Enerdrive DC2DC+ Manual

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Owner’s Manual
Enerdrive ePOWER DC2DC+ Battery Charger Owner’s Manual (Rev. 1.00)
Table of Contents
1. Introduction 4
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 6
Please read and follow the instructions and precautions carefully. 6
3. PRODUCT DESCRIPTION 8
4. UNDERSTANDING THE UNIT 9
Multistage Charging Process - GEL, AGM, Flooded & Program Modes 9
Lithium Charging Process 9
Smart Charging Feature 10
ePOWER charger algorithm 10
Lithium Battery charging algorithm 11
Battery Charger Voltage 11
Battery Bank Size Recommendation 12
EN3DC40+ (Current Settings): 12
5. INSTALLING THE CHARGER 13
Mounting The Charger 14
6. CONNECTING THE CHARGER 15
Chassis Grounding Connection 15
DC Output Wiring 15
DC2DC+ Battery Charger Connections 16
Recommended Cable Length, Size and Fuse Protection. 17
Standard Temperature Sensor Connection 18
Battery Wiring (Towing Applications): 19
Battery Wiring (Vehicle & Marine Applications): 20
7. UNIT OPERATION 21
Understanding The Charging Mechanism 21
Operating from a Start Battery / Alternator (CH3) 21
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 2
DC Input (CH2 – Solar / PV): 23
Maximising your Solar Harvest using the DC2DC+ 24
Understanding the Display & Function Keys during normal operation 25
Understanding The Function Key ‘MENU’, ‘SET’ And ‘SEL’ During Charger Setting 26
Digital Display: 26
Button Functions: 27
Automatic Override Functions: 28
Programming Your Charger 28
Understanding the Two-Stage (Mode 2) Charging 28
Understanding The Three-Stage (Mode 3) Charging 28
Understanding The Battery Temperature Functions 28
Battery Temperature Compensation: 29
Battery Temperature Sensor (BTS) Voltage Adjustment: 29
Procedure To Set Or View Charger Setting 29
Procedure To Equalise Flooded Batteries 30
Use the following procedure to setup the charger for battery equalisation. 30
Understanding The Protection Features 31
Charging A Flat Battery 31
Understanding The Display Codes 31
8. SPECIFICATIONS 34
9. WARRANTY 35
2 Year Limited Warranty 35
3 Year Pro Rata Support Program 35
Return and/or Repair Policy 35
Limitations 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
EN3DC40+ ePOWER DC2DC+ Battery Charger 12V / 40+Amp
*ePOWER DC2DC+ Batter y Charger Owners Manual Rev. 1.00.
This user manual is applicable to DC2DC+ models sold after July 2017 only.
Service Contact Information
ENERDRIVE PTY LTD
P.O. Box 9159, Wynnum Plaza, Queensland, Australia 4178
Ph: 1300 851 535 / Fax: 07 3390 6911
Email: support@enerdrive.com.au
Web: www.enerdrive.com.au
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 4
Notice of Copyright
Enerdrive ePOWER DC2DC+ Battery Charger owner’s manual © 2017 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, 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
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.
Avoid moisture ingress. Never expose the unit to snow, water, etc..
WARNING: Shock Hazard.
Keep Away From Children!
WARNING:
Fire &/or Chemical Burn Hazard!
When charging batteries they can release explosive and corrosive gasses / chemicals.
Please wear safety glasses and protective clothing including gloves when working around
batteries
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. 1.00)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 Charger
1 x Battery Temperature Sensor
7.5 Meter Cable)
1 x Owner’s manual
Owner’s Manual
Enerd rive e POWER DC2DC+ Ba tter y Charg er Owner ’ s Ma nua l (R ev. 1.03)
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 8
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 ability 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 on-board DC loads.
Multistage Charging Process - GEL, AGM, Flooded & Program Modes
The ePOWER DC2DC+ Battery 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 underway; 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 up to the 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 oas the battery 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 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.
