IMPAQ™ Battery Charger
SOLUTIONS FOR CHARGING The information contained in this document is essential for the safe handling and correct use of the IMPAQ™ charger. It provides a global system specification, associated safety measures, codes of conduct, a commissioning guide, and recommended maintenance. This document should be kept and made available to users working with the battery and responsible for the battery charger. All users are responsible for ensuring that all system applications are adequate and safe, based on anticipated or encountered operating conditions. This user manual contains important safety instructions. Read and understand all instructions before installing, handling, or using the battery charger. Failure to follow these instructions may result in serious personal injury, death, property damage, damage to the battery charger, and/or voiding of the warranty. This user manual is not intended to replace material handling and equipment operation training that may be required by local laws, entities, and/or industry standards for handling materials, batteries, or the IMPAQ™ charger. Adequate theoretical and practical training for all users must be ensured before handling the battery charger system. For service, contact your sales representative or call: EnerSys EMEA EnerSys APAC EnerSys Global Headquarters ⚠️ WARNING Failure to follow instructions can lead to death or serious injury. Definitions from the identification plate label: EnerSys TC3 IMP 3 Modules 360VAC-440VAC 50/60Hz S/N: XEEA055001 (*) Optional Occasional Profile Operation: In Occasional Charge mode, the user can charge the battery during breaks, lunch, or any available interval during the working schedule. The Occasional Charge profile allows safe battery charging while maintaining it at a partial charge level of 20%-80% of C6, throughout the working week. After weekly charging, sufficient time must be scheduled to allow the battery to cool down and to perform periodic electrolyte level checks. Daily Charge: This option can be set to add extra daily charging time if the work schedule permits. It should only be considered when daily work demands require additional capacity. Equalization Charge: Equalization charging for traditional flooded lead-acid batteries, performed after normal charging, balances the electrolyte densities in the battery cells. NOTE: The factory default value is DAILY CHARGE DEACTIVATED, 6-8 hours Equalization, Sunday, at 00:00 for flooded electrolyte NexSys® charging profiles, 2 hours per week/maintenance charge. Lockout Time: This function prevents the charger from charging the battery during the lockout time interval. If a charging cycle begins before the lockout window, it is stopped during the lockout window and will automatically restart the charging cycle at the end of the lockout window. Refresh Charge: Refresh or maintenance charging allows the charger to keep the battery at maximum charge level as long as it is connected to the charger. ⚠️ WARNING THE BATTERY CHARGER CABINET CONTAINS HAZARDOUS VOLTAGE. ONLY A QUALIFIED PERSON SHOULD BEGIN TO ADJUST OR OPERATE THIS BATTERY CHARGER. For safe operation, choose a location free from excessive humidity, dust, combustible materials, and corrosive vapors. Also, avoid high temperatures (above 45°C (113°F)) or potential liquid leaks onto the charger. Do not obstruct the charger's ventilation openings. Observe the charger's warning label when mounting it on a combustible surface. It is recommended to mount the charger at least 72 cm away from the nearest battery top edge. The charger must be mounted on a wall, stand, shelf, or floor in a vertical position. The minimum distance between two chargers must be 31 cm. If mounted on a wall, ensure the surface is vibration-free and the charger is mounted vertically; if mounted on the floor, ensure surfaces are vibration-free, dry, and not humid. Mounting chargers in areas where they may be splashed with water is strictly prohibited. The charger must be secured by 2 or 4 fasteners appropriate for the type of support. The drilling pattern varies depending on the charger model (refer to the technical sheet). To prevent charger failure, ensure it is connected to the correct line voltage. Observe local and national standards and legislation regarding these connections. ⚠️ WARNING Ensure the power supply is switched off and the battery is disconnected before connecting the power to the charger terminals. Mains: Connection to the single-phase 230V AC or 400V AC electrical network (depending on factory setting) must be made exclusively using a standard socket and an adapted circuit breaker (not supplied with the product). Current consumption is indicated on the charger's identification plate. Battery Connection: The charger will be connected to the battery using the supplied cables: The user must ensure adequate protection of the branch circuit and a method of disconnection from the AC power source to the charger to allow for safe service operations. [DANGER] Fire/Electric Shock Hazard. Use only on circuits provided with branch circuit protection, in accordance with legislation and standards. Applicable safety provisions must be observed. The system protection installed on the charger's power supply must comply with the charger's electrical characteristics. Installation of an appropriate circuit breaker is recommended. It is mandatory to ensure that only fuses of the specified type and correct size are used when replacing fuses. This equipment complies with Class 1 safety standards, meaning the apparatus must be grounded and