Stryten Energy M-SERIES X-3

TABLE OF CONTENTS

• X-3 Features and Benefits: 2
• Technical Specifications: 3
• Chassis Model Numbers: 6
• Charger Configuration Label: 6
• Safety Precautions: 7
• Installation Schemes: 9
• Installation: 10
• Connection to Main Power: 14
• Lithium-ion Battery Charging: 16
• Battery Communications: 16
• Connector and Battery Module Compatibility: 16
• Operating Instructions: 18
• Charge Modes: 20
• Viewing Charger Information: 21
• USB: 23
• Service and Troubleshooting: 23
• Index: 28

X-3 FEATURES AND BENEFITS

The X-3 charger is a multi-voltage modular design for industrial battery fleet applications and is offered in 3, 6, and 10 bay cabinet sizes. It uses Silicon Carbide MOSFET (Metal Oxide Semiconductor Field-Effect Transistor) power technology to provide efficient high frequency power conversion to minimize infrastructure costs, reduce your carbon footprint and provide multi-shift standard, opportunity and fast charging capabilities.

*X-3 chargers are field upgradeable to all capabilities as they are developed.

X-3 TECHNICAL SPECIFICATIONS - 3 BAY

X-3 - MODULAR MULTI-VOLTAGE INDUSTRIAL BATTERY CHARGERS

**Stated output currents require single or dual connectors and electrical cables of adequate capacity-consult your Stryten representative

***72/80V Modules are DC output rated up to 40A but are limited to 3.2kW. Therefore the average max output for 80V lead acid batteries is 35A and 80V Li-Ion Batteries is 38A

* Stated output currents will require connectors and electrical cables of adequate capacity. Consult your factory representative.

**CEC Certification pending

X-3 TECHNICAL SPECIFICATIONS - 6 BAY

X-3 - MODULAR MULTI-VOLTAGE INDUSTRIAL BATTERY CHARGERS

**Stated output currents require single or dual connectors and electrical cables of adequate capacity-consult your Stryten representative

***72/80V Modules are DC output rated up to 40A but are limited to 3.2kW. Therefore the average max output for 80V lead acid batteries is 35A and 80V Li-Ion Batteries is 38A

* Stated output currents will require connectors and electrical cables of adequate capacity. Consult your factory representative.

**CEC Certification pending

X-3 TECHNICAL SPECIFICATIONS - 10 BAY

X-3 - MODULAR MULTI-VOLTAGE INDUSTRIAL BATTERY CHARGERS

**Stated output currents require single or dual connectors and electrical cables of adequate capacity-consult your Stryten representative

***72/80V Modules are DC output rated up to 40A but are limited to 3.2kW. Therefore the average max output for 80V lead acid batteries is 35A and 80V Li-Ion Batteries is 38A

* Stated output currents will require connectors and electrical cables of adequate capacity. Consult your factory representative.

**CEC Certification pending

CHASSIS MODEL NUMBERS

Each charger has a chassis model number located on the charger's data sticker. The data sticker can be found on the back of the charger. Examples for each type of cabinet size are shown below:

CHARGER CONFIGURATION LABEL

Each charger has a configuration label located on the backside of the charger. The label contains the configuration model number, which is defined by the model numbering scheme in the X-3 Technical Specification table. This label also shows the CEC (California Energy Commission) compliance trademark.

SAFETY PRECAUTIONS

SAVE THESE INSTRUCTIONS. This manual contains important safety and operating instructions.

⚠️ This danger symbol indicates that personnel must practice safety procedures to prevent equipment damage, bodily injury, or death.

CAUTION! BATTERIES CAN BE DANGEROUS. Batteries generate explosive gases during normal charging and usage. Do not smoke, use open flame or cause sparking near the battery. To reduce risk of battery explosion always follow charging instructions and those of the battery manufacturer.

WARNING! DO NOT ATTEMPT TO CHARGE NON-RECHARGEABLE BATTERIES. Fast chargers are designated to be used only for charging rechargeable batteries. Attempting to charge a non-rechargeable battery could lead to possible injury or death from exploding batteries.

WARNING! RISK OF ELECTRICAL SHOCK THAT CAN CAUSE SERIOUS INJURY OR DEATH. Do not touch un-insulated battery terminals, connectors or other live electrical parts. Always make sure the charger is OFF before disconnecting it from the battery. Disconnect the charger from input power and battery before servicing. Only qualified personnel should install, use, or service the charger.