Lithium Charging Process
The ePOWER DC2DC+ charger has a specic charging prole for Lithium batteries. It has its
own charging voltage and current settings that needs to be set by the user. It also requires
the user to set the charger termination current (“L“ setting). Once the user dened charge
voltage is reached, the charger will start reducing the current output and the charging process
will terminate when the charging current drops to the set termination current. This can take
anywhere between 3 to 15 minutes. The unit will then act as a power supply to support
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additional loads connected to the battery while the DC2DC+ is powered from either the
vehicle or solar inputs. A Bulk re-start will occur when battery voltage drops below 13.3V DC.
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.
ePOWER charger algorithm
Battery Charging Curve For GEL, AGM, Flooded & Program Batteries:
CHARGE
CURRENT
V out ≥ V abs
for 1 min
V out ≥ V abs
for 1 min L out < L setting
for 1 min
If V out < 12.5 Vdc
for 15 min
BULK
CV ABS timeout 5 hr
Total ABS timeout 8 hr
FLOAT BULK
TIME
CC
ABS CV ABS
Battery Charging Curve (Current) Battery Charging Curve (Voltage)
(Battery
recharge in Bulk
mode)
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 10
Lithium Battery charging algorithm
14.4V
14.2V
14.0V
13.8V
13.6V
13.4V
13.2V
13.0V
12.8V
Battery Current
Bulk Power Supply Mode
Time out 8 hrs max Time out 7 days
Diagram does not illustrate our current set points.
Maint. Power Supply Mode Return to Bulk
Battery Voltage
13.3VDC triggers
Bulk Restart
Note: Actual voltages depend on chosen algorithm.
Battery Charger Voltage
Battery Type Absorption Float (See Note 3) Equalisation
GEL 14.4 V 13.7 V N.A.
AGM 14.6 V 13.6 V N.A.
Flooded 14.4 V 13.3 V 15.5 V (See Note1)
Lithium 13.9 V-14.6V (0.1V Step)
(see Note2)
13.5V-14.2V
(0.1V Step) N.A
Program (Custom
Settings) 13.8V-14.8 (0.1V Step) 13.0V-13.8 (0.1V Step) N.A
* For Concorde™ branded batteries (lifeline, sun xtender) 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.
Note 3: Charger is acting as a power supply with selected constant output voltage and
preset maximum output current.
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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.
EN3DC40+
Current Setting 5A 10A 20A 30A 40A 50A
Battery Capacity Min 25Ah Min 250AhMin 50Ah Min 200AhMin 100Ah Min 150Ah
EN3DC40+ (Current Settings):
EN3DC40+ Available Current Settings
Bulk
(“h” Setting) 5A 25A10A 15A 20A
ABS Float
(“L” Setting) 1A/1.5A/2A 1A/1.5A/2A 1A/1.5A/3A 2A/3A/4A 2A/4A/5A
Bulk
(“h” Setting) 30A 40A 50A35A 45A
ABS Float
(“L” Setting) 3A/4A/6A 3A/5A/7A 4A/6A/8A 4A/6A/9A 5A/7A/10A
Use the above table to set the Bulk and its related Absorption (ABS) to Float Charge Current.
IMPORTANT NOTE: If in doubt of the “L” setting, use the highest available current setting
for battery protection.
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 12
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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Mounting The Charger
• Choose an appropriate mounting location.
•
For installing in an indoor location, the unit should be mounted vertically (with the
battery terminals facing downwards). This provides the best thermal performance and
drip protection. The unit should NOT be mounted upside down.
•
For installing in a boat or marine environment, the unit should only be mounted vertically
(Battery Terminals facing downwards only) to provide adequate drip protection.
•
Use the base of the charger as a mounting template to mark the positions of the xing
screws.
•
Drill the 4 xing holes and place the Charger in position and fasten the unit to the mounting
surface.
119mm 55mm
160mm
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 14
6. CONNECTING THE CHARGER
Chassis Grounding Connection
BEST PRACTICE
This Charger SHOULD BE CORRECTLY GROUNDED.