powered from a grounded power source. Connect the ground wire to the corresponding terminal, usually marked with one of the two symbols on the right. [grounding symbol] GND [DANGER] FAILURE TO GROUND THE CHARGER CAN RESULT IN FATAL ELECTRIC SHOCK. Observe the National Electrical Code for grounding conductor sizing. The DC connector polarity. The charging cables are connected to the charger's DC output: the red charging cable (POS) is connected to the charger's positive busbar, and the black charging cable (NEG) is connected to the charger's negative busbar. The charger's output polarity must be observed when connecting to the battery. Incorrect connection will blow the DC fuses in the power modules. EnerSys® hereby declares that the chargers in the NexSys®+ charger ranges comply with the following UK and European regulations: NOTE: The charger's DC cables emit low-frequency magnetic fields into the surrounding environment (<5 cm). Even if the emissions are below standard limits, individuals with medical implants should avoid working near the charger during charging. Control Panel Features When the charger is inactive, press and hold All menus are accessed from the Main Menu; a detailed description of each menu is included in the following sections of this manual. Menus requiring a password are not displayed until the correct password is entered. The menus provide access to the following functions: The charger can display details of the last 200 charging cycles. The display in Figure 1 shows a stored charge. MEMO 1 is the most recent stored charge. After storing the two hundredth charge, the oldest record is erased and replaced by the next in order of age. Proceed as follows: This menu displays the internal counters of the charger (number of normal and partial charges, errors by type, etc.). This menu allows access to the USB function for software updates. Software Update: Updates the charger's internal software. Software is provided by EnerSys. Date/Time: Sets the charger's date and time. The clock has a backup battery that will keep time when the charger power is off. Language: Selects the language displayed in the menus. Region: Selects the format for date, metric (EU) or imperial (USA) unit of measure for temperature, length, and cable size. Contrast: Adjusts the display contrast level (20 to 29). Screensaver: Activate or deactivate the screensaver function. Timeout: Set the time the screen remains lit. The delay time can be set from minutes up to one hour and 59 minutes. Activates or deactivates automatic clock adjustment for daylight saving time. When activated, the time will advance by one hour at 02:00 on the second Sunday in March and will revert by one hour at 02:00 on the first Sunday in November. The charger must be powered on at the time of the change for the change to take effect. The password is entered here to access service-level menus performed by authorized EnerSys service personnel. At this point, the charger should have been configured by a qualified service person. Charging can only begin if a battery of the correct type, capacity, and voltage is connected to the charger. With the charger in standby mode (no battery connected) and without pressing the Stop/Start button, the display will show the information presented in Figure 1 and Figure 2. Starting a Charge Cycle The charger will start automatically when a battery is connected or if the ENTER/STOP & START button is pressed, if the battery is already connected. Delayed Start If the charger has been programmed for delayed start, charging will begin after this delay. When the battery is connected to the charger, the display shows the remaining time until the programmed charge begins. Actual Charging After a few moments of actual charging, the display will begin to alternate between the charging information shown in Figure 3, Figure 4, and Figure 5. End of Charge Without Equalization The GREEN LED lights up completely after the corresponding charge is finished. The GREEN LED is fully lit, and the display indicates AVAIL. The display alternates between: Any other lit LED indicates a problem during charging. Consult the Control Panel section on page 9 for more information. If the battery remains connected and the refresh charge has been activated, refresh cycles will be performed to maintain optimal charge. The battery is now ready for use. Before disconnecting the battery, press the ENTER/STOP & START button. Completion of Charge with Equalization An equalization charge can be started manually or automatically. If an equalization day has been programmed in the charger's configurations, the equalization charge will automatically start on the scheduled day of the week after the charge is completed. NOTE: The factory default value is IEI Equalize, equalization time of 6 hours, Sunday, at 00:00. The battery will be available when the GREEN fully charged LED lights up again, and the display indicates AVAIL. The battery is now ready for use. If the battery remains connected and the refresh charge has been activated, refresh cycles will be performed to maintain optimal charge. Before disconnecting the battery, press the ENTER/STOP & START button. In case of a fault, one of the corresponding error codes listed below will appear on the screen. If it is a critical fault, charging will stop, and the red error LED will light up. ⚠️ WARNING HAZARDOUS VOLTAGE EXISTS INSIDE THE BATTERY CHARGER CABINET. ONLY A QUALIFIED PERSON SHOULD BEGIN TO ADJUST OR OPERATE THIS BATTERY CHARGER. The charger requires minimal maintenance. Connections and terminals must be kept clean and tight. The unit (especially the heat exchanger) should be periodically cleaned with low-pressure air to prevent excessive dirt accumulation on components. When cleaning, be careful not to strike or move any adjustments. Before cleaning, ensure that both AC power lines and the battery are disconnected. The frequency of these types of maintenance depends on the environment in which this unit is installed. The data, descriptions, or specifications presented in this document may be changed without prior notice. Before using the products, the user is advised and warned to make their own determination and evaluation of the suitability of the products for the specific use in question and is also advised to rely on the information contained in this document, as it may relate to any general use or indistinct application. The user is responsible for ensuring that the product is suitable and that the information is applicable according to the user's application. Products presented in this document will be used under conditions not dependent on the manufacturer's control, and therefore, any warranties, express or implied, relating to the suitability or appropriateness of such products for a particular use or application are excluded. The user expressly assumes all risks and liability under contract, tort, or otherwise, in connection with the use of the information contained in this document or the product itself.Introduction
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10
No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333
2366 Bernville Road
Reading, PA 19605, USA
Tel: +1-610-208-1991
+1-800-538-3627Characteristics and Information
Characteristics
1 Phase 3 Phase 12V 24/36/48V 24V 72/80V 36/48V 96V 120V Technical Information
Item Description Serial Number Specifies the date code. Hertz Input voltage frequency. Never use the charger at a different frequency or from a generator with unstable frequency. Phase TCX. '1' indicates a single-phase charger and '3' indicates a three-phase charger. AC Voltage The nominal voltage at which this charger is designed to operate. DC Voltage The nominal DC output voltage of the charger. Modules The actual number of power modules installed in the charger cabinet. DC Current The continuous current the charger will supply to a discharged battery with the number of installed power modules and according to the nominal voltage.
EnerSys Sp.z o.o
ul.Leszczynska 73
43-300 Bielsko-Biala, Poland
24V/36V/48V
210A/195A/180A
Pmax=11150WTechnical Information
Alphabetical Output Power Codes
Output Power (kW) Number of Modules Module Power (kW) 1.0 1 1.0 2.0 2 1.0 3.0 3 1.0 3.5 1 3.5 7.0 2 3.5 10.5 3 3.5 14.0 4 3.5 17.5 5 3.5 21.0 6 3.5 24.5 7 3.5 28.0 8 3.5 Cabinet Dimensions (Number of Modules Available) and DC Cable Size
Phase Module Positions Standard Cable Size Comments 1 Phase Max 1 6 mm² Standalone cabinet 1 Phase Max 3 25 mm² Three-slot cabinet, 3 kW 3 Phase Max 2 35 mm² Two-slot cabinet, 7 kW 3 Phase Max 4 70 mm² Four-slot cabinet, 3.5 - 14 kW 3 Phase Max 6 95 mm² Six-slot cabinet, max. 21 kW 3 Phase Max 8 70 mm² or 1 x 95 mm² Eight-slot cabinet, max. 28 kW. Double cable for 24/36/48 V DC, single cable for 72/80 V DC. Charging Profile Codes
Profile Code Charger Profile Description P22 HDUTY High capacity flooded cell pulse profile. The charging profile diagnoses battery status during the recharge phase and adjusts its parameters to optimize charging of flooded electrolyte battery technology. Max 0.25 C5. Battery capacity automatically matches continuous current loops. P21 STDWL Standard flooded cell profile (no water). IUI profile Max 0.13 to 0.20 C5. Battery capacity automatically matches single-phase loops. Battery capacity can be manually set if necessary. Weekly equalization is required. P02 GEL IUI profile. Max 0.17 to 0.22 C5. Battery capacity automatically with single-phase loops. Battery capacity can be manually set if necessary. Weekly equalization is required. P06 AGM IUI profile. Max 0.20 C5. Battery capacity automatically with single-phase loops. Finish time limitation. Battery capacity can be manually set if necessary. Weekly equalization is required. Technical Information (cont.)
Profile Code Charger Profile Description P07 OPP (*) Occasional PzQ cell charging. IU (main) & IUI pulse (daily) charging profile @0.25 C5. Finishing current 5%. Daily full charge option must be set. Weekly equalization is required. P04 AIRMIX Compressed air/air mix profile. An air kit must be fitted to use this profile. IUI profile Max 0.13 to 0.25 C5. Battery capacity automatically with single-phase loops. Battery capacity can be manually set if necessary. Weekly equalization is required. P25 LOWCHG Low discharge rate charging profile. IUI profile 0.09 to 0.13 C5. If necessary, manually adjust battery capacity. Weekly equalization is required. P31 NXBLOC (*) For NexSys® block battery under normal charging conditions. Charging rate 0.18 to 0.70 C5. Battery capacity, temperature, and equalization values must be set (NexSys® BLOC battery). Weekly equalization is required. P29 NXSTND (*) For NexSys® 2V battery under normal charging conditions. Charging rate 0.18 to 0.25 C5. Battery capacity, temperature, and equalization values must be set (NexSys® 2 V battery). Weekly equalization is required. List of Charger Options
Suffix Description LMEB Late production/Early pause Airmix Electrolyte circulation system Safety Instructions
Installation
Location
Electrical Cabinet Mounting
Electrical Connections
AC Circuit Protection
Charger Grounding
DC Connector Polarity
Installation (cont.)
EU Declaration
Operating Instructions
Ref. Function Description 1 LCD Display Displays charger operating information/menus 2 Up Navigation Button Navigate menus/Modify values 3 ENTER/STOP & START Button Select menu items/Enter values/ Stop and restart battery charging 4 RIGHT/EQUALIZE Navigation Button Scroll right/Start equalization or desulfation 5 Down Navigation Button Navigate menus/Modify values 6 LEFT/ESC Navigation Button Access main menu/Scroll left/Exit menus 7 RED Fault Indicator OFF (off) = no error
INTERMITTENT = error currently detected
ON (on) = error8 YELLOW Charging Indicator OFF (off) = charger off or battery not available
ON = charging in progress9 GREEN Fully Charged Indicator OFF (off) = charger off or battery not available
INTERMITTENT = cooling phase
ON (on) = battery ready and available10 BLUE AC Power Indicator OFF (off) = AC missing
ON (on) = AC present11 USB Port Download memos/Load software Operating Instructions
Menu Access
Main Menu
Displaying Memorized Data
Displaying a Charge Cycle
Memorized Data
Memo Description Memo Description Profile Selected profile Charging Time Charging cycle time (minutes) Capacity Nominal battery capacity (Ah) Ah Ampere-hours returned during the charging cycle Battery Voltage Nominal battery voltage (V) Charge Level Charging start date and time Temp Battery temperature at the start of charging (F) DBa Battery disconnection date and time % init Battery voltage at the start of charging (%) Status Partial or complete U start Battery voltage at the start of charging (Vpc) Fault Fault codes U end Battery voltage at the end of charging (Vpc) CFC Termination code (for service technician) I end Current at the end of charging Operating Instructions (cont.)
Status
Status Description Status Display Charge Total number of charges corresponding to the total of charges completed normally and charges completed with errors or due to an error. Normal charges Number of charges completed normally Abnormal charges Number of charges completed abnormally DF1 etc. Number of faults recorded by the charger (refer to Fault Codes) TH Number of faults related to charger temperature USB
Parameters
Display
Daylight Saving Time
Password
Operating Instructions (cont.)
Battery Charging
1 DC Charging Voltage / Charging Current 2 Firmware Version 3 System Time 4 Battery Connection 5 System Date 6 Selected Charging Profile 1 DC Charging Voltage / Charging Current 2 Charging Current 3 Equalization standby symbol (if selected) 4 Charged Ah 5 Charging Voltage (Total V) 6 Charging Time 7 Charging Voltage (V/c) 8 Estimated Remaining Charging Time 9 Charge Percentage Operating Instructions (cont.)
Manual Equalization Start
Automatic Equalization Start
Fault Codes
Fault Cause Solution DF-CUR Current fault before DF1 (may be low network, missing phase, or faulty module). Service call. DF1 Critical current fault, all modules are in DF1 error (check power supply and missing phase). Service call. DF2 Output fuse fault, battery reverse polarity. Check battery connection (possible cable polarity reversal) and output fuse. DF3 Incorrect battery voltage for charger setting. Battery voltage is too high or too low. Battery voltage must be between 1.6 V and 2.4 V per cell for lead-acid technology. Use a charger suitable for the battery. DF4 Over-discharge. Continuous charging. Fault Codes (cont.)
Fault Cause Solution DF5 Battery or charger setting check (Ah security, charging wait time, negative voltage Dv/Dt). DF5 occurs when the charging profile has been reached with an error condition, which may be an increase in current in the regulation phase, indicating battery heating or a wrongly programmed regulation voltage or the charging time is too long and has exceeded the safety limit. Check charging parameters: profile, temperature, capacity, cables. Check the battery (faulty cells, high temperature, water level). DF7 Air pressure pump error. Di-Dt current, uncontrolled thermal development. Service call. TH Charger thermal fault, all modules are in thermal fault (check air flow and ambient temperature). Check if the fan(s) are working correctly and/or if the ambient temperature is not too high or