CAUTION! NEVER PLACE THE CHARGER DIRECTLY ABOVE OR BELOW THE BATTERY BEING CHARGED. Never place the charger directly above or below the battery being charged; gases or fluids from the battery will corrode and damage the charger. Locate the charger as far away from the battery as DC cables permit.

INSTALLATION SCHEMES

Due to the side-to-side airflow design of the X-3 charger, adequate spacing between chargers or other arrangements are required for proper operation. The following diagrams show possible placement options for multi-charger installations:

STANDARD SIDE-TO-SIDE The minimum side-to-side spacing of chargers is 18 inches (46cm) for standard installations.

SIDE-TO-SIDE WITH DIVIDERS Metal panels can be placed between chargers for closer spacing. Please consult factory for divider installations. The minimum charger-to-divider spacing is 4 inches (10cm).

OFFSET (45° ANGLE) Chargers may also be installed at a 45° offset for higher density installations.

INSTALLATION

• Installation must only be carried out by suitably qualified personnel and in accordance with current local and national wiring regulations.
• Battery leads should not be altered without prior consultation with service personnel.
• The charger should be sited in a cool, dry, well-ventilated location away from corrosive fumes and humid atmospheres. Ambient temperature range must be maintained between 32°F-104°F.
• Ensure ventilation is not obstructed at the left air intake and right exhaust vents.
• The charger is for indoor use only.
• Before installation, check that the charger has not sustained any damages during transit. Make sure the electrical ratings are suitable for both the intended AC input supply and the DC output current and voltage for the batteries to be charged. Also ensure that the connector polarity is correct and matches the polarity of the battery connector.
• CAUTION – To reduce the risk of fire, use only on circuits provided with branch circuit protection consistent with the current indicated on the Factory Charger Configuration label and in accordance with the National Electrical Code, ANSI/NFPA 70 or equivalent.
• The circuit breakers rating should be based on the charger's maximum input current, as stated on the Factory Charger Configuration label. (See the Technical Specifications pages for more details)

CONNECTION TO MAIN POWER

CAUTION! Electrical connections are to be made by a qualified electrician only! Make sure that the service AC input voltage is OFF before wiring charger.

Risk of Fire! Use on circuits provided with the following branch circuit protection in accordance with your regional electric code. (National Electrical Code, NFPA 70 or IEC)

**Ensure the AC wiring and AC plugs used meet regional requirements. Refer to the technical specification section of this manual to view AC input information.

STEP 1. REMOVE TOP PANEL OF CHARGER Remove the top panel of the charger by removing the six screws shown.

STEP 2. ATTACH SHIELDED INPUT CABLE OR CONDUIT TO CHARGER Use an NEC or IEC-approved conduit or AC input cable (such as type SOOW) to connect to the charger. Use appropriate minimum wire size or larger for maximum kilowatt rating of charger – See Technical Specification Tables: Min. AC Input Wire Size (AWG or mm²). The hole located in the top left corner of the charger must be used for the AC service entrance. Place an appropriate cable or conduit clamp in this AC service entrance hole.

STEP 3. CONNECT 3-PHASE AC INPUT POWER CABLES Ensure ground and power cables have been properly stripped (approximately a half inch of insulation from the ends). Loosen the securing screws in the AC input block and insert the stripped ends of the ground and power cables. Retighten the screws. The 3-phase input is not phase specific, so AC line input positions are interchangeable. Ensure cable or conduit clamp has been properly tightened.

DC OUTPUT POWER CABLES

STEP 4. CONNECT DC OUTPUT POWER CABLES Use an NEC or IEC-approved DC output cable (if not already equipped from the factory) such as type UL 3311, UL 3279, or CSA CL 905 - battery cable, with a polarized connector appropriate for battery charging (such as REMA MRC 80, 160, 320, REMA DIN 640, or Anderson Power Products Euro, SBX, or SB connectors).

Use appropriate minimum wire size or larger for maximum kilowatt rating of charger – See Technical Specification Table: Min. DC Output Wire Size (AWG or mm²).

The panel located at the bottom left of the charger must be used for the DC power output cables. There are threaded studs for the attachment of cable terminals which must be crimped or soldered to the DC cable. The positive (red) cable is attached on the right and the negative (black) cable is attached on the left. The clamps(s) at bottom are provided to secure the DC output cables.

