Express Encore Battery Charger Service Manual: Model: Exe3

Model: EXE3
Express ® EnCore™ Battery Charger
Service Manual
To automatically be connected to your closest Service Center, call us toll-free at:

1-800-ENERSYS (1-800-363-7797)
I.B. 1661
Rev AA 8/17
IMPORTANT
Read and understand your user’s manual before installing, operating or servicing this
product.
DO NOT DESTROY THIS BOOK
Express® EnCore™ Service Manual I.B. 1661
TABLE OF CONTENTS

Important Safety Instructions ............................................2 Delay Saving ....................................................... 20
Technical Information .........................................................3 Themes ............................................................... 21
Part Number .................................................................3 Daylight Savings .......................................................... 22
Output Power Letter Codes .................................4 Password ............................................................................ 22
Cabinet Size/Gauge Letter Codes .......................4 Settings ............................................................................... 23
DC Voltage Number Codes .................................4 Charge ................................................................................. 24
AC Line Voltage Letter Codes .............................5 Profile........................................................................... 24
Charge Profile Letter Codes ................................5 Charge Delay ............................................................... 24
Specialty Charger Option List ..............................5 Daily Charge ................................................................ 24
Serial Number ..............................................................5 Block Out Charge ........................................................ 24
Battery Type .................................................................6 Conditional Charge ...................................................... 24
Max AH.........................................................................6 Floating ........................................................................ 25
No. Cells .......................................................................6 Battery Rest ................................................................. 25
Max Modules ................................................................6 Cold Pulse ................................................................... 25
Config Modules ............................................................6 Refresh ON/OFF .......................................................... 25
Hertz .............................................................................6 Imax ............................................................................. 25
Phase ...........................................................................6 Battery ................................................................................. 26
AC Volts .......................................................................6 NB Cells ....................................................................... 26
Config AC Amps ...........................................................6 Cap Manu/Auto ............................................................ 26
Max AC Amps ..............................................................6 Capacity ....................................................................... 26
Max DC Amps ..............................................................6 Battery Temperature .................................................... 26
DC Volts .......................................................................6 High Temperature ........................................................ 26
Config DC Amps...........................................................7 Cable.................................................................................... 26
CEC ..............................................................................7 Length .......................................................................... 26
cULus ...........................................................................7 Section ......................................................................... 26
Installation ...........................................................................8 Equalization ........................................................................ 27
Location ........................................................................8 Manu Current ............................................................... 27
Cabinet Mounting .........................................................8 Time ............................................................................. 27
Electrical Connections ..................................................8 Delayed Start (Delay)................................................... 27
Connecting Input Power ...............................................8 Frequency .................................................................... 27
AC Disconnect..............................................................9 Options ................................................................................ 27
Plug Polarity .................................................................9 Options Test ................................................................ 27
Grounding the Charger .................................................9 Electrovalve Time ........................................................ 27
Description of Operation ....................................................10 Comm IQ ON/OFF ............................................................... 27
General.........................................................................10 Network ............................................................................... 27
Starting the Charge Cycle ............................................10 Protocol........................................................................ 27
Charging Current ..........................................................10 Baud Rate .................................................................... 27
AC Power Fail ..............................................................10 Address JBUS ............................................................. 27
Series Charging............................................................10 Charging the Battery .......................................................... 28
Glossary...............................................................................11 Charger Idle Display .................................................... 28
Wi-iQ® Device ...............................................................11 Starting a Charge Cycle ............................................... 29
Charging Profile............................................................11 Delayed Start ............................................................... 29
Cold Storage Profile .....................................................11 Count Down Display .................................................... 29
Equalization Charging ..................................................11 Charger Display ........................................................... 30
Fast Profile ...................................................................11 End of Charge Display ................................................. 31
IONIC™ Profile.............................................................11 End of Charge without Equalization ............................. 31
Opportunity Profile ........................................................11 End of Charge with Equalization .................................. 31
Operation ...............................................................11 Manual Equalization Start ................................... 31
Daily Charge ..........................................................12 Automatic Equalization Start ............................... 32
Block Out Time .............................................................12 Fault Codes ......................................................................... 33
Refresh Charging .........................................................12 Fault Display ................................................................ 33
Abbreviations and Acronyms ............................................13 Maintenance and Service................................................... 35
Operating Instructions........................................................14 Testing of Components ..................................................... 35
Control Panel.......................................................................15 LEDs on the Module ............................................................. 35
Menu Access .......................................................................16 Component Replacement .................................................. 36
Main Menu Display .......................................................16 DC Output Fuse ........................................................... 36
Main Menu....................................................................16 AC Input Fuses ............................................................ 36
Logs .....................................................................................17 DC Cables ................................................................... 37
Memorizations Display Screen .....................................17 Display Board .............................................................. 37
Displaying a Charge Cycle ...........................................17 Power Modules ................................................................... 38
Memorization Data .......................................................17 Fan Cleaning ....................................................................... 38
Status ...................................................................................18 Component Locations........................................................ 41
Status Screen ...............................................................18 Parts List ............................................................................. 43
Charger ................................................................................19 Mounting Dimensions ........................................................ 45
Information ...................................................................19 3.5 kW 4 Bay Cabinet
Charger Information Display .........................................19 Mounting Dimensions .................................................. 45
USB ......................................................................................20 3.5 kW 6 Bay Cabinet Mounting
Update Software...........................................................20 Dimensions .................................................................. 46
Settings ................................................................................20 3.5 kW 8 Bay Cabinet Mounting
Parameters ...................................................................20 Dimensions .................................................................. 47
Date/Time .....................................................................20 Technical Specifications.................................................... 48
Language .....................................................................20 Maintenance Log ................................................................ 52
Region ..........................................................................20
Display..........................................................................20
Screen Saver .......................................................20
1
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.
2
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
3
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 (kW) Modules (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 number of slots and size of the DC cables.
Letter Module Standard Cable

