Express ENCORE EXE3 User manual

I.B. 1660
Rev AB 7/17
IMPORTANT
Read and understand your user’s manual before installing, operating or servicing this
product.
DO NOT DESTROY THIS BOOK
Model: EXE3
Express
®
EnCore™Battery Charger
Owner’s Manual
To automatically be connected to your closest Service Center, call us toll-free at:
1-800-ENERSYS (1-800-363-7797)

Express®EnCore™ Owner’s Manual I.B. 1660
1
TABLE OF CONTENTS
Important Safety Instructions ..................... 2
Technical Information ................................. 3
Part Number ............................................ 3
Output Power Letter Codes .............. 4
Cabinet Size/Gauge Letter Codes .... 4
DC Voltage Number Codes .............. 4
AC Line Voltage Letter Codes .......... 5
Charge Profile Letter Codes ............. 5
Specialty Charger Option List ........... 5
Serial Number ......................................... 5
Battery Type ............................................ 6
Max AH .................................................... 6
No. Cells .................................................. 6
Max Modules ........................................... 6
Config Modules ....................................... 6
Hertz ........................................................ 6
Phase ...................................................... 6
AC Volts .................................................. 6
Config AC Amps ...................................... 6
Max AC Amps ......................................... 6
Max DC Amps ......................................... 6
DC Volts .................................................. 6
Config DC Amps ..................................... 7
CEC ......................................................... 7
cULus ...................................................... 7
Installation .................................................... 8
Location ................................................... 8
Cabinet Mounting .................................... 8
Electrical Connections ............................. 8
Connecting Input Power .......................... 8
AC Disconnect ........................................ 9
Plug Polarity ............................................ 9
Grounding the Charger ........................... 9
Description of Operation ............................ 10
General .................................................... 10
Starting the Charge Cycle ....................... 10
Charging Current ..................................... 10
AC Power Fail ......................................... 10
Series Charging ...................................... 10
Glossary ....................................................... 11
Wi-iQ® Device .......................................... 11
Charging Profile ...................................... 11
Cold Storage Profile ................................ 11
Equalization Charging ............................. 11
Gel-Bloc Profile ....................................... 11
IONIC™ Profile ....................................... 11
VRLA Profile ............................................ 11
Opportunity Profile .................................. 11
Operation ............................................ 11
Daily Charge ....................................... 12
Block Out Time ........................................ 12
Refresh Charging .................................... 12
Abbreviations and Acronyms ..................... 13
Operating Instructions ................................ 14
Control Panel ............................................... 15
Menu Access ................................................ 16
Main Menu Display .................................. 16
Main Menu ............................................... 16
Logs .............................................................. 17
Memorizations Display Screen ................ 17
Displaying a Charge Cycle ...................... 17
Memorization Data .................................. 17
Status ............................................................ 18
Status Screen .......................................... 18
Charger ......................................................... 19
Information .............................................. 19
Charger Information Display ................... 19
USB ............................................................... 20
Update Software ...................................... 20
Settings ......................................................... 20
Parameters .............................................. 20
Date/Time ................................................ 20
Language ................................................ 20
Region ..................................................... 20
Display ..................................................... 20
Screen Saver .................................... 20
Delay ................................................. 20
Themes ............................................. 21
Daylight Savings ...................................... 22
Password ...................................................... 2 2
Charging the Battery ................................... 23
Charger Idle Display ................................ 23
Starting a Charge Cycle .......................... 24
Delayed Start ........................................... 24
Count Down Display ................................ 24
Charger Display ....................................... 25
End of Charge Display ............................ 26
End of Charge without Equalization ........ 26
End of Charge with Equalization ............. 26
Manual Equalization Start ................. 26
Automatic Equalization Start ............. 27
Fault Codes .................................................. 28
Fault Display ............................................ 28
Maintenance and Service ............................ 30
Mounting Dimensions ................................. 31
3.5 kW 4 Bay Cabinet
Mounting Dimensions .............................. 31
3.5 kW 6 Bay Cabinet Mounting
Dimensions .............................................. 32
3.5 kW 8 Bay Cabinet Mounting
Dimensions .............................................. 33
Technical Specifications ............................. 34
3.5 kW Standard Technical
Specifications .......................................... 34
Maintenance Log .......................................... 38