The unit chassis has a stud point on it for grounding. Connect the unit’s chassis ground to
the common ground point through the ground stud located near one of the unit mounting
slots. (Battery DC negative is the best ground reference point in your installation) .
DC Output Wiring
WARNING: Correct DC Wiring Is Required
The DC wiring used must be of appropriate size.
An individual fuse or breaker is required to be installed within 20cm of the both the start
battery and house battery bank.
A DC isolator or fuse is also recommended for the solar input.
All devices must be rated for DC voltage and current.
The solar input fuse or breaker must be able to withstand the short circuit current rating
stated on the solar panel array.
All wiring must conform or exceed the recommendations stated in this manual (page 17).
This is a Dual Input device. Dierent cable sizes are required for the alternator input,
solar array input and the DC2DC+ charger to battery connection.
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DC2DC+ Battery Charger Connections
SOLAR INPUT SOLAR INPUTBATTERY INPUT BATTERY INPUT BATTERY OUTPUT BATTERY OUTPUTIGNITION SENSE
TERMINAL
Battery
Temperature
Sensor Port
Unit Ground
Start Battery House BatterySolar Array
CH2 CH1CH3
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 16
Recommended Cable Length, Size and Fuse Protection.
DC2DC Connection
Inputs Require Length & Battery Cable Size
DC2DC set to
=<30A Output
2 Meters to 5
Meters (2)
Up to 10
Meters (2)
Greater than
10 Meters
From Alternator Battery 6-16mm2 @ 12vdc
/ 4-8mm
2 @ 24vdc
16-35mm2 @ 12vdc
/ 8-16mm2 @ 24vdc Not Recommended
Primary Battery
Connection (2) 16mm2 Not Recommended Not Recommended
DC2DC Connection
Inputs Require Length & Battery Cable Size
DC2DC set to
=<40A Output
2 Meters to 5
Meters (2)
Up to 10
Meters (2)
Greater than
10 Meters
From Alternator Battery 10-25mm2 @ 12vdc
/ 10mm2 @ 24vdc
25-50mm2 @ 12vdc
/ 25mm2 @ 24vdc Not Recommended
Primary Battery
Connection (2) 16-25mm2Not Recommended Not Recommended
DC2DC Connection
Inputs Require Length & Battery Cable Size
DC2DC set to
50A Output
2 Meters to 5
Meters (2)
Up to 10
Meters (2)
Greater than
10 Meters
From Alternator Battery 16-25mm2 @ 12vdc
/ 8-10mm
2 @ 24vdc
35-50mm2 @ 12vdc
/ 16-25mm2 @ 24vdc Not Recommended
Primary Battery
Connection (2) 16-25mm2Not Recommended Not Recommended
Note: Cable size quoted is one way from battery to device, however suggested cable size is calculated with return run.
1) Note: If solar panels are wired in Series (increased voltage), then typically 1 x 4mm
2 cable run per series string
is suitable.
2) Based on 3% voltage drop.
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Recommended Fuse Protection
From Alternator Battery
70amp Fuse or Circuit Breaker no greater than 20cm from source
battery.
PLEASE NOTE: Automatic re-settable circuit breakers are
NOT recommended.
From Solar Panels
Fusing recommended no greater than 20cm from input to DC2DC+
Charger. Typically 15amps per solar panel (consult your panel
specications for further details).
Primary Battery
Connection 60amp Fuse or Circuit Breaker.
Standard Temperature Sensor Connection
•
To install the temperature sensor, simply connect the RJ12 plug from the sensor to the
RJ12 Temperature Sensor Port located next to the Remote Port.
•
On the temperature sensor end, simply connect the ring terminals to the negative terminal
of the main house battery bank.
PLEASE NOTE: For lithium installations, the standard supplied temperature sensor is not
required to be installed for these applications.