Comments
Code Positions Gauge
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 Output
Code Voltage(s)
4 24/36/48
5 72/80
6 64
7 60
4
AC Line Voltage Letter Codes

the AC line voltage(s) and AC line frequency at which the charger can be operated.
Line
Letter Voltage(s)
Frequency Comments
Code (volts rms)
(Hertz)
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 48.
Charge Profile Letter Codes

the Charging profile of the charger.
Letter
Profile
Code
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
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.
5
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.
6
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):
7
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 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.
NOTE: Ambient temperature at all levels cannot exceed 113° F (45° C).
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

Remove the top and connect the AC input to the terminal blocks provided on top, NOT on the
backplane. 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:
8
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:
9
DESCRIPTION OF OPERATION
General
Express® EnCore™ chargers are microprocessor-controlled. When using the Fast Profile, the
battery voltage and capacity is communicated to the charger by the Wi-iQ® device. The charging
coefficient is maintained absolutely on all types of batteries. 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.
Starting the Charge Cycle

When a battery 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 including the percentage of battery
capacity.
AC Power Fail
If the AC power fails with a battery connected to the charger during a charge cycle, the charger
will reset and start a new charge cycle when power is restored. All charger settings as well as
the time and date are preserved.
Series Charging
In series charging, the voltages of both batteries add up and must match charger’s nameplate
DC Volts rating. The charger’s amp-hour rating must be equal to each battery’s ampere-hour
rating. Charge cycle will not start unless both batteries are connected.
10
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. The Wi-iQ® device is required when using the Fast Profile.
Charging Profile
The charging profile defines the rate of charge current over time. The charger adapts to the
battery’s age and level of discharge. Controlling the overcharge coefficient, whatever the
battery’s discharge level, reduces the amount of electricity consumed.
Cold Storage Profile

This is a charging profile that allows the configuration of the charger for use with batteries in cold
storage application. The profile is an IEI (constant current, constant voltage, constant current)
type with a number of user configurable parameters.
Equalization Charging
Equalization charging, performed after normal charging, balances the electrolyte densities in the
battery’s cells.
Fast Profile
This charging profile is an IEI charging profile designed to charge batteries at rates between 40-
50% of their rated amp hour 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 active material, causing sulfuric acid to
be distributed outside the plates and balances out differences in density, homogenizing the
electrolyte across the surface of the plates.
Opportunity Profile
This charging profile is used when opportunity charging is desired. It includes a start rate of up
to 25% of the battery’s 6-hour rated amp hour capacity and requires an equalize charge
performed once a week. The weekly equalize charge can be programmed to run automatically.
Operation
During opportunity charging the user should charge the battery during breaks, lunch or
any available time during the work day. The Opportunity Profile allows the battery to be
safely charged while it is kept in a partial state of charge between 20% and 80% of the
6-hour rated capacity during the work week. Sufficient time should be scheduled after
the weekly equalize charge to check and maintain electrolyte levels and allow the
battery to cool to ambient temperatures.
11
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.
Complete Charge Time

The time of day for a Complete 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 Charging
Refresh or maintenance charging enables the battery to be maintained at maximum charge all
of the time that it is connected to the charger.
12
ABBREVIATIONS AND ACRONYMS
AGM Absorbed Glass Mat
AGV Auto Guided Vehicle
AH Amp-Hour
AWG American Wire Gauge
AVAIL Available
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
13
OPERATING INSTRUCTIONS
The Express® EnCore™ series of chargers are compatible with batteries of 24, 36, 48,60,64,
72 and 80 volts (depending on the version supplied).
Battery recognition (voltage, capacity and state of charge) is accomplished automatically by the
microprocessor. Several charging profiles are available (Cold Storage, 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 wirelessly
transmitted to the Express EnCore to optimize charging, alerts the operator to battery issues,
and safeguard the battery from being permanently damaged.
14
CONTROL PANEL
10
3
1
9 8 11 6
Ref Function Description

1 Graphical TFT display Display charger operation info/Menus
2 Navigate UP button Navigate menus/Change values
Select menu items/Enter values/Stop and
3 ENTER/STOP and START button
restart battery charge
4 Navigate RIGHT/EQUALIZE button Scroll right/Start equalize or desulfation
5 Navigation DOWN button Navigate menus/Change values
6 Navigation LEFT/ESC button Enter Main Menu/Scroll left/Exit menus
OFF = no fault
7 RED fault indicator FLASHING = ongoing fault detected
ON = fault
OFF = charger output is off
8 YELLOW charging indicator
ON = charging in progress
OFF = charger off or battery not available
9 GREEN charge complete indicator Flashing = cooling phase
ON = battery ready and available
OFF = AC missing
10 BLUE AC supply indicator ON = AC present
11 USB port Download memos/Upload software
15
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> button.
Main Menu
All 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 and others (SETTINGS icon).
 Management of password (PASSWORD icon).
 Exit main menu (EXIT icon).
16
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. After memorizing the three-hundredth charge, the oldest record is deleted and
replaced by the next oldest.
Displaying a Charge Cycle

Proceed as follows:
1. Select a record (MEMO x) using the ▲/▼ buttons.
2. Display the first History screen by pressing Enter.
3. Display the second History screen by pressing▼.
4. Return to the Main Menu by pressing Esc.
The charge history is displayed; use the ▲/▼ to scroll through the parameters.
Memorization Data
Memo Description Memo Description

Wi-iQ® device serial
S/N I end Current at end of charge
number
Battery temperature at
Capacity Rated battery capacity (AH) Temp end
end of charge (F)
Time of the charge cycle
U batt Rated battery voltage (V) Chg Time
(minutes)
Battery temperature at start Amp-hours returned
Temp AH
of charge (F) during charge cycle
Kilowatt-hours returned
Techno Battery technology kWh
during charge cycle
Profile Selected profile Status Partial or Complete
State of charge at start of
% init Default Fault codes
charge (%)
Battery voltage at start of Start of charge date and
U start SoC
charge (Vpc) time
Battery voltage at end of Battery disconnect date
U end DBa
charge (Vpc) and time
Termination code
Warning Wi-iQ® device warnings CFC
(for service tech)
17
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
Charge
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)
18
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
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
19
USB
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.
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 illuminated. The delay time is adjustable in minutes up to
one hour and 59 minutes.
20
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.
FUNCTION Theme A Theme B
Battery Disconnects while

