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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

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Summary of Contents for ENCORE EXE3

Page 1: ...ser 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 ...

Page 2: ...nity 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 Softwar...

Page 3: ...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...

Page 4: ...s 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 V...

Page 5: ...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 n...

Page 6: ...e 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 c...

Page 7: ...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 ...

Page 8: ... 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 ...

Page 9: ...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 ...

Page 10: ...he 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...

Page 11: ... is connected to the charger the control board senses the voltage and after a short delay the charger starts charging the battery Charging Current Charging current is determined by the battery voltage and state of the charge condition Charging current declines automatically as battery voltage rises during the charge As the battery charges the graphical display will output various charge parameters...

Page 12: ...r capacity Requires Wi iQ device on battery IONIC Profile The IONIC charging profile consistently diagnoses the battery throughout the recharge and adjusts the charging profile to effectively charge the battery The intelligent diagnostic sampling provides more rapid optimized charging of flooded cell batteries subject to very high demands The short current pulses stimulate gas formation in the act...

Page 13: ...e charge NOTE The factory default is daily charge disable 6 hour Equalize Sunday at 00 hour Block Out Time This function inhibits the charger from charging the battery during the block out time window If a charge cycle has started before the block out window it is inhibited during the block out window and will automatically restart the charge cycle at the end of the block out window Refresh Chargi...

Page 14: ...CEC California Energy Commission CFC Termination Code dBm Decibel milliwatts DF Fault Number DoD Depth of Discharge GND Ground kW Kilowatt L A Lead Acid MAC Media Access Control MANU Manual mVpc Millivolts Per Cell NEMA National Electronics Manufacturers Association SoC State of Charge TH Thermal Fault TH Amb Thermal Ambient Temperature Faults TFT Thin Film Transistor ...

Page 15: ...rage IONIC Opportunity Fast based on the configuration chosen by the operator Furthermore equalization and refresh charges are integrated The Express EnCore charger includes an adapter to communicate with a Wi iQ device The Wi iQ device is an advanced battery module that measures tracks and stores important battery parameters such as temperature electrolyte level voltage and AH This data is wirele...

Page 16: ...e or desulfation 5 Navigation DOWN button Navigate menus Change values 6 Navigation LEFT ESC button Enter Main Menu Scroll left Exit menus 7 RED fault indicator OFF no fault FLASHING ongoing fault detected ON fault 8 YELLOW charging indicator OFF charger output is off ON charging in progress 9 GREEN charge complete indicator OFF charger off or battery not available Flashing cooling phase ON batter...

Page 17: ...ll menus are accessed from Main Menu a detailed description of each menu is included in the next sections of this manual The menus that require a password are not displayed until the correct password has been entered The menus provide access to the following functions View status and memorizations LOGS icon Viewing of faults alarms etc CHARGER icon USB functions USB icon Setting of date language a...

Page 18: ...e the to scroll through the parameters Memorization Data Memo Description Memo Description S N Wi iQ device serial number I end Current at end of charge Capacity Rated battery capacity AH Temp end Battery temperature at end of charge F U batt Rated battery voltage V Chg Time Time of the charge cycle minutes Temp Battery temperature at start of charge F AH Amp hours returned during charge cycle Tec...

Page 19: ...etc Status Screen Status Description Charge Total number of charges corresponds to the total of normally terminated charges and charges terminated with or by faults Complete Number of charges normally terminated Partial Number of charges terminated abnormally TH Number of charger temperature faults DF1 etc Number of faults recorded by the charger see Fault Codes ...

Page 20: ...isplays the following information on the charger s configuration Charger Information Display Information Description Profile Selected Charging Profile Temperature Programmed or Wi iQ device temperature Capacity Automatic or Manual Max Current Maximum Current of Charger Floating ON OFF Cable Length of DC Cable Equal Equalize Time and Current Delay Charge In Hours and Minutes Auto Start ON OFF ...