EXAMPLE CABLE: COBRA BRAND BATTERY CABLE CHART

*Allowable Ampacities of Single Insulated Conductors, per NEC table 310-17 Cable manufactured in accordance with Federal EPA Rule, Title 40-part 82, (ODC's)

**The 105°C cable ampacities are adapted from ICEA P-54-440/NEMA WC51-1986(R1991). The ampacities are provided for informational purposes only. Acceptance of these values by any governing authority is the responsibility of the end user. Ampacities are based on a single conductor, in free air, at 30°C ambient air temperature.

MAXIMUM CURRENT CARRYING CAPACITIES FOR CABLE AND CONNECTOR COMBINATIONS

NOTE: Many of the mm² wire sizes are based on calculations. See the catalog for specific mm² wire sizes.

LITHIUM ION BATTERY CHARGING

The X-3 charger is capable of charging Stryten Energy 24V/36V/48V/72V/80V lithium ion batteries. All lithium batteries charged with the X-3 require an approved Battery Management System (BMS), CAN communications, X-Loop disconnect sensing, and a recognized charging protocol. Please consult with an authorized Stryten representative before using the X-3 to charge lithium batteries other than Stryten Energy brand to ensure absolute compatibility.

BATTERY COMMUNICATIONS

The X-3 charger supports several communication interfaces for opportunity and fast charging of almost any motive power battery including lithium ion. The following shows information on the different communication options:

Note: Lead acid batteries may be charged without a battery module or X-Loop up to 20% of the battery's nameplate capacity, however, battery data is not available without a module.

X-LOOP

X-Loop disconnect sensing uses a current sense loopback auxiliary contact wiring for sensing battery disconnect. X-Loop provides anti-arc protection for hot disconnects while charging. Since battery temperature data is not available with X-loop, charging will be limited to standard rate.

CAN BUS (LI-ION)

When charging a Li-ion battery, a Battery Management System (BMS) communicates with the charger using a CAN bus. The charger will recognize connector separation using X-Loop disconnect sensing. CAN bus communication is required for lithium-ion battery charging.

Communication Compatibility Table

*WARNING: Using Euro/REMA connectors without disconnect sensing contacts may result in premature connector failure. Stryten strongly recommends using auxiliary contacts (X-Loop or PL3) in the Euro/REMA connectors to sense battery/charger disconnects and prevent arcing that causes premature connector failure. The factory will provide auxiliary contacts at no charge for all Euro/REMA installations.

OPERATING INSTRUCTIONS

STOP CHARGING

To stop charging, press the START/STOP button during a charge. If a charge cycle is stopped by pressing the START/STOP button, the User Stopped Screen is displayed.

Note: While charging, always press the stop button before disconnecting battery to prevent damage to the charger and battery. If the battery is disconnected during a charge cycle, the charger will stop automatically.

CHARGE COMPLETE (LEAD ACID ONLY)

When the charger completes a charge cycle, the Charge Complete Screen is displayed. The complete screen displays the battery's state of charge along with its initial state of charge. There is also the option to view charge details by pressing the down arrow. The details screen provides the same information as the record detail screen. If the battery is left connected to the charger for a consecutive 5 days after completing a charge, the charger will perform a refresh charge to ensure the battery remains at its maximum capable capacity.

CHARGE MODES

LEAD-ACID CHARGE MODES

Constant Current (CC) The charger operates in constant current mode until the target voltage is reached. In CC mode, the current is equal to the user specified start rate which typically ranges from 10-40% of the battery's capacity.

Constant Voltage (CV) The charger will switch over from constant current mode to constant voltage mode once the battery's target voltage has been reached. In CV mode, the charging voltage will remain constant as the current slowly decreases. Once the current decreases to a certain percentage of the battery capacity, the charger will transition to one of the following modes in order of priority: Finish mode, Mix mode, or Charge Complete.

Finish (FN) Finish mode charges the battery at a low, constant rate of charge to achieve the battery's maximum state of charge. Finish mode can only occur after constant voltage mode has completed. A finish charge is typically performed no more than once per week to prevent excessive overcharging.

Equalize (EQ) Equalize mode charges a battery at low charge rate with a high float voltage to balance or equalize the battery's cell voltages. An equalization charge can only be performed after completing a finish charge.

Mix (MX) Mix mode is essentially a short finish. Mixing can only occur after constant voltage mode has completed and is typically performed daily.

Trickle (TK) Trickle mode is used to charge a battery with a lower than normal voltage. When the charger detects a battery with a voltage below an expected threshold, the charger will attempt to charge the battery at a low current until the battery's voltage is suitable for constant current mode.