Charging. Alternates every two
IDLE Screen
seconds with CONNECT BATTERY.
Charger paused
while battery connected
CHARGING
Screen
21
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. 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. The default password is 0099.
22
SETTINGS
This menu allows for the configuration of the charger. A password is required to view this menu.
Required Setup – The following parameters must be set including Date and Time:
PARAMETERS / DAYLIGHT US – CANADA

PARAMETERS / DISPLAY / SCREEN SAVER ON
PARAMETERS / DISPLAY / TIME 01H00
PARAMETERS / SERIAL NUMBER PER ORDER
CONFIGURATION / CHARGE / CHARGE DELAY / TYPE OFF
CONFIGURATION / CHARGE / CHARGE DELAY / VALUE HOUR/DELAY 00H00
CONFIGURATION / BATTERY / CAP MANU AUTO AUTO
CONFIGURATION / EQUALIZATION / DELAY 00H00
CONFIGURATION / EQUALIZATION / FREQUENCY SUNDAY
CONFIGURATION / EQUALIZATION / REFRESH ON/OFF OFF
CONFIGURATION / POWER SUPPLY PER ORDER
CONFIGURATION / CHARGE / IMAX PER ORDER
PROFILE OPPOR
CONFIGURATION / BATTERY / CAP MANU AUTO AUTO
CONFIGURATION / BATTERY / CAPACITY PER ORDER
CONFIGURATION / BATTERY / TEMPERATURE 77° F
CONFIGURATION / CHARGE / DAILY CHARGE / ON – OFF OFF
CONFIGURATION / CHARGE / DAILY CHARGE / DAILY CHG START 22H00
CONFIGURATION / CHARGE / DAILY CHARGE / DAILY CHG END 04H00
CONFIGURATION / EQUALIZATION / MANU CURRENT 0.045*CAP
CONFIGURATION / EQUALIZATION / TIME 06H00
PROFILE IONIC
PROFILE COLD
PROFILE FAST
(Default Factory Ship Configurations)
23
CHARGE
Profile
For selecting the right charging profile for the application:
IONIC™, FAST, OPP, COLD STORAGE
Without Wi-iQ® device: Profile selected will be used. Values stored in the BATTERY menu,
such as CAPACITY (except Ionic) and TEMPERATURE, are used to determine key charging
parameters. Make sure these values match the battery to be charged or the battery may be over
or under charged which will result in decreased battery life or performance.
With Wi-iQ® device: The appropriate profile for the battery technology will be selected at the
start of charge. Battery capacity and temperature will also be transmitted to the charger control.
Charge Delay
Type - sets OFF, DELAY, or TIME OF DAY.
Value hour delay - sets the amount or time of day for the delay (00:00 to 24:00).
Delay: Start of charge is delayed for the amount of time stored in VALUE (0 to 24 hours).
Time of Day: Charge will not start until the time of day stored in VALUE (24 hour format).
Daily Charge
ON/OFF – Sets daily charge ON or OFF.
Daily Chg Start – Sets daily charge start time.
Daily Chg End – Sets daily charge end time.
Block Out Charge

ON/OFF – Sets block out charge ON or OFF.
Block Out Start – Sets daily charge start time.
Block Out End – Sets daily charge end time.
Conditional Charge
Set conditional charge %.
The charger will only commence the charge if the battery has reached the limit of Depth of
Discharge (DoD) of more than x%. For example if the user wants to charge the battery only if it
is discharged more than 30%, the parameter 30 has to be entered in the conditional charge. The
0 value disables the function.
24
Floating
ON/OFF- Sets float mode ON or OFF.
Current – Sets float current.
Voltage – Sets float voltage.
This feature can be turned ON or OFF depending on the application. A float charge at the end
of standard charge is intended to compensate for consumption by the truck electronics that are
left on when truck is not used (typically AGV). The parameter VOLTAGE is in mVpc (millivolts
per cell) determines the maximum float voltage. The parameter CURRENT defines the current
output during float, the current will automatically decrease to keep the battery voltage at the
maximum defined by the VOLTAGE parameter.
Battery Rest
Set battery rest time in hours.
Cold Pulse
Sets Cold pulses ON or OFF.
Refresh ON/OFF
Sets refresh mode ON or OFF.
Imax
Sets charger maximum output current.
25
BATTERY
NB Cells
Sets number of battery cells: Auto, 6, 12, 18, 24, 30, 32, 36 and 40 Cells.
Cap Manu/Auto
When in Ionic mode, the charger can estimate the capacity of the connected battery
automatically “Auto” or the charger will use the capacity entered manually “Manu” in the Capacity
menu.
Capacity
Without Wi-iQ® device: Battery AH capacity used by the charger (must be set to “Manu” for
Ionic profile) to determine start and finish rates.
With Wi-iQ® device: the battery AH capacity will be automatically transmitted from Wi-iQ device.
Battery Temperature
This parameter adjusts the regulation voltages on the charging profile – values from 5°F (-15°C)
to 149°F (65°C).
Without Wi-iQ® device: defines the average operating battery temperature before the charge.
It is recommended the average electrolyte temperature be entered, especially in cold areas.
With Wi-iQ® device: the battery operating temperature will be automatically transmitted from
Wi-iQ® device. The battery temperature will be analyzed during the charge; if it increases too
much, the charger will stop to prevent any possible damage.
High Temperature
Defines a battery temperature safety limit.
Without Wi-iQ® device: Not used.
With Wi-iQ® device: If the battery temperature, during the charge, reaches the programmed
limit, the charger will stop the charge and wait until the temperature decreases.
CABLE
Length
Select the length of DC cables from the charger to the battery terminals in one foot increments
from three to 99 ft.
Section
Sets the DC cable gauge. Selections are 4, 1/0, 2/0 and 3/0 (AWG).
26
EQUALIZATION
Manu Current
This defines the equalization or desulphation current for a manual start.
Time
Sets the equalization time from one to 48 hours.
Delayed Start (Delay)