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 18
Battery Wiring (Towing Applications):
For Towed Applications i.e. Caravans, Camper Trailers
(Optional Ignition - On)
VSO
(Voltage Sense Override)
Anderson Plug (Optional)
MPPT Solar Panel Input
Max: 500w / 45VOC
(For xed or portable panels)
Start / Vehicle Battery
12V or 24V
Fuse / Breaker
12V - 70A
24V - 40A
Fuse Size 1A
Fuse / Breaker Fuse / Breaker
60A
Temp Sensor Cable
(Included)
12V House Battery Bank
This diagram is for a reference only. No cables, fuse/breakers, batteries or solar panels are supplied with this unit.
Local rules and regulations should be followed when installing this unit.
Please NOTE
The negative cable from the start battery must
be carried to the DC2DC input terminal for
correct operation in a towed application.
Smart alternator
battery sense
module.
Please NOTE
Vehicles with a Smart alternator,
the Negative cable must be
connected to the vehicle side of
the Battery Sense Module.
POSITIVE WIRE
NEGATIVE WIRE
TEMPERATURE SENSOR
CABLE (INCLUDED)
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Battery Wiring (Vehicle & Marine Applications):
For In Vehicle & Marine Installation. i.e. Motorhomes, 4WD’s & Trucks.
(Optional Ignition - On)
VSO
(Voltage Sense Override)
MPPT Solar Panel Input
Max: 45VOC
(For xed or portable panels)
Start / Vehicle Battery
12V or 24V
Fuse / Breaker
12V - 70A
24V - 40A
Fuse Size 1A
Fuse / Breaker Fuse / Breaker
60A
Temp Sensor Cable
(Included)
12V House Battery Bank
This diagram is for a reference only. No cables, fuse/breakers, batteries or solar panels are supplied with this unit.
Local rules and regulations should be followed when installing this unit.
POSITIVE WIRE NEGATIVE WIRE TEMPERATURE SENSOR
CABLE (INCLUDED)
Smart alternator
battery sense
module.
Please NOTE
Vehicles with a Smart alternator, the Negative
cable must be connected to the vehicle side of
the Battery Sense Module.
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 20
7. UNIT OPERATION
Understanding The Charging Mechanism
Note 1: The Charger is powered by the battery connected to DC Output (CH1) and also
supplied by CH2 or CH3 if available. The display will turn oto save power when Input
Channel CH2 and CH3 are out of operating range.
Operating from a Start Battery / Alternator (CH3)
Normal Operation: Input Battery / Source
12V Input 24V Input
Input Voltage Range 10.5V – 16.0V 21.0– 32.0V
Normal Start-Up Voltage (Note A) > 13.2V > 26.4V
Normal Under Voltage Recovery Voltage (Note A) > 12.8V > 25.6V
Ignition Sense Terminal
Ignition Sense Terminal must see
a minimum of 10.5V to trigger low
voltage “Priority Mode”.
Low Start-Up Voltage (using Ignition Sense Terminal or
using Manual Over-ride setting) (Note B) > 12.3V > 24.6V
Note A:
When the battery is charging through CH3 with normal operation (not through Ignition
or override setting), the charger will charge for 3 minutes, it will then rest for 5 seconds to
verify the Input voltage.
During the 5 seconds rest period, if the measured voltage is >12.8Vdc on a 12V System
(>25.6Vdc on a 24V system), the unit will continue the charging cycle through CH3.
If the measured voltage on CH3 is <12.8Vdc (<25.6Vdc on a 24V system), the unit will
disconnect from the vehicle source and switch back to charge from CH2 (solar if installed)
until the CH3 voltage returns to >13.2Vdc on a 12V System (>26.4V on a 24V system).
Also, during the 3 minutes charging process, if the measured terminal voltage drops below
<11.5V for a 12V system, (<23V for a 24V system), the charger will start to derate the output
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Low Under Voltage Recovery Voltage (Note B) > 12.0V > 24.0V
De-Rated Voltage (with load) (Note C) 11.5V 23.0V
Under Voltage Shutdown (with load) 10.5V 21.0V
Over Voltage Shutdown 16.0V 32.0V
Over Voltage Recovery 15.5V 31.0V
Input Battery System Reset Voltage (NoteD) < 7V < 7V
Maximum Input Current - EN3DC40+ 50A 0A5
current. This function is used to compensate for the use of long or thin wire between the
Input Battery System and the unit input terminals. If the input voltage continues to drop
below the <10.5V for a 12V system (<21V for a 24V system), the charging process will terminate
and the unit will switch back to charge from CH2 (solar if installed) if installed. It will only
switch back to CH3 if the CH3 voltage is >13.2V on a 12V system (>26.4V on a 24V system.
