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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)
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
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Table of Contents
Summary of Contents for Express ENCORE EXE3
- Page 1 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) I.B. 1660 Rev AB 7/17 IMPORTANT Read and understand your user’s manual before installing, operating or servicing this product.
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Page 2: Table Of Contents
® EnCore™ Owner’s Manual I.B. 1660 Express TABLE OF CONTENTS Important Safety Instructions ..... 2 Main Menu Display ........16 Technical Information ......... 3 Main Menu ..........16 Part Number ..........3 Logs .............. 17 Output Power Letter Codes ....4 Memorizations Display Screen .... -
Page 3: Important Safety Instructions
® EnCore™ Owner’s Manual I.B. 1660 Express 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. -
Page 4: Technical Information
® EnCore™ Owner’s Manual I.B. 1660 Express 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. -
Page 5: Output Power Letter Codes
® EnCore™ Owner’s Manual I.B. 1660 Express 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 Output Power Number Module Power Code... -
Page 6: Ac Line Voltage Letter Codes
EnCore™ Owner’s Manual I.B. 1660 Express 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. -
Page 7: Battery Type
® EnCore™ Owner’s Manual I.B. 1660 Express 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. -
Page 8: Config Dc Amps
EnCore™ Owner’s Manual I.B. 1660 Express Config DC Amps This is the output DC Amps this charger is configured for to deliver to a battery. This logo is applied to chargers that are certified with the California Energy Commission in... -
Page 9: Installation
® EnCore™ Owner’s Manual I.B. 1660 Express 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. -
Page 10: Ac Disconnect
® EnCore™ Owner’s Manual I.B. 1660 Express 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. -
Page 11: Description Of Operation
Express EnCore chargers adapt to the battery’s capacity and its discharge level. Express EnCore chargers can easily be set to charge flooded batteries used in Cold or freezer storage applications, IONIC™, Fast or Opportunity profiles. This battery charger is also designed to charge flooded lead acid storage batteries within the range of the cell and ampere-hour rating as marked on the nameplate. -
Page 12: Glossary
® EnCore™ Owner’s Manual I.B. 1660 Express GLOSSARY ® Wi-iQ Device This unit, permanently mounted on the battery, ensures that certain battery parameters can be sent to the charger for the purposes of optimizing the charge and monitoring the charging and discharging characteristics. -
Page 13: Daily Charge
® EnCore™ Owner’s Manual I.B. 1660 Express Daily Charge When using the Opportunity Profile, the Daily Charge option can be set to add additional charging time every day if the work schedule allows. This option should be considered only when the daily work demand requires additional capacity. -
Page 14: Abbreviations And Acronyms
® EnCore™ Owner’s Manual I.B. 1660 Express ABBREVIATIONS AND ACRONYMS Absorbed Glass Mat Auto Guided Vehicle Amp-Hour American Wire Gauge AVAIL Available California Energy Commission Termination Code Decibel-milliwatts Fault Number Depth of Discharge Ground Kilowatt Lead Acid Media Access Control... -
Page 15: Operating Instructions
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 wirelessly transmitted to the Express EnCore to optimize charging, alerts the operator to battery issues, and safeguard the battery from being permanently damaged. -
Page 16: Control Panel
® EnCore™ Owner’s Manual I.B. 1660 Express CONTROL PANEL Function Description Graphical TFT display Display charger operation info/Menus Navigate UP button Navigate menus/Change values Select menu items/Enter values/Stop and ENTER/STOP and START button restart battery charge Navigate RIGHT/EQUALIZE button Scroll right/Start equalize or desulfation... -
Page 17: Menu Access
® EnCore™ Owner’s Manual I.B. 1660 Express MENU ACCESS Main Menu Display When the charger is idle, press and hold <ESC>, the Main Menu is then displayed. The main menu is automatically exited after 60 seconds of inactivity or can be exited voluntarily by pressing the <ESC>... -
Page 18: Logs
® EnCore™ Owner’s Manual I.B. 1660 Express LOGS Memorizations Display Screen The charger can display the details of the last 300 charge cycles. The display here shows 3 charges have been stored in memory. MEMO 1 is the latest charge memorized. -
Page 19: Status
® EnCore™ Owner’s Manual I.B. 1660 Express STATUS This menu displays the status of the charger’s internal counters (number of normal and partial charges, fault code, etc.). Status Screen Status Description Total number of charges - corresponds to the total of normally... -
Page 20: Charger
® EnCore™ Owner’s Manual I.B. 1660 Express CHARGER This menu displays information on the chargers configuration and output current of the charger and the power modules. Information This screen displays the following information on the charger’s configuration. Charger Information Display... -
Page 21: Usb
® EnCore™ Owner’s Manual I.B. 1660 Express This menu provides access to the USB function to update software. Update Software ® Updates charger’s internal software. The software is provided by EnerSys SETTINGS Parameters: Date/Time Sets date and time of the charger. The clock has a battery backup which will preserve the time when power to the charger is off. -