Sets the delay between the normal charge and the equalization charge from zero to 23 hours.
Frequency
Selects one or several periods for carrying out the equalization charge. The user can select one
or several days per week.
OPTIONS
Options Test
Turns on Battery Status (Red/Green) and Electrovalve output briefly to test operation.
Electrovalve Time
Sets time ON in seconds.
COMM IQ ON/OFF
Turns IQ communications ON or OFF.
NETWORK
Protocol
Set a protocol to Jbus, LAN, or BFM.
Baud Rate
Sets baud rate.
Address JBUS
Sets address.
27
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.
With the charger in wait mode (no battery connected) and without pressing the Stop/Start button,
the display will show the following information:
1
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
28
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.
Count Down Display
Without a Wi-iQ® Device

If the Wi-iQ® device adapter is not 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 routine determines which Wi-iQ device in range the battery charger is
connected to. Once the charger makes the determination it downloads data from Wi-iQ
device, displays the battery S/N, updates the profile capacity, and temperature for
charging, and starts the main charge.
*Not applicable to Fast Charge Profile.
29
Charger Display
A few moments into the effective charge, the display will begin alternating between the following
charging information:
5 1
2 6
4
3
10
10 11 12 7 8 9
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
30
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:
 Total charging time.

 Amp-Hours restored to the battery.
L2 0 1 0 24-3 6 -48V U S11
Any other lit LED indicates a problem during charging. Please refer to paragraph Control Panel
for more information.
If the battery 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
equalize button can also be pressed any time during the charge and an equalize charge
will be started after charging is complete.
NOTE: When an Equalize charge is manually started, the output current will be set
to the value saved in the charger configuration.
31
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.
010 24 US1
3. The battery will be available when the green LED comes back on and the display shows
AVAIL.
4. The battery is now ready for use. If the battery remains plugged in and refresh charge
has been enabled, refreshes will 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 8 hours on Sunday at 00 hour.
The battery will be available when the green LED comes back on and the display shows AVAIL.
The battery is now ready for use. If the battery remains plugged in and refresh charge has been
enabled, refreshes will occur to maintain an optimal charge. Push the ON/OFF button before
unplugging the battery.
32
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.
Fault Critical Cause Solution

DF1 Yes Low output current Check input voltage and fuses.
Check for proper battery connection
DF2 Yes Output fault
(reversed polarity). Check output fuse.
Battery voltage too high (>2.4 Vpc) or
DF3 Yes Incorrect battery too low (<1.6 Vpc). Use proper
charger for battery.
The battery has been Prevent future over discharging of
DF4 No discharged more than battery. Battery charge gauges and lift
80% of its capacity. interrupts may need calibration.
Non critical fault. Check battery cables
for condition and size, check for loose
DF5 No Battery requires inspection
connections, check for defective cells.
Check for defective cells.
Non critical fault. This will cause the
charge to terminate early. Battery may
require service.
Check the battery (Temperature,
DF7 No Inspect battery
Specific gravity...).
Check the battery condition of use.
Check the configuration in the menu
(charge cables parameters).
Fault Critical Cause Solution
33
Check that fans are working.

TH Verify that ambient temperature is not
or Yes Charger overheating too high – above 113° F (45° C).
TH-Amb Inspect to see if charger ventilation is
obstructed or impaired.
No Low battery electrolyte Check battery electrolyte level.
WATER
Yes Critical battery electrolyte Check battery electrolyte level.
LEVEL
Battery temperature reached
BAT TEMP Yes Allow battery to cool down.
maximum level.
Display on the top left corner Check that the fan(s) is (are) working
- one or more module in correctly and/or that the ambient
thermal fault – the charge temperature is not too high or whether
TH No
process continues – the fault there is poor natural ventilation to the
module(s) is (are) displayed charger. If all modules are in thermal
+ red led flashing. fault a TH fault will follow.
Display on the top left
corner - one or more
module in DF1 fault –
Check power modules. If all modules
DFMOD** No the charge process
in DF1 fault a DF1 error will follow.
continues – the fault
module(s) is (are)
displayed + red led flashing.
Blocking fault – one or more
modules are not compatible
with the charger
configuration (for example
24 V charger with one 48 V
DEF ID Yes Use correct module(s).
module). This can happen if
the user replaces one
module with another one
with a different voltage
setting.
Check the AC input, AC fuses, if AC
Failed power module, AC
DF-CUR Yes fuses are open, perform internal
fuses or AC input
module tests
No Battery balance fault Check battery cell voltages.
34
**DFMOD: Go to the menu Charger/Information for the details (x is the module number)
..................... Module is unplugged or no CAN communication
MOD x TH Thermal Fault
MOD x VLMFB LMEB input fault
MOD x VBATMAX Module reached max voltage value
MOD x FUSE-OUT Output fuse open
MOD x PWM-MAX Module reached max current
MOD x ERROR Module internal error
MOD x VBAT VBAT input fault
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 a minimum of maintenance. Connections and terminals should be kept
clean and tight. The unit (especially the module heatsink and fan) should be periodically cleaned
with low pressure air 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 installed.
TESTING OF COMPONENTS
IMPORTANT: DISCONNECT BATTERY AND TURN AC POWER OFF BEFORE

SERVICING.
NOTE: Only qualified personnel should service this battery charger.
LEDs on the Module