Note B:
When the unit has activated the battery charging process using the ignition sense terminal
(Priority Mode) or using the Manual Override through the unit setting, the input voltage
specication is reduced. It has the same charging process but with a Low Start-Up Voltage
set to >12.3Vdc 12V system (>24.6V on a 24V system). This feature is designed to be used for
vehicles tted with “Smart Alternators”.
If the measured voltage on CH3 is <12.0 Vdc (<24Vdc on a 24V system), the unit will disconnect
from the vehicle source and switch back to charge from CH2 (solar if installed) until the CH3
voltage returns to >12.3Vdc on a 12V System (>24.6V on a 24V system).
The Low Under Voltage Recovery Voltage is set to > 12V (from 12.8V) on a 12V system and
> 24V (from 26.4V) on a 24V system. During the 5 second rest period, if the input voltage
returns above 12V/24V, it will continue the charging process and if the input voltage does
not return to > 12V/24V, it will switch back to charge from the Solar - CH2 (if connected) until
the Start - CH3 input has returned to the Low Start-Up voltage of 12.3V on a 12V system and
24.6V on a 24V system.
Note C:
During the 3 minute charging process, if the measured terminal voltage drops below the
Under Voltage de-rated limit (11.5V for a 12V system, 23V for a 24V system), the charger will
start to de-rate the charger current. This function is used to compensate the use of long
or thin cable between the Input Battery and the unit terminals. If the voltage continues to
drop to below the Under Voltage Shutdown limit of (10.5V for a 12V system and 21V for a
24V system), the charging process will terminate and the unit will switch back to charge from
CH2 (solar if installed). It will only switch back to CH3 if the CH3 voltage returns to 13.2V
(12.3v with ignition sense connected) on a 12V system and 26.4V (24.6V with ignition sense
connected) on a 24V system.
Note D:
The CH3 DC Input (Battery Input) can accept a 12V or 24V battery with an alternator system.
When the unit is rst connected, the unit will measure the input voltage. If the voltage is
>17V, it will assume it is connected to a 24V Input Battery/Alternator system. If the voltage
detect is < 17V, it will assume it is connected to a 12V Input Battery/Alternator system. Once
detected, it will store this into the microprocessor and it will only be erased if the Input
battery is disconnected or if the measured Input Voltage drops to < 7Vdc.
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 22
DC Input (CH2 – Solar / PV):
PV Input Voltage Range 14.5 - 45V
PV Input Under Voltage Shutdown < 14.5V
PV Input Under Voltage Recovery 15.0V
PV Input Over Voltage Shutdown > 45V
PV Input Over Voltage Recovery = < 44V
PV Charging Mechanism MPPT type ( approx. 97% eciency)
Maximum Input 500W *See Note below and “Maximising your
Solar Harvest using the DC2DC+“
*Note: The recommended maximum solar wattage input for the DC2DC+ Charger is 500w.
You can however “overdrive” the MPPT controller. Please note that doing this is partially
an economic decision. You can install more power than the controller can use and this will
contribute to better power availability. Enerdrive suggest a total maximum overdrive of
20% (total 600w). On cloudy (or intermittent sunny) days there will be little or no power
shaving and the extra power will serve the battery well with more energy harvest earlier
and later in the day.
www.enerdrive.com.au Page 23
Maximising your Solar Harvest using the DC2DC+
The Solar Input on the DC2DC+ unit has a maximum rated INPUT current of 30amps. This
means it is optimised for using higher voltage ‘grid’ type modules for best output performance
The maximum achievable output using standard 20Voc solar modules will be approximately
35amps @ 14.4Vdc output.