Page 22: Themes
® EnCore™ Owner’s Manual I.B. 1660 Express Themes Themes A and B are two different ways that information is displayed throughout the charge cycle as seen in table below. Theme A is selected by default and will be used in this manual. -
Page 23: Daylight Savings
® EnCore™ Owner’s Manual I.B. 1660 Express AVAIL Screen EQUALIZATION Screen Daylight Saving Enables or disables automatic clock adjustment for daylight savings 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. -
Page 24: Charging The Battery
EnCore™ Owner’s Manual I.B. 1660 Express CHARGING THE BATTERY At this point, the charger should have been set up by a qualified service person. Charging can only begin when a battery of the proper type, capacity and voltage is connected to the charger. -
Page 25: Starting A Charge Cycle
® EnCore™ Owner’s Manual I.B. 1660 Express Starting a Charge Cycle The charger will start automatically when a battery is connected or if Stop/Start button is pushed if the battery is already connected. Delayed Start If the charger was programmed for delayed start, charging will begin following that delay. When the battery is plugged in to the charger, the display shows the time remaining before the programmed charging starts. -
Page 26: Charger Display
® EnCore™ Owner’s Manual I.B. 1660 Express Charger Display A few moments into the effective charge, the display will begin alternating between the following charging information: Description Charge Voltage (total V and V/c) Charge Current ® Battery S/N from Wi-iQ... -
Page 27: End Of Charge Display
® EnCore™ Owner’s Manual I.B. 1660 Express End of Charge Display End of Charge without Equalization The green complete LED comes on after proper end of charge. The green complete LED is on and the display shows AVAIL. The display alternates between: ... -
Page 28: Automatic Equalization Start
® EnCore™ Owner’s Manual I.B. 1660 Express 2. The start of the equalization charge is indicated by the symbol . During the equalization charge, the charger displays the output current and alternates: the battery voltage, voltage per cell and remaining time. -
Page 29: Fault Codes
® EnCore™ Owner’s Manual I.B. 1660 Express FAULT CODES Fault Display In case of a fault, one of the corresponding fault codes listed below will appear on the display. If it is a critical fault, charging will stop and the red Fault LED will be illuminated. - Page 30 ® EnCore™ Owner’s Manual I.B. 1660 Express Fault Critical Cause Solution Check that fans are working. Verify that ambient temperature is not Charger overheating too high – above 113° F (45° C). TH-Amb Inspect to see if charger ventilation is obstructed or impaired.
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Page 31: Maintenance And Service
® EnCore™ Owner’s Manual I.B. 1660 Express MAINTENANCE AND SERVICE WARNING: THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET. ONLY A QULIFIED PERSON SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER. The charger requires minimal maintenance. Connections and terminals should be kept clean and tight. -
Page 32: Mounting Dimensions
EnCore™ ® Owner’s Manual I.B. 1660 Express MOUNTING DIMENSIONS 3.5 kW 4 Bay Cabinet Mounting Dimensions Dimensions shown are in inches. -
Page 33: 3.5 Kw 6 Bay Cabinet Mounting Dimensions
EnCore™ ® Owner’s Manual I.B. 1660 Express 3.5 kW 6 Bay Cabinet Mounting Dimensions Dimensions shown are in inches. -
Page 34: 3.5 Kw 8 Bay Cabinet Mounting Dimensions
EnCore™ ® Owner’s Manual I.B. 1660 Express 3.5 kW 8 Bay Cabinet Mounting Dimensions Dimensions shown are in inches... -
Page 35: Technical Specifications
® EnCore™ Owner’s Manual I.B. 1634 Express TECHNICAL SPECIFICATIONS 3.5 kW Standard Technical Specifications AC Input DC Output Max 8 Hour Charger Capacity (Ah) Cable Voltage Max Amps Phase NEMA Cells Part Number Cord Plug Current EXE3-GN-4YF L16-20 12/18/24 80/80/60... - Page 36 ® EnCore™ Owner’s Manual I.B. 1634 Express AC Input DC Output Max 8 Hour Charger Capacity (Ah) Cable Voltage Max Amps Phase NEMA Cells Part Number Cord Plug Current 14.0 320/320/240 800/800/600 EXE3JJR-4YF 38.4 HW** 12/18/24 14.0 320/320/240 800/800/600 EXE3-GN-5YF...
- Page 37 ® EnCore™ Owner’s Manual I.B. 1634 Express AC Input DC Output Max 8 Hour Charger Capacity (Ah) Cable Voltage Max Amps Phase NEMA Cells Part Number Cord Plug Current EXE3-IP-4CF 11.4 L17-30 12/18/24 10.5 240/240/180 600/600/450 EXE3-JP-4CF 15.2 L17-30 12/18/24...
- Page 38 ® EnCore™ Owner’s Manual I.B. 1634 Express AC Input DC Output Max 8 Hour Charger Capacity (Ah) Cable Voltage Max Amps Phase NEMA Cells Part Number Cord Plug Current EXE3-MR-5CF 26.6 3765C* 36/40 24.5 280/252 700/630 EXE3-NR-5CF 30.4 3765C* 36/40...
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Page 39: Maintenance Log
EnCore™ ® Owner’s Manual I.B. 1634 Express MAINTENANCE LOG 1. Modifications to Factory Settings Date Variable Change Service Technician 2. Service Date Description Service Technician... - Page 40 ENERSYS WORLD HEADQUARTERS ENERSYS CANADA INC. ENERSYS DE MEXICO 2366 Bernville Road 61 Parr Boulevard Unit 3 Ave Lopez Mateos #4210 Reading, PA 19605 Bolton, Ontario Colonia Casa Blanca • C.P. 66475 San Nicolas +1-800-EnerSys Canada L7E 4E3 de los Graza, N.L. Mexico Fax: +1-610-372-8613 +1-800-363-4877 +52-818-329-6400...
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