All 3 LEDs flash for 6 seconds at power up.
Yellow LED: If ON, AC power is ok. If OFF, AC power is missing or charger is in idle mode.
Green LED: If flashing, no DC current. If ON, DC current is present.
Red LED: If ON or flashing, refer to fault code on display.
All LEDs OFF: No AC power, phase loss or in idle mode.
35
COMPONENT REPLACEMENT
DC Output Fuse
Important: Before replacing the DC fuse, test the output diodes to make sure none of them are
shorted. To do that, use a multimeter and test voltage between the shunt (red lead) and the
charger side of the DC fuse (black lead) as shown below. You should read over 0.3 VDC. If
voltage reads over 0.3 VDC, replace fuse with same value and torque the nuts to 44 in.lb, if
voltage reading is below 0.3 VDC, replace the module.
(Set meter to diode junction symbol )
AC Input Fuses
Important: Before replacing any of the AC fuses, make sure DC bus has no shorted
components. To do that, use a multimeter (set meter to diode junction symbol ) and test
across MOV marked as M7 or M4 (some modules show M7 and some newer ones like in the
600V show M4) as shown below. If you read around 0.7 VDC, replace the faulty AC fuse(s), if
you read lower than 0.55VDC, replace the module.
36
DC Cables
Replace where needed and torque nuts to 44 in.lb
TORQUE 5 PLACES TO 44 in.lb
Display Board
CAUTION: Use an anti-static wrist strap when removing and replacing circuit board
assemblies.
REMOVAL
Please follow these steps to remove a Display board.
1. Touch your finger to a ground to remove any static charge.
2. Unplug all connectors from the display board. Some connectors may be secured by
screws.
3. Pull the board out from its mounting standoffs. NOTE: Handle the Display board with
care. Do NOT place it on top of the battery or other acid-contaminated surfaces.
4. Place the removed display board into the anti-static bag (or foam) that the replacement
board was in.
REPLACEMENT
1. Align the board mounting holes to the standoffs and carefully push the board in until it
locks to the standoffs.
2. Carefully attach the connectors back to the replacement board.
3. Attach connectors with screws, if used.
37
POWER MODULES
Heat Sinks
DC Fuse
Heat Sinks
Fans
FAN CLEANING
1) Follow all required lockout/tagout procedures required by EnerSys and/or the customer
to ensure that the charger is electrically dead prior to opening the charger door.
2) Put on electrical Personal Protective Equipment (PPE) as required.
3) Open the charger door and, using a multimeter, ensure that the charger is electrically
dead.
38
Charger Door
Screws
4) Remove the modules from the charger, one at a time, by loosening the two (2) Phillips
head screws (one top and one bottom) and pulling the module out.
39
5) Using a Phillips head screw driver, remove the screws on the side of the module in order
to gain clear access to the parts to be cleaned.
3.5KW module
6) Using low pressure air (must be less than 30psi per OSHA):
a) Blow out the fan in the front of the module
b) Blow out the heat sinks
c) Blow out areas where dust appears to be accumulating
d) Canned air can be used in place of compressed air
Replace each module after it has been cleaned, then repeat the process with the remaining
module(s).
40
COMPONENT LOCATIONS
BACKPLANE
POWER SUPPLY
TRANSFORMER
TORQUE:
2 AND 4 BAY: 10 IN.LB
6 BAY: 20 IN.LB
DC CABLES
TORQUE:
44 IN.LB
41
TORQUE ALL AC
CONNECTIONS
ON 8-BAY TO
15 IN.LB
TORQUE ALL AC
CONNECTIONS
ON 3 & 6-BAY TO
15 IN.LB
42
3.5 kW PARTS LIST

Part# Description QTY
X225-40-EXE3 Display/Control Board, Express® EnCore™ 1
X014-99-2 AC Fuse, backplane, 0.5 A, 500 VAC, 1.25”x0.25” 1
X014-34-1/2 AC Fuse, backplane, 0.5A, 600VAC, Class CC, 1.5”x0.4” 1
X014-208-16 AC Fuse, 16A, 240/480V power module, Bussmann 1.25”x0.25” 3
X014-208-20 AC Fuse, 20A, 240/480V power module, Litellfuse 1.25”x0.25” 3
X014-34-6 AC Fuse, 600V power module, 6A Class CC, 1.5”x0.4” 3
X014-208-80 DC fuse, 80A, Bussmann 80LET 1
X014-208-125 DC fuse, 125A, Bussmann 125LET 1
090-6LA01028 Ribbon Cable, 3.5kW, 2/4/6bay, Display 1
090-6LA01025 Ribbon Cable, 3.5kW, 2/4/6bay, Options 1
090-6LA01132 Ribbon Cable, 8bay, Display 1
090-6LA01126 Ribbon Cable, 8bay top to bottom backplane 1
090-6LA01133 Ribbon Cable, 8bay, Options 1
X225-AC-MOD3 AC Terminal Block and wiring kit, 3.5kW 1
256-184-3 AC terminal block, 8bay 3
256-184-1 AC terminal block, 3.5kW, 2/4/6/bay 3
X1106-6LA01127 Wiregroup, 8bay, AC terminal blocks to disconnect switch 1
X1106-6LA01128 Wiregroup, 8bay, single display, disconnect switch to contactor-in & Top backplane 1
X1106-6LA01130 Wiregroup, 8bay, single display, contactor-out to bottom backplane 1
X1106-6LA01136 Wiregroup, 8bay, dual display, disconnect switch to top & bottom backplane 1
006-6LA12613 Standoff Insulator for bussbar, metric 8
090-6LA22627 Bussbar, positive DC, 8bay 2
090-6LA22628 Bussbar, negative DC, 8bay 2
X129-6LA10552 Contactor, 8bay 1
X002-6LA10728 AC disconnect switch, 8bay, 80A 1
159-6LA22532 Lower Mounting Bracket 2
159-208-36 Upper Mounting Bracket, 4 Bay 1
159-6LA22555 Upper Mounting Bracket, 6 Bay 1
X225-6LA20671 Power Module, 24/36/48 VDC, 480 VAC 1
X225-6LA20656 Power Module, 72/80 VDC, 480 VAC 1
X225-6LA20677 Power Module, 24/36/48 VDC, 600 VAC 1
X225-6LA20678 Power Module, 72/80 VDC, 600 VAC 1
X225-1/0-175 10 Ft of DC cable, 1/0, 175A Connector 1
X225-1/0-175-15 15 Ft of DC cable, 1/0, 175A Connector 1
X225-1/0-350-L15 15 Ft of DC cable, 1/0, 350A Connector 1
X225-6-15-16L6 6 Ft of 16 AWG AC cable 1
X225-6LA11943 Backplane Board Assembly, 4 Bay, 480V 1
43
X225-6LA11953 Backplane, 8 Bay, 1 display Top, 2 display Top & Bottom, 240/480V 1
X225-6LA11974 Backplane, 8 Bay,1 display Bottom, 240/480/600V 1
X225-6LA11989 Backplane, 8 Bay, 1 display Top, 2 display Top & Bottom, 600V 1
X225-EIP-4-3 Replacement Cabinet, 3.5 kW, 4 Bay, 480V 1
X225-EIP-6-3 Replacement Cabinet, 3.5 kW, 6 Bay, 480V 1
X225-EIP-4-3C Replacement Cabinet, 3.5 kW, 4 Bay, 600V 1
X225-EIP-6-3C Replacement Cabinet, 3.5 kW, 6 Bay, 600V 1
X225-EXE-8-2DCY Replacement cabinet, 3.5kW, 8 Bay, Express, 1 display, 2 DC out, 480V 1
X225-EXE-8-2DCC Replacement cabinet, 3.5kW, 8 Bay, Express, 1 display, 2 DC out, 600V 1
44
MOUNTING DIMENSIONS
3.5 kW 4 Bay Cabinet Mounting Dimensions
Dimensions shown are in inches.
45
46
47
TECHNICAL SPECIFICATIONS
3.5 kW Standard Technical Specifications
AC Input DC Output Max 8 Hour Charger