LITHIUM-ION CHARGE MODES

Main Charge Constant Current (CC) The charger puts out a constant current determined by the battery's Battery Module System (BMS). Once a target voltage has been reached the BMS will transition to Equalize mode.

Equalize Lithium Equalize mode equalizes the cell voltages until the target SOC and cell voltages are achieved across all cells.

Voltage Hold Once a lithium battery reaches 100% SOC, the BMS will enter Voltage Hold mode. This mode maintains the battery voltage above a certain threshold to compensate for self-discharge while continuing to equalize cell voltages until reaching a “well balanced” state.

VIEWING CHARGER AND CHARGING INFORMATION

RECORD DETAIL

SETTINGS

Settings Menu: This menu allows a user to browse current user settings for the charger.

• User Settings: Displays the currently configured user settings.
• Schedule: Displays the Finish/EQ, Mix, and Finish Makeup schedules.
• Max Amps: Displays the max ampere settings for various battery sizes.
• Set Date: Allows a user to set the date on the display.
• Set Time: Allows a user to set the time on the display.

USB

DOWNLOAD CHARGE RECORDS A charger can transfer its charge records to a USB drive. For instructions on transferring data, contact your local sales representative.

UPDATE SOFTWARE A USB stick can be used to update the charger's software. If you need assistance with updating charger software, please contact your local sales representative.

SERVICE AND TROUBLESHOOTING

X-3 MODULE UPGRADES

Consult your local Stryten sales representative to determine an appropriate upgrade package. This will require an on-site visit from an Stryten authorized technician to assess your power and upgrade requirements.

Upgrading the X-3 with a different number of power modules requires:

1. Consultation with a Stryten authorized representative to determine your new power and configuration requirements
2. Ordering and receiving the authorized upgrade package service from Stryten
3. Upgrading of the electrical AC service to the charger (if required) by a professional electrician
4. Having a Stryten factory authorized technician install the upgrade package consisting of:
   • a. Power Module(s)
   • b. New DC output cables & connector (if required)
   • c. New charger configuration sticker (calls out new electrical requirements)
   • d. Updating of the charger's control panel factory settings

WARNING: Only Stryten factory trained and authorized technicians should upgrade your X-3 charger. Stryten is not responsible for unauthorized X-3 charger changes or upgrades.

WARNING: The number of power modules in the charger must match the module quantity on the charger's Info screen. Do not add power modules to a charger without the help of an authorized Stryten factory representative.

WARNING: Adding additional power modules to your X-3 charger may require upgrading your AC service wiring and DC output cables. Your Stryten factory authorized technician will refer to the X-3 Technical specifications page to determine if AC breaker size, AC wiring, DC output cables, and DC connectors will meet the specified requirements when installing additional power module(s).

WARNING: Electrical AC service wiring upgrades should only be performed by a licensed electrician.

POWER MODULE REPLACEMENT

IMPORTANT! Make sure the charger is completely POWERED OFF and NO BATTERY CONNECTED before opening the charger's door and replacing a power module. Power module replacement should only be performed by qualified personnel.

Required Tools: Flat Head Screwdriver 7mm Socket Wrench

STEP 1. OPEN CHARGER DOOR Using the flat head screw driver, turn the latch on the side of the charger clockwise to unlock the door and open it.

STEP 2. DISCONNECT POWER CABLES Disconnect the 3-phase AC input and the DC output cables from the power module you intend to replace by squeezing the clamp releases and pulling. Use a 7mm socket wrench to disconnect the ground cable.

STEP 3. DISCONNECT POWER MODULE COMMUNICATION CABLE(S) There are two possible configurations for power module communications. Directions for disconnecting each type are shown:

STEP 4. LOOSEN MOUNTING SCREWS AND REMOVE POWER MODULE Using a flat head screwdriver, turn each mounting screw counter clockwise until the spring ejects and releases the screw from the nut. Carefully pull the power module out.

STEP 5. INSERT REPLACEMENT MODULE AND SET MODULE POSITION SELECTOR Insert the replacement power module. Use a flat head screwdriver to tighten the mounting screws by pushing in and turning clock-wise. Using a flat head screwdriver, adjust the module position selector to match the module's position. For each charger size, the power module positions are shown in the module position tables.

STEP 6. RECONNECT COMMUNICATION AND POWER CABLES Reconnect all communication cables that were disconnected in step 3. Reconnect ground, DC output, and AC input cables. Close charger door and use flat head screwdriver to turn the latch counter-clockwise to lock.

INDEX

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