Panel Array Rated Wattage & Volts Open Circuit rating Estimated DC Amps
* Maximum achievable output on the DC2DC+ unit when using 20Voc Solar Panels will be
the approximately 35amps.
** Maximum achievable output on the DC2DC+ unit when using 43Voc Solar Panels will be
the approximately 47amps.
## IMPORTANT NOTE: Estimated Amps Output is quoted based upon PERFECT Solar
conditions including Sun Angle, Panel Mounting angle and Orientation to the sun. It
needs to be noted that panel performance alters dramatically between Summer and
Winter periods and actual performance may be impossible to predict.
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 24
Output (## See Below)
1 150watt @ 20Voc 150watts 10
1 200watt @ 43Voc 200watts 13
2 150watt @ 20Voc 300watts 21
2 200watt @ 43Voc 400watts 27
3 150watt @ 20Voc 450watts 31
3 200watt @ 43Voc 600watts 42
4 150watt @ 20Voc 600watts 35*
4 200watt @ 43Voc 800watts 47**
5 150watt @ 20Voc 750watts Not Recommended
5 200watt @ 43Voc 1000watts Not Recommended
Understanding the Display & Function Keys during normal operation
Display
Digital Display LCD with back lighting
Digital Display Info : CH1
CH2 & CH3
Fault/Warning
Charging Status, Voltage, Current
Voltage
Error code E01-08, Warning A01-02
‘CH3’ Icon Flashing
CH3 > 12.0V on a 12V Input system
CH3 > 24.0V on a 24V Input system
and not charging from (alternator)
‘CH3’ Icon Solid Charging from CH3 input ( )Start Battery / Alternator
‘CH2’ Icon Flashing CH2 > 14.5V and not charging from solar array
‘CH2’ Icon Solid Charging from CH2 input (solar)
•
During normal operation, the display will cycle through and show CH1 battery voltage,
charging current and charging stage (‘bul’ – Bulk stage, ‘Abs’ – Absorption stage, ‘Ful – Float
stage) alternatively. When the ‘MENU’ key is pressed, it will display the other channel’s
battery voltage only
•
CH3 icon will ash when the input voltage is above (> 12 on a 12V system or > 24V on a
24V system and it is not the source charging the battery. It will change to solid when it
becomes the source charging the battery.
• CH2 icon will ash when the input voltage is above the Flashing Voltage (> 14.5V) and is
not the source charging the battery. It will change to solid when it becomes the source
charging the battery.
•
During normal operation, Every time the menu button is pressed once, the display will
scroll through and show CH1, CH2 & CH3: Voltage’ for 3 seconds and it will return to the
normal display automatically. If CH2 or CH3 is not connected, it will show 0V.
• The display will remain ON when either one or both CH2 & CH3 inputs are available. The
display will turn OFF if CH2 or CH3 is not available.
•
During equalisation operation (for ooded batteries only), the numerical section on the
display will show a ashing ‘eq’ indicating the equalisation process is in progress and it
will not show the battery voltage or the charging current.
www.enerdrive.com.au Page 25
Understanding The Function Key ‘MENU’, ‘SET’ And ‘SEL’ During
Charger Setting
CH1 - display is showing the charging battery
info (charging status, voltage and current).
CH2 or CH3 - When displayed symbol is solid
this means the power is coming from the related
channel and the other channel will be ashing if
it is connected but not charging.
“V“ - Display is showing the voltage
“A“ - display is showing the current
“Auto“ - units Silent mode is switched on
“Priority“ - the units “ignition Sense” terminal
is connected or the unit is set to Manual Override
mode
“Mode“ - charging mode setting*
“Temp“ - Temperature setting*
*Will only display when selected setting is active
Digital Display:
•
During the charging process, the display shows ‘CH1’ charging status, voltage and current
repeatedly, and ‘CH2’ or ‘CH3’ symbol is solid to indicate the active input source. If the other
input channel is available and the voltage is above the ‘CH2 and CH3 Flashing Voltage’ the
icon will be ashing. When the menu button is pressed once, the display will change to
show CH1 Voltage for 3 seconds, CH2 voltage for 3 seconds and CH3 voltage for 3 seconds.