Voltage Max Amps Phase Min NEMA Cells kW Max Capacity (Ah) Cable
Part Number Cord Plug Current AWG
AWG (A)
EXE3-GN-4Y 400 5.6 3 14 L16-20 12, 18, 24 3.5 70/65/60 175/165/150 3/0
EXE3-HN-4Y 400 11.2 3 14 L16-20 12, 18, 24 7 140/130/120 350/325/300 3/0
EXE3-IN-4Y 400 16.8 3 12 L16-30 12, 18, 24 10.5 210/195/180 525/490/450 3/0
EXE3-JN-4Y 400 22.4 3 10 L16-30 12, 18, 24 14 280/260/240 700/650/600 3/0
EXE3-IP-4Y 400 16.8 3 12 L16-30 12, 18, 24 10.5 210/195/180 525/490/450 3/0
EXE3-JP-4Y 400 22.4 3 10 L16-30 12, 18, 24 14 280/260/240 700/650/600 3/0
EXE3-KP-4Y 400 28 3 8 CS8165C* 12, 18, 24 17.5 320/320/300 800/800/750 3/0
EXE3-LP-4Y 400 33.6 3 8 CS8165C* 12, 18, 24 21 320/320/320 800/800/800 3/0
3.5 70/65/60 175/165/150 3/0
EXE3GGR-4Y 400 11.2 3 14 L16-20 12/18/24
3.5 70/65/60 175/165/150 3/0
3.5 70/65/60 175/165/150 3/0
EXE3GHR-4Y 400 16.8 3 12 L16-30 12/18/24
7.0 140/130/120 350/325/300 3/0
7.0 140/130/120 350/325/300 3/0
EXE3HHR-4Y 400 22.4 3 10 L16-30 12/18/24
7.0 140/130/120 350/325/300 3/0
7.0 140/130/120 350/325/300 3/0
EXE3HIR-4Y 400 28 3 8 CS8165C* 12/18/24
10.5 210/195/180 525/490/450 3/0
10.5 210/195/180 525/490/450 3/0
EXE3IIR-4Y 400 33.6 3 8 CS8165C* 12/18/24
10.5 210/195/180 525/490/450 3/0
10.5 210/195/180 525/490/450 3/0
EXE3IJR-4Y 400 39.2 3 6 HW** 12/18/24
14.0 280/260/240 700/650/600 3/0
14.0 280/260/240 700/650/600 3/0
EXE3JJR-4Y 400 44.8 3 6 HW** 12/18/24
14.0 280/260/240 700/650/600 3/0
* Non NEMA plug ** Hard-Wired only
48

AWG (A)
EXE3-GN-5Y 400 5.6 3 14 L16-20 36, 40 3.5 40/36 100/90 3/0

EXE3-HN-5Y 400 11.2 3 14 L16-20 36, 40 7 80/72 200/180 3/0
EXE3-IN-5Y 400 16.8 3 12 L16-30 36, 40 10.5 120/108 300/270 3/0
EXE3-JN-5Y 400 22.4 3 10 L16-30 36, 40 14 160/144 400/360 3/0
EXE3-IP-5Y 400 16.8 3 12 L16-30 36, 40 10.5 120/108 300/270 3/0
EXE3-JP-5Y 400 22.4 3 10 L16-30 36, 40 14 160/144 400/360 3/0
EXE3-KP-5Y 400 28 3 8 CS8165C* 36, 40 17.5 200/180 500/450 3/0
EXE3-LP-5Y 400 33.6 3 8 CS8165C* 36, 40 21 240/216 600/540 3/0
EXE3-MR-5Y 400 39.2 3 6 HW** 36/40 24.5 280/252 700/630 3/0
EXE3-NR-5Y 400 38.4 3 6 HW** 36/40 28 320/288 800/720 3/0
3.5 40/36 100/90 3/0
EXE3GGR-5Y 400 9.6 3 14 L16-20 12/18/24
3.5 40/36 100/90 3/0
3.5 40/36 100/90 3/0
EXE3GHR-5Y 400 14.4 3 14 L16-20 12/18/24
7.0 80/72 200/180 3/0
7.0 80/72 200/180 3/0
EXE3HHR-5Y 400 19.2 3 10 L16-30 12/18/24
7.0 80/72 200/180 3/0
7.0 80/72 200/180 3/0
EXE3HIR-5Y 400 24 3 10 L16-30 12/18/24
10.5 120/108 300/270 3/0
10.5 120/108 300/270 3/0
EXE3IIR-5Y 400 28.8 3 8 CS8165C* 12/18/24
10.5 120/108 300/270 3/0
10.5 120/108 300/270 3/0
EXE3IJR-5Y 400 33.6 3 8 CS8165C* 12/18/24
14.0 160/144 400/360 3/0
14.0 160/144 400/360 3/0
EXE3JJR-5Y 400 38.4 3 6 HW** 12/18/24
14.0 160/144 400/360 3/0
EXE3-GN-4YF 480 4.8 3 14 L16-20 12/18/24 3.5 80/80/60 200/200/150 3/0
EXE3-HN-4YF 480 9.6 3 14 L16-20 12/18/24 7 160/160/120 400/400/300 3/0
EXE3-IN-4YF 480 14.4 3 14 L16-20 12/18/24 10.5 240/240/180 600/600/450 3/0
EXE3-JN-4YF 480 19.2 3 10 L16-30 12/18/24 14 320/320/240 800/800/600 3/0
49