Page 21: ...as a battery backup which will preserve the time when power to the charger is off Language Selects the language displayed in the menus Region Selects the format for date metric EU or imperial US units for temperature length and cable gauge Display Set screen saver function and display Themes Screen Saver Enables or Disables the screen saver function Delay Saving Set the time the screen stays illum...

Page 22: ... is displayed throughout the charge cycle as seen in table below Theme A is selected by default and will be used in this manual FUNCTION Theme A Theme B IDLE Screen Battery Disconnects while Charging Alternates every two seconds with CONNECT BATTERY Charger paused while battery connected CHARGING Screen ...

Page 23: ... time When enabled time will move ahead one hour at 02 00 on the second Sunday in March and will move back one hour at 02 00 on the first Sunday of November The charger must be powered up at the time of the change for it to take effect PASSWORD This is where the password is entered to gain access to service level menus by authorized EnerSys service personnel ...

Page 24: ...y of the proper type capacity and voltage is connected to the charger With the charger in wait mode no battery connected and without pressing the Stop Start button the display will show the following information Charger Idle Display Ref Description 1 Charger DC Voltage 2 Firmware Version 3 Selected Charge Profile 4 System Time and Date 5 Connect Battery S11 36 48V US11 3 4 2 1 5 ...

Page 25: ...enabled or no Wi iQ devices are in range effective charging starts after the programmed delay The charger uses Profile Capacity and Temperature settings programmed in the Configuration menu With a Wi iQ Device If a Wi iQ device adapter is present and one or more Wi iQ device is in range the charger will turn on and apply current to the battery The display will show SCAN followed by IQLINK This rou...

Page 26: ...on Ref Description 1 Charge Voltage total V and V c 2 Charge Current 3 Battery S N from Wi iQ Device 4 Battery Temperature Alternates with AH Returned 5 Charge Time 6 Percent of Charge 7 USB Connection 8 Battery Capacity 9 Wi iQ Device Link 10 Wi iQ Device Warning Low Water 11 Wi iQ Device Warning Weak Cell 12 Wi iQ Device Warning Hot Battery 1 10 2 6 5 3 4 9 8 10 7 12 11 ...

Page 27: ...tery remains plugged in and refresh charge has been enabled refreshes will occur to maintain an optimal charge The battery is now ready for use Push the ON OFF button before unplugging the battery End of Charge with Equalization An Equalize charge can be started manually or automatically Manual Equalization Start 1 At the end of charge green LED on or flashing press on the EQUALIZE button The equa...

Page 28: ...occur to maintain an optimal charge Push the ON OFF button before unplugging the battery Automatic Equalization Start If an equalization day has been programmed in Charger configurations the equalization charge will start automatically on the programmed day of the week after charging is complete NOTE The factory default FAST profile s Equalize is 12 hours on Sunday at 00 hour The battery will be a...

Page 29: ...oo high 2 4 Vpc or too low 1 6 Vpc Use proper charger for battery DF4 No The battery has been discharged more than 80 of its capacity Prevent future over discharging of battery Battery charge gauges and lift interrupts may need calibration DF5 No Battery requires inspection Non critical fault Check battery cables for condition and size check for loose connections check for defective cells Check fo...

Page 30: ... module s is are displayed red led flashing Check that the fan s is are working correctly and or that the ambient temperature is not too high or whether there is poor natural ventilation to the charger If all modules are in thermal fault a TH fault will follow DFMOD No Alternating with charge parameters one or more module in DF1 fault the charge process continues the fault module s is are displaye...

Page 31: ...kept clean and tight The unit especially the heatsink should be periodically cleaned with an air hose to prevent any excessive dirt build up on components Care should be taken not to bump or move any adjustments during cleaning Make sure that both the AC lines and the battery are disconnected before cleaning The frequency of this type of maintenance depends on the environment in which this unit is...

Page 32: ...Express EnCore Owner s Manual I B 1660 31 MOUNTING DIMENSIONS 3 5 kW 4 Bay Cabinet Mounting Dimensions Dimensions shown are in inches ...

Page 33: ...Express EnCore Owner s Manual I B 1660 32 3 5 kW 6 Bay Cabinet Mounting Dimensions Dimensions shown are in inches ...

Page 34: ...Express EnCore Owner s Manual I B 1660 33 3 5 kW 8 Bay Cabinet Mounting Dimensions Dimensions shown are in inches ...

Page 35: ...320 320 800 800 800 3 0 EXE3 KP 4YFDC 480 24 3 10 L16 30 12 18 24 17 5 400 400 300 1000 1000 750 Dual 3 0 EXE3 LP 4YFDC 480 28 8 3 8 CS8165C 12 18 24 21 480 480 360 1200 1200 900 Dual 3 0 EXE3 MR 4YFDC 480 33 6 3 8 CS8165C 12 18 24 24 5 560 560 420 1400 1400 1050 Dual 3 0 EXE3 NR 4YFDC 480 38 4 3 6 HW 12 18 24 28 640 640 480 1600 1600 1200 Dual 3 0 EXE3GGR 4YF 480 9 6 3 14 L16 20 12 18 24 3 5 3 5 ...

Page 36: ... 40 24 5 280 252 700 630 3 0 EXE3 NR 5YF 480 38 4 3 6 HW 36 40 28 320 288 800 720 3 0 EXE3GGR 5YF 480 9 6 3 14 L16 20 12 18 24 3 5 3 5 40 36 40 36 100 90 100 90 3 0 3 0 EXE3GHR 5YF 480 14 4 3 14 L16 20 12 18 24 3 5 7 0 40 36 80 72 100 90 200 180 3 0 3 0 EXE3HHR 5YF 480 19 2 3 10 L16 30 12 18 24 7 0 7 0 80 72 80 72 200 180 200 180 3 0 3 0 EXE3HIR 5YF 480 24 3 10 L16 30 12 18 24 7 0 10 5 80 72 120 1...

Page 37: ...11 4 3 14 L17 30 12 18 24 3 5 7 0 80 80 60 160 160 120 200 200 150 400 400 300 3 0 3 0 EXE3HHR 4CF 600 15 2 3 12 L17 30 12 18 24 7 0 7 0 160 160 120 160 160 120 400 400 300 400 400 300 3 0 3 0 EXE3HIR 4CF 600 19 3 10 L17 30 12 18 24 7 0 10 5 160 160 120 240 240 180 400 400 300 600 600 450 3 0 3 0 EXE3IIR 4CF 600 22 8 3 10 L17 30 12 18 24 10 5 10 5 240 240 180 240 240 180 600 600 450 600 600 450 3 ...

Page 38: ...36 40 36 100 90 100 90 3 0 3 0 EXE3GHR 5CF 600 11 4 3 14 L17 30 36 40 3 5 7 0 40 36 80 72 100 90 200 180 3 0 3 0 EXE3HHR 5CF 600 15 2 3 12 L17 30 36 40 7 0 7 0 80 72 80 72 200 180 200 180 3 0 3 0 EXE3HIR 5CF 600 19 3 10 L17 30 36 40 7 0 10 5 80 72 120 108 200 180 300 270 3 0 3 0 EXE3IIR 5CF 600 22 8 3 10 L17 30 36 40 10 5 10 5 120 108 120 108 300 270 300 270 3 0 3 0 EXE3IJR 5CF 600 26 6 3 8 3765C ...

Page 39: ...Express EnCore Owner s Manual I B 1634 38 MAINTENANCE LOG 1 Modifications to Factory Settings Date Variable Change Service Technician 2 Service Date Description Service Technician ...

Page 40: ...7 Fax 1 905 951 4441 ENERSYS DE MEXICO Ave Lopez Mateos 4210 Colonia Casa Blanca C P 66475 San Nicolas de los Graza N L Mexico 52 818 329 6400 Fax 52 818 329 6489 I B 1660 Rev AB 7 17 2017 EnerSys All rights reserved Trademarks and logos are the property of EnerSys and its affiliates except for the BC and UL logos which are not the property of EnerSys Subject to revisions without prior notice E O ...

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