Enerdrive EN3DC30 User Manual

Enerdrive ePOWER DC2DC Battery Charger Owner’s Manual (Rev. 2.03) April 2017

Owner’s Manual

Table of Contents

1. INTRODUCTION

Please Keep This Manual For Future Reference 4

Disclaimer 4

Important Note 4

Product Numbers 4

Service Contact Information 4

Notice of Copyright 5

2. WARNINGS

Please read and follow the instructions and precautions carefully. 6

3. PRODUCT DESCRIPTION

4. UNDERSTANDING THE UNIT

Multistage Charging Process 9

Smart Charging Feature 9

ePOWER charger algorithm 10

Battery Charger Voltage 10

Battery Bank Size Recommendation 11

Unit Setting for Lithium Type Battery (Voltage and Current): 11

5. INSTALLING THE CHARGER

Mounting The Charger 13

4

6

8

9

12

6. CONNECTING THE CHARGER

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

Battery Wiring: Connecting The Batteries The Right Way 17

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7. UNIT OPERATION 18

Understanding The Charging Mechanism 18

Operating from a Start Battery / Alternator (CH3) 18

DC Input (CH2 – Solar / PV): 20

Understanding the Display & Function Keys during normal operation 21

Understanding The Function Key ‘MENU’, ‘SET’ And ‘SEL’ During Charger Setting 22

Digital Display: 22

Button Functions: 23

Automatic Override Functions: 24

Programming Your Charger 24

Understanding The Three-Stage (Mode 3) Charging 24

Understanding The Battery Temperature Functions 24

Battery Temperature Compensation: 25

Battery Temperature Sensor (BTS) Voltage Adjustment: 25

Procedure To Set Or View Charger Setting 25

Procedure To Equalise Flooded Batteries 26

Use the following procedure to setup the charger for battery equalisation. 26

Understanding The Protection Features 27

Charging A Dead Battery 27

Understanding The Display Codes 27

8. SPECIFICATIONS

9. WARRANTY

30

31

Two Year Limited Warranty 31

Return and/or Repair Policy 31

Limitations 31

Appendix A1

Appendix A2

32

34

Appendix A3 36

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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. 2.03. 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. 2.03)Page 4

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:

When charging batteries they can release explosive and corrosive gasses / chemicals.
Please wear safety glasses and protective clothing including gloves when working around
batteries

Fire &/or Chemical Burn Hazard!

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.

Enerdrive ePOWER DC2DC Battery Charger Owners Manual (Rev. 2.03)Page 6

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

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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 abilit y 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 Bat tery 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 under way; 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 batter y 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

BULK

V out ≥ V abs

for 1 min

CC

ABS

I out < 10% I ratin g

for 1 min

CV ABS

If V out < 12.5 Vdc

for 15 min

FLO AT BULK

(Batter y

recharg e in Bulk

mode)

CV ABS time out 5 hr

Total ABS timeo ut 8 hr

Battery Charging Curve (Current) Battery Charging Curve (Voltage)

Note: Actual voltages depend on chosen algorithm.

TIME

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)

* For Concorde™ branded bat teries (lifeline, sun x tender) 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.

13.8V-14.8 (0.1V Step) 13. 0V-13.8 (0 .1V Step) N.A

Enerdrive ePOWER DC2DC Battery Charger Owners Manual (Rev. 2.03)Pag e 10

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 Mi n 150A h

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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