AWG (A)
EXE3-IP-4YF 480 14.4 3 14 L16-20 12/18/24 10.5 240/240/180 600/600/450 3/0

EXE3-JP-4YF 480 19.2 3 10 L16-30 12/18/24 14 320/320/240 800/800/600 3/0
EXE3-KP-4YF 480 24 3 10 L16-30 12/18/24 17.5 320/320/300 800/800/750 3/0
EXE3-LP-4YF 480 28.8 3 8 CS8165C* 12/18/24 21 320/320/320 800/800/800 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
3.5 80/80/60 200/200/150 3/0
EXE3GGR-4YF 480 9.6 3 14 L16-20 12/18/24
3.5 80/80/60 200/200/150 3/0
3.5 80/80/60 200/200/150 3/0
EXE3GHR-4YF 480 14.4 3 14 L16-20 12/18/24
7.0 160/160/120 400/400/300 3/0
7.0 160/160/120 400/400/300 3/0
EXE3HHR-4YF 480 19.2 3 10 L16-30 12/18/24
7.0 160/160/120 400/400/300 3/0
7.0 160/160/120 400/400/300 3/0
EXE3HIR-4YF 480 24 3 10 L16-30 12/18/24
10.5 240/240/180 600/600/450 3/0
10.5 240/240/180 600/600/450 3/0
EXE3IIR-4YF 480 28.8 3 8 CS8165C* 12/18/24
10.5 240/240/180 600/600/450 3/0
10.5 240/240/180 600/600/450 3/0
EXE3IJR-4YF 480 33.6 3 8 CS8165C* 12/18/24
14.0 320/320/240 800/800/600 3/0
50

AWG (A)
14.0 320/320/240 800/800/600 3/0

EXE3JJR-4YF 480 38.4 3 6 HW** 12/18/24
14.0 320/320/240 800/800/600 3/0
EXE3-GN-5YF 480 4.8 3 14 L16-20 36/40 3.5 40/36 100/90 3/0
EXE3-HN-5YF 480 9.6 3 14 L16-20 36/40 7 80/72 200/180 3/0
EXE3-IN-5YF 480 14.4 3 14 L16-20 36/40 10.5 120/108 300/270 3/0
EXE3-JN-5YF 480 19.2 3 10 L16-30 36/40 14 160/144 400/360 3/0
EXE3-IP-5YF 480 14.4 3 14 L16-20 36/40 10.5 120/108 300/270 3/0
EXE3-JP-5YF 480 19.2 3 10 L16-30 36/40 14 160/144 400/360 3/0
EXE3-KP-5YF 480 24 3 10 L16-30 36/40 17.5 200/180 500/450 3/0
EXE3-LP-5YF 480 28.8 3 8 CS8165C* 36/40 21 240/216 600/540 3/0
EXE3-MR-5YF 480 33.6 3 8 CS8165C* 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
3.5 40/36 100/90 3/0
EXE3GGR-5YF 480 9.6 3 14 L16-20 12/18/24
3.5 40/36 100/90 3/0
3.5 40/36 100/90 3/0
EXE3GHR-5YF 480 14.4 3 14 L16-20 12/18/24
7.0 80/72 200/180 3/0
7.0 80/72 200/180 3/0
EXE3HHR-5YF 480 19.2 3 10 L16-30 12/18/24
7.0 80/72 200/180 3/0
7.0 80/72 200/180 3/0
EXE3HIR-5YF 480 24 3 10 L16-30 12/18/24
10.5 120/108 300/270 3/0
10.5 120/108 300/270 3/0
EXE3IIR-5YF 480 28.8 3 8 CS8165C* 12/18/24
10.5 120/108 300/270 3/0
10.5 120/108 300/270 3/0
EXE3IJR-5YF 480 33.6 3 8 CS8165C* 12/18/24
14.0 160/144 400/360 3/0
14.0 160/144 400/360 3/0
EXE3JJR-5YF 480 38.4 3 6 HW** 12/18/24
14.0 160/144 400/360 3/0
EXE3-GN-4CF 600 3.8 3 10 L17-30 12/18/24 3.5 80/80/60 200/200/150 3/0
EXE3-HN-4CF 600 7.6 3 10 L17-30 12/18/24 7 160/160/120 400/400/300 3/0
EXE3-IN-4CF 600 11.4 3 10 L17-30 12/18/24 10.5 240/240/180 600/600/450 3/0
EXE3-JN-4CF 600 15.2 3 12 L17-30 12/18/24 14 320/320/240 800/800/600 3/0
51