Express®EnCore™ Owner’s Manual I.B. 1660
2
IMPORTANT SAFETY INSTRUCTIONS
WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE OPERATION.
1. This manual contains important safety and operating instructions. Before using the battery charger, read all
instructions, cautions and warnings on the battery charger, the battery and the product using the battery.
2. This charger has been designed to only charge lead acid batteries. Read and understand all setup and
operating instructions before using the battery charger to prevent damage to the battery and to the charger.
3. Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock.
4. During charge, batteries produce hydrogen gas which can explode if ignited. Never smoke, use an open flame
or create sparks in the vicinity of the battery. Ventilate well when the battery is in an enclosed space.
5. Do not connect or disconnect the battery plug while the charger is on. Doing so will cause arcing and burning
of the connector resulting in charger damage or battery explosion.
6. Lead-acid batteries contain sulfuric acid which causes burns. Do not get in eyes, on skin or on clothing. In
cases of contact with eyes, flush immediately with clean water for 15 minutes. Seek medical attention
immediately.
7. Only factory qualified personnel can service this equipment. De-energize all AC and DC power connections
before servicing the charger.
8. The charger is not for outdoor use.
9. Do not expose the charger to moisture. Operating conditions should be 32º to 113º F (0º to 45º C); 0 to 70%
relative humidity.
10. Do not operate the charger if it has been dropped, received a sharp hit or otherwise damaged in any way.
11. For continued protection and to reduce the risk of fire, install chargers on a floor of non-combustible material
such as stone, brick or grounded metal.

Express
®
EnCore™ Owner’s Manual I.B. 1660
3
TECHNICAL INFORMATION
The nameplate, located on the outside of the charger, should be used to check this application
before installation.
Part Number
This is the charger part number and specifies the characteristics of this particular charger and
for this reason it is required in any discussion or correspondence regarding this unit.
Single Display Cabinet:
EXE3 - GN - 4YF *
Model Type
Phase
Power Level Top
Cabinet Size
DC Voltage Code
Input Voltage Code
Charge Profile
Options
Dual Display Cabinet:
EXE3GHR - 4YF *
Model Type
Phase
Power Level Top
Power Level Bottom
Cabinet Size
DC Voltage Code
Input Voltage Code
Charge Profile
Options

Express®EnCore™ Owner’s Manual I.B. 1660
4
Output Power Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the Output Power of the charger.
Letter
Code
Output Power
(kW)
Number
Modules
Module Power
(kW)
G 3.5 1 3.5
H 7.0 2 3.5
I 10.5 3 3.5
J 14.0 4 3.5
K 17.5 5 3.5
L 21.0 6 3.5
M 24.5 7 3.5
N 28.0 8 3.5
Cabinet Size/Gauge Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the number of slots and size of the DC cables.
Letter
Code
Module
Positions
Standard Cable
Gauge Comments
N 4 3/0 Four slot, 3.5 kW cabinet
P 6 3/0 Six slot, 3.5 kW cabinet
R 8 3/0 Eight slot, 3.5 kW cabinet
DC Voltage Number Codes
The following table describes the number codes to be used in charger part numbers to
indicate the DC output voltage(s) of the charger.
Number
Code
Output
Voltage(s)
4 24/36/48
5 72/80

Express®EnCore™ Owner’s Manual I.B. 1660
5
AC Line Voltage Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the AC line voltage(s) and AC line frequency at which the charger can be operated.
Letter
Code
Voltage(s)
(volts rms)
Line
Frequency
(Hertz)
Comments
C 600 50/60 600 VAC only
Y 480 50/60 480 VAC
*For 480VAC chargers with line voltage of 400VAC, see specifications starting on page 34.
Charge Profile Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the Charging profile of the charger.
Letter
Code Profile
C Cold Storage
I IONIC™
O Opportunity
F Fast
Specialty Charger Options List
Suffix Description
C6 6 Ft of AC Cord
C10 10 Ft AC Cord
C12 12 Ft of AC Cord
L10 10 Ft of DC cable
L13 13 Ft of DC cable
L15 15 Ft of DC cable
L18 18 Ft of DC cable
L20 20 Ft of DC cable
L25 25 Ft of DC cable
L30 30 Ft of DC cable
Serial Number
This number indicates complete information about the specific charger. It must be supplied with
the part number on any correspondence or discussion regarding this charger.

Express®EnCore™ Owner’s Manual I.B. 1660
6
Battery Type
The chemical content construction of the battery this unit is designed to charge is given in this
part of the nameplate. (L-A = Lead Acid)
Max AH
This is the maximum amp-hours capacity of this cabinet.
No. Cells
This is the number of battery cells this unit will charge. This number must match exactly with
any battery connected to the charger output.
Max Modules
This is the maximum number of modules the cabinet can hold.
WARNING: THE NUMBER OF MODULES MUST MATCH THE NUMBER OF “CONFIG
MODULES” ON THE NAMEPLATE. DO NOT ADD MORE MODULES IN THE FIELD.
CONSULT THE MANUFACTURER IF MORE MODULES ARE NEEDED.
Config Modules
This is the number of modules for which this cabinet is configured.
Hertz
This gives the frequency in cycles per second of the AC input voltage. Under no conditions
operate the charger at a different frequency or from a generator with unstable frequency.
Phase
Number "3" indicates a Three Phase Charger.
AC Volts
This is the nominal voltage for which this charger is rated. The charger will only operate on this
voltage.
Config AC Amps
This is the AC Amps for which this charger is configured.
Max AC Amps
This is the maximum AC Amps for which this cabinet is rated.
Max DC Amps
This is the maximum output DC Amps for which this charger is rated .
DC Volts
This gives the nominal DC output voltage of the charger.

Express
®
EnCore™ Owner’s Manual I.B. 1660
7
Config DC Amps
This is the output DC Amps this charger is configured for to deliver to a battery.
CEC
This logo is applied to chargers that are certified with the California Energy Commission in
compliance with Appliance Efficiency Regulations:
cULus
This logo is applied to chargers that have been tested to applicable standards and requirements
by Underwriters Laboratories (UL) and the Canadian Standards
Association (CSA):

Express
®
EnCore™ Owner’s Manual I.B. 1660
8
INSTALLATION
WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE
OPERATION.
Location
For maximum safe operation, choose a location which is free of excess moisture, dust,
combustible material and corrosive fumes. Also, avoid locations where temperatures are high
or where liquids will drip on the charger. Do not obstruct the ventilation openings. Follow charger
warning label when mounting on or over a combustible surface. The recommended charger
mounting should be at least 28 inches above the battery.
Cabinet Mounting
The charger must be mounted on a wall, stand, shelf or floor in a vertical position. 8 bay chargers
may only be mounted to the floor or an appropriate stand. The minimum distance between two
chargers must be 12 inches.
The charger will be installed with four 5/16 inch bolts or with the bracket supplied. See the
Mounting Dimensions section at the end of this manual for proper bolt pattern. Charger should
be permanently fastened in place.
For shelf mounting, part number 159-6LA22723 is required – two per charger.
Electrical Connections
To prevent failure of the charger, make sure it is connected to the correct line voltage.
Follow your local and National Electric Code (NEC) in making these connections.
WARNING: MAKE SURE THE POWER TO THE CHARGER IS OFF AND THE BATTERY
IS DISCONNECTED BEFORE CONNECTING THE INPUT POWER TO THE TERMINALS
OF THE CHARGER.
Connecting Input Power
Connect the input power to the appropriate terminals and apply appropriate torque as follow:
Phase Power (kW) Cabinet (Bay) Terminals Torque (in-lbs)
3 3.5 4 and 6 L1 L2 L3 15
3 3.5 8 L1 L2 L3 25
Connect ground wire to terminal marked with either of the two symbols below and apply same
torque value per table above:
NOTE: Ambient temperature at all levels cannot exceed 113° F (45° C).

Express
®
EnCore™ Owner’s Manual I.B. 1660
9
AC Disconnect
The user must provide suitable branch circuit protection and a disconnect method from the AC
power supply to the charger to allow for safe servicing.
Plug Polarity
The charging cable is connected to the DC output of the charger with the positive lead marked
RED. The output polarity of the charger must be strictly observed when connecting to the battery
(read warning above). Improper connection may open the DC fuse and/or damage the charger.
Grounding the Charger
DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC
SHOCK. Follow National Electric Code for ground wire sizing.
Connect a grounding conductor to the Ground lug provided on the horizontal support panel.
This lug is marked with either of these symbols: