRE AND/OR CHEMICAL BURN HAZARD
•
WARNING
SHOCK HAZARD. KEEP AWAY FROM CHILDREN!
• Avoid moisture ingress. Never expose the unit to snow, water, etc.
WARNING: EXPLOSION HAZARD!
•
gases (such as gas bottles or large engines).
•
• Prolonged contact to high heat or freezing temperatures will decrease the working life of the unit.
www.enerdrive.com.au Page 5

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.
•
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.
•
• 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.
• 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.
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)
Page 6

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 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.
2. PRODUCT DESCRIPTION
The Enerdrive ePOWER Industrial Battery Charger package includes the items listed below.
• ePOWER Industrial Battery Charger
•IEC 240Vac Power Lead
•
• Owner’s manual
3. OPERATION ILLUSTRATION
LED Indicators and Fault Signals
LED Indicators during start up:
1. Make sure the DC cables are not connected to the battery.
2. Connect the AC input to the charger and switch on.
3.
www.enerdrive.com.au Page 7

LED Indicators and Digital Display:
Common Mode (Default) & BMS Mode:
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 input voltage), CPU X.XX
(corresponding software version number), b**(Current charging prole code).
To change the charging prole, press & hold the Select button for 5 seconds, then press the
Select button to choose the desired prole. Once selected, press & hold the Select key for 5
seconds, and the charging prole 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.
A: The charger enters BMS mode when being connected to lithium-ion battery through Can Bus;
B: . For safety reason, the charger will ash "bnS" 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 prole via USB drive.
%Capacity Percentage Indicator: Display shows charging percentage. e.g. 10 20 30...100 (%)
Charging Status Indicator and Status Display
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).
Additional Battery Voltmeter Function
VCharging Voltage Indicator: Display shows charging voltage. e.g. 24.0 (V)
ACharging Current Indicator: Display shows charging voltage. e.g. 36.0 (V)
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)Page 8

Battery Capacity Indicators:
LED4 LED3 LED2 LED1
Capacity LED2 (100%) LED3 (75%) LED4 (50%)
<50% (Blinking)
>50% (Blinking)
>75% (Blinking)
100%
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;
www.enerdrive.com.au Page 9

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 with
no 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.
Connecting the Cables:
1 2 3 4 5 6
7
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)Page 10

1
234a 4b 4c
5
1
234a 4b 4c
5
www.enerdrive.com.au Page 11

4a
4c
4b
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.
Normally open
Normally closed
Common
Images on previous page refer to EPI-2430, EPI-3620, EPI-4815 & EPI-4835
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)Page 12

Image refers to EPI-4860
AC Input
DC Battery Connection
Brake Switch
Red = Positive
Black = Negative
White =Temp. Sens
When AC has power - open circuit
When AC has NO power - closed circuit
Charger Switch
Remote LED
Open circuit - charger ON
Closed circuit - charger OFF
123 54
4
5
1
2
3
www.enerdrive.com.au Page 13
4. 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 with a cable that is a
detachable cable, 3 conductor, 1.5 mm² minimum, and rated appropriate foruseinthecountryofdestination.
ACinputtypetothechargeris,typeIEC60320C14plug.
safety approved

5. FAULT INDICATION
WITH LED DISPLAY
When a fault occurs, LED2(100%)/LED3(75%)/LED4(50%)will blink at the same time.
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)Page 14
Blinking
Frequency
(every 4 sec)
The battery is not connected or the battery
voltage is too low
1) Check battery connection is correct.
2) Check charger connection is correct.
3) Check each battery is good.
2.
3.
Abnormal AC Power Input (Voltage)
Charger HighTemperature Protection
4. Battery High Temperature Protection
Output Current is too large Return to the factory for repair.
1) Check AC input cord is connected between
charger and AC outlet.
2) Make sure AC plug is tightly inserted into AC outlet.
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.
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.
Battery Voltage is too high Check and assure that the correct output battery voltage
is connected.
6.
Fault Cause Solution