The display will then revert back to normal operation and will show the CH1 info.
•
When the Battery (CH1) is fully charged, it will show ‘CH1’ and ‘FLO’, voltage and current
repeatedly on the display.
•
The selected “battery type” icon is always ON at all times during the whole charging process.
• The ‘Priority’ Icon turns ON when the “ignition sense” terminal is connected or the unit is
set to ‘Manual Override’ mode.
Priority
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 26
Button Functions:
•
During normal charging operation, press once to change the display to show
• CH1, CH2 and CH3 voltage.
• During normal charging operation, press and hold for more than 3 seconds
to enter Charger Function Setting Menu
•
When CH2 or CH3 is not available (voltage detect is below the sense voltage),
display will turn OFF. Press once will temporary trigger on the display and
it will automatically cycle through all three channels voltage, the software
revision and then turn o.
•
During the charger Setup Menu, this button is used to conrm the setting
and continue to the next menu.
• Manual Override Mode: During normal operation, when the input source is
charging from CH2, press and hold for more than 10 seconds to turn Priority
mode ON, ‘Priority’ icon on display will turn ON. This will force the charger
from being connected to CH2 and connect it to CH3 (subject to CH3 being
12.3v or 24.6V or higher). If CH3 is not connected or out of operating range,
it will go back to CH2. This setting mode is used when CH2 (Solar) is available
but the charging current is too small due to the availability of sunlight. Use the
same procedure to turn o the ‘Manual Override’ mode when not required.
•
Please Note: If Manual Override Mode is used and left on there is a risk of attening
the start battery. The preferred method is to use the automatic override method
by connecting the ignition source to the ignition terminal of the DC2DC+ charger.
•
With Flooded Battery Type setting, press and hold the “SET“ and “SEL“ buttons
together for more than 5 seconds will force the charger into Equalized Mode
and it will start equalizing the ooded battery. Please note; the battery has
to be set to ‘Flooded’ battery type in-order to have this function activated.
•
During the charger Setup Menu, this button is used to change to the next
available setting.
•
‘Silent’ mode (Fan OFF mode): During normal operation, Press and hold for
more than 10 seconds will force the fan to turn OFF. ‘Auto’ icon will turn ON.
The charger current will reduce to half of the set current. The unit will go back
to normal after 12 hours and the ‘Auto’ icon will turn OFF.
•
Note: Every time the “MENU“, “SET“ and/or “SEL“ buttons are pressed, the back
light will illuminate and will automatically turn o after 60 seconds.
www.enerdrive.com.au Page 27
Automatic Override Functions:
When positive power is applied to the “Ignition Sense” terminal (do not connect to ground),
it will force the charger to connect to CH3 as long as CH3 is within the voltage range >12.3V
or 24.6V on a 24v input.
Programming Your Charger
Press and hold the key for longer than 3 seconds to enter charger setting mode and
show function setting. Once new setting is done, press ‘MENU’ again for longer than 3
seconds to exit the charger setting mode.
Press the key once to keep / save the chosen setting and change the display to show the
next menu to continue other settings.
Note: The selected setting will quickly ash 3 times to acknowledge the setting.
Press the key to view other available settings.
Understanding the Two-Stage (Mode 2) Charging
(Default setting is 3)
The DC2DC+ can be set to act as a 2 stage charger (Bulk/Float). Certain applications may
require a 2 stage charge process and by setting this option, the DC2DC+ unit will act
accordingly to meet this requirement.
During the Bulk stage, the battery accepts the maximum constant current from the charger.
In Float stage, the charger continuously produces a lower constant oat voltage to maintain
the battery in a fully charged stage.
Understanding The Three-Stage (Mode 3) Charging
The Three-Stage Charging (Mode 3) has a Bulk/Absorption/Float sequence. During the Bulk
stage, the battery accepts the maximum constant current from the charger. In the Absorption
stage, the battery voltage is held to constant voltage and the charging current will slowly
reduce. In Float stage, the charger continuously produces lower constant oat voltage to
fully top up and maintain the battery in a fully charged stage.