AWG (A)
EXE3-IP-4CF 600 11.4 3 10 L17-30 12/18/24 10.5 240/240/180 600/600/450 3/0

EXE3-JP-4CF 600 15.2 3 12 L17-30 12/18/24 14 320/320/240 800/800/600 3/0
EXE3-KP-4CF 600 19.0 3 10 L17-30 12/18/24 17.5 320/320/300 800/800/750 3/0
EXE3-LP-4CF 600 22.8 3 10 L17-30 12/18/24 21 320/320/320 800/800/800 3/0
EXE3-KP-4CFDC 600 19.0 3 10 L17-30 12/18/24 17.5 400/400/300 1000/1000/750 Dual 3/0
EXE3-LP-4CFDC 600 22.8 3 10 L17-30 12/18/24 21 480/480/360 1200/1200/900 Dual 3/0
EXE3-MR-4YFDC 600 26.6 3 8 3765C* 12/18/24 24.5 560/560/420 1400/1400/1050 Dual 3/0
EXE3-NR-4YFDC 600 30.4 3 8 3765C* 12/18/24 28 640/640/480 1600/1600/1200 Dual 3/0
3.5 80/80/60 200/200/150 3/0
EXE3GGR-4CF 600 7.6 3 14 L17-30 12/18/24
3.5 80/80/60 200/200/150 3/0
3.5 80/80/60 200/200/150 3/0
EXE3GHR-4CF 600 11.4 3 14 L17-30 12/18/24
7.0 160/160/120 400/400/300 3/0
7.0 160/160/120 400/400/300 3/0
EXE3HHR-4CF 600 15.2 3 12 L17-30 12/18/24
7.0 160/160/120 400/400/300 3/0
7.0 160/160/120 400/400/300 3/0
EXE3HIR-4CF 600 19 3 10 L17-30 12/18/24
10.5 240/240/180 600/600/450 3/0
10.5 240/240/180 600/600/450 3/0
EXE3IIR-4CF 600 22.8 3 10 L17-30 12/18/24
10.5 240/240/180 600/600/450 3/0
10.5 240/240/180 600/600/450 3/0
EXE3IJR-4CF 600 26.6 3 8 3765C* 12/18/24
14.0 320/320/240 800/800/600 3/0
14.0 320/320/240 800/800/600 3/0
EXE3JJR-4CF 600 30.4 3 8 3765C* 12/18/24
14.0 320/320/240 800/800/600 3/0
EXE3-GN-5CF 600 3.8 3 10 L17-30 36/40 3.5 40/36 100/90 3/0
EXE3-HN-5CF 600 7.6 3 10 L17-30 36/40 7 80/72 200/180 3/0
EXE3-IN-5CF 600 11.4 3 10 L17-30 36/40 10.5 120/108 300/270 3/0
EXE3-JN-5CF 600 15.2 3 12 L17-30 36/40 14 160/144 400/360 3/0
EXE3-IP-5CF 600 11.4 3 10 L17-30 36/40 10.5 120/108 300/270 3/0
EXE3-JP-5CF 600 15.2 3 12 L17-30 36/40 14 160/144 400/360 3/0
EXE3-KP-5CF 600 19.0 3 10 L17-30 36/40 17.5 200/180 500/450 3/0
EXE3-LP-5CF 600 22.8 3 10 L17-30 36/40 21 240/216 600/540 3/0
* Non NEMA plug
52

AWG (A)
EXE3-MR-5CF 600 26.6 3 8 3765C* 36/40 24.5 280/252 700/630 3/0

EXE3-NR-5CF 600 30.4 3 8 3765C* 36/40 28 320/288 800/720 3/0
3.5 40/36 100/90 3/0
EXE3GGR-5CF 600 7.6 3 14 L17-30 36/40
3.5 40/36 100/90 3/0
3.5 40/36 100/90 3/0
EXE3GHR-5CF 600 11.4 3 14 L17-30 36/40
7.0 80/72 200/180 3/0
7.0 80/72 200/180 3/0
EXE3HHR-5CF 600 15.2 3 12 L17-30 36/40
7.0 80/72 200/180 3/0
7.0 80/72 200/180 3/0
EXE3HIR-5CF 600 19 3 10 L17-30 36/40
10.5 120/108 300/270 3/0
10.5 120/108 300/270 3/0
EXE3IIR-5CF 600 22.8 3 10 L17-30 36/40
10.5 120/108 300/270 3/0
10.5 120/108 300/270 3/0
EXE3IJR-5CF 600 26.6 3 8 3765C* 36/40
14.0 160/144 400/360 3/0
14.0 160/144 400/360 3/0
EXE3JJR-5CF 600 30.4 3 8 3765C* 36/40
14.0 160/144 400/360 3/0
* Non NEMA plug
53
MAINTENANCE LOG
1. Modifications to Factory Settings

Date Variable Change Service Technician
2. Service
Date Description Service Technician
54
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
www.enersys.com Fax: +1-905-951-4441 Fax: +52-818-329-6489
I.B. 1661 Rev AA 8-17 © 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.E.

Express Encore Battery Charger Service Manual: Model: Exe3

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Express Encore Battery Charger Service Manual: Model: Exe3

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Model: EXE3

Express ® EnCore™ Battery Charger

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IMPORTANT SAFETY INSTRUCTIONS

Single Display Cabinet:

Dual Display Cabinet:

Output Power Letter Codes

Letter Output Power Number Module Power

Cabinet Size/Gauge Letter Codes

Letter Module Standard Cable

DC Voltage Number Codes

AC Line Voltage Letter Codes

Charge Profile Letter Codes

Specialty Charger Options List

WARNING: THE NUMBER OF MODULES MUST MATCH THE NUMBER OF “CONFIG

Connecting Input Power

Phase Power (kW) Cabinet (Bay) Terminals Torque (in-lbs)

Grounding the Charger

DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC

Starting the Charge Cycle

Cold Storage Profile

Complete Charge Time

Block Out Time

ABBREVIATIONS AND ACRONYMS

AGM Absorbed Glass Mat

AGV Auto Guided Vehicle

AWG American Wire Gauge

CEC California Energy Commission

CFC Termination Code

DF# Fault Number

DoD Depth of Discharge

L-A Lead Acid

MAC Media Access Control

mVpc Millivolts Per Cell

NEMA National Electronics Manufacturers Association

SoC State of Charge

TH-Amb Thermal - Ambient Temperature Faults

TFT Thin Film Transistor

Ref Function Description

Main Menu Display

The menus provide access to the following functions:

Displaying a Charge Cycle

Memo Description Memo Description

Charger Information Display

This menu provides access to the USB function to update software.

FUNCTION Theme A Theme B

Battery Disconnects while

PARAMETERS / DAYLIGHT US – CANADA

Block Out Charge

Without Wi-iQ® device: Not used.

Delayed Start (Delay)

Turns IQ communications ON or OFF.

CHARGING THE BATTERY

Starting a Charge Cycle

Count Down Display

Without a Wi-iQ® Device

With a Wi-iQ® Device

*Not applicable to Fast Charge Profile.

End of Charge Display

End of Charge without Equalization

 Total charging time.

End of Charge with Equalization

Manual Equalization Start