WITH DIGITAL DISPLAY
www.enerdrive.com.au Page 15
Blinking
Frequency
The battery is not connected or the battery
is in reverse or the battery is damaged
1) Check battery connection is correct.
2) Check charger connection is correct.
3) Check each battery is good.
E01 bAt
E02 AC
E03 Hot
E04 bAt
E05 Err
E06 bAt
Abnormal AC Power Input (Voltage)
Charger HighTemperature Protection
Battery High Temperature Protection
Internal error in product Return to the factory for repair.
1) Check AC input cord is connected between
charger and AC outlet.
2) Make sure AC plug is tightly inserted into AC outlet.
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.
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.
Battery Voltage is too high Check and assure that the correct output battery voltage
is connected.
Fault Cause Solution

6. WATERPROOFING INSTALLATION
Waterproof ring installation of the AC input cable.
1. Slip waterproof ring or grommet over the AC input cable
2.
correctly
3.
*NOTE: Take care to not overtighten the waterproof clamp.
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)Page 16

7. SPECIFICATIONS
Model:
Voltage-nom (V)
Voltage-max (V)
Current-max (A)
Applicable to Battery
Reverse Polarity
Short Circuit
Voltage Range (V)
Frequency (Hz)
*IP Rating: IP66 when AC input waterproof ring/grommet is used. See Page 12.
Power max (W)
Dimensions
Weight
OperatingTemperature
StorageTemperature
AGM, Flooded, GEL, Lithium
Electronic Protection - auto - reset
Electronic Protection - auto - reset
100 - 240V 100 - 240V
45 - 65Hz 45 - 65Hz
850W 3400W1985W
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
4.6 kg 5.2 kg 10 kg
-20C ~ +50C -20C ~ +50C -20C ~ +50C
-40C ~ +70C -40C ~ +70C -40C ~ +70C
DC Output
AC Input
EPI-2430
24V
34V
30A 20A 15A 35A 60A
36V
51V
48V 48V
68V 68V
48V
68V
EPI-3620 EPI-4815 EPI-4835 EPI-4860
www.enerdrive.com.au Page 17

8. CHARGE PROFILE
NOTE: You will require a formatted (FAT32) USB memory stick with a capacity of 1024KB or
larger.
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.
4.
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 stick.
7. Plug the AC power cord into the charger and switch ON AC power.
8. Please allow up to 1 min for programming. Programming is complete once USB status LED
is “SOLID”.
9. Switch OFF AC power to the charger.
10.Remove USB memory stick and screw USB cap back on.
11.
Battery Capacity LED’s. See user manual for explanation.
12.Switch OFF AC power to the charger.
13.Connect the charger to the DC battery.
14.
batteries please contact Enerdrive.
PLEASE NOTE:
Enerdrive ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)
Page 18

Algorithm No. Manufacturer Model Batt Type Ah_C20
b38 Custom Setup Custom Setup Custom Custom
b01 Common Flooded 300
b02 Trojan TROJAN T105 Flooded 225
b04 Discover Discover AGM AGM 250
b05 US US battery Flooded Flooded 250
b06 Trojan Trojan 30XHS Flooded 130
b07 Trojan Trojan T125 Flooded 240
b08 Trojan Trojan J305 Flooded 330
b10 Trojan Trojan T145 Flooded 260
b11 Trojan Trojan T1275 Flooded 150
b12 Discover Discover DGC6A-220D AGM AGM 220
b13 Trojan Trojan T605 Flooded 210
b18 Trojan Trojan T875 Flooded Flooded 170
b19 US US2000 Flooded Flooded 216
b20 US US2200 Flooded Flooded 232
b21 US US250hc Flooded Flooded 280
b25 Fullriver Fullriver DC224-6 AGM Flooded 224
b27 Trojan Trojan L16P-AC Flooded Flooded 420
b28 Common Generic 200-370Ah AGM AGM 300
b29 US US.8VGCXC2 Flooded Flooded 170
b30 US US. 12VXC2 Flooded Flooded 155
b31 US US 305XC Flooded Flooded 310
b32 US US 125 XC2 FLA Flooded 242
b33 US US 145 XC2 FLA Flooded 251
b34 Crown Crown CR-235 FLA Flooded 235
b35 Crown Crown CR-245 FLA Flooded 245
www.enerdrive.com.au Page 19

9. WARRANTY
5 Year Warranty
Important Note: Consumer Protections
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 ecient expertise and rst class product support.
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/
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 ePOWER Industrial Battery Charger Owner’s Manual (Rev. 1.6)
Page 20