The charger will automatically restart the full charging cycle if it senses the battery bank is
discharged to lower than 12.5V for lead acid batteries and 13.3V for lithium batteries.
Understanding The Battery Temperature Functions
The Battery Temperature Sensor is included with the charger to protect your battery and
provide better charging voltage accuracy.
When the battery temperature sensor output is used, it is highly recommended to be
installed on the main battery bank at the negative terminal. The sensor senses the battery
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 28
temperature and overrides the manual temperature settings and makes small adjustments
to the charging voltage.
If using lithium batteries, leave temp set to “NOR” (Normal) and leave temp sensor
disconnected.
Battery Temperature Compensation:
There are three manual battery temperature settings on the unit (‘Lo’, ‘nor’ and ‘hi’). See the
table below for voltage adjustments for temperature compensation.
Temperature Setting Recommended
Battery Temperature Battery Type
Voltage adjustment
from 25°C normal
setting
Low (Lo) < 5°C GEL, Flooded + 0.675 V
AGM + 0.525 V
Normal (Nor) > 5°C and < 30°C GEL, Flooded 0 V
AGM 0 V
High (HI) > 30°C GEL, Flooded - 0.27 V
AGM - 0.21 V
Battery Temperature Sensor (BTS) Voltage Adjustment:
Battery Temperature Battery Charging Voltage Adjustment from 25°C
Flooded and GEL type AGM type
< 25°C + 0.027V / °C + 0.021V / °C
25°C 0V 0V
> 25°C - 0.027 / °C - 0.021 / °C
Note: The above voltage compensation will only work with the supplied Battery Temperature Sensor tted which
will override the unit temperatures’ (Lo, Nor, Hi) setting. If using lithium batteries, leave temp setting “NOR“ (Normal)
and leave temp sensor disconnected.
Procedure To Set Or View Charger Setting
Follow the procedure or sequence in Appendix A1 and A2 (see back of this manual) to set
or view the charger setting.
www.enerdrive.com.au Page 29
Procedure To Equalise Flooded Batteries
DANGER
Explosion Hazard And Risk Of Battery Damage.
The battery generates explosive gases during equalisation. Follow all the battery safety
precautions listed in the manual.
When using the equalisation mode, the user has to be sure the battery connected to
the battery charger is a ooded battery type. Equalizing a non-ooded battery may
overcharge the battery and may cause the battery to explode.
CAUTION
Risk of battery and equipment damage.
Only Flooded lead-acid can be equalised. Consult your battery manufacturer or read the
battery manual when you try to equalise your batteries.
Disconnect any DC load connected to the battery, as during equalise mode, the charger will
produce 15.5V to the batteries. You must monitor the battery specic gravity throughout
the equalisation process to determine the end of the equalising cycle.
Before setting the equalisation mode, please be sure the battery is a ooded battery type.
When the battery equalisation has started, the charger will automatically fully charge the
battery bank and will then follow with 1 hour of equalisation. Check the battery electrolyte
level during the equalisation period. If necessary, rell with distilled water only. All cells
should have similar electrolyte levels. If distilled water is added, batteries must undergo a
complete charge cycle. The charger cannot determine when to terminate the equalisation
of the battery, a one hour time-out is set and this is used as a safety feature to require the
user to continually re-activate it as necessary after checking batteries manually.
Use the following procedure to setup the charger for battery
equalisation.
With Flooded Battery Type setting, Press and Hold Button “SET“ and “SEL“ together for
more than 5 seconds. This will force the charger to go into to Equalized mode and it will
start equalizing the ooded battery. Please note the battery mode setting has to be set to
‘Flooded’ battery type in-order to have this function activated.
Enerdrive ePOWER DC2DC+ Battery Charger Owners Manual (Rev. 1.00)Page 30

Produkt Specifikationer

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Model: DC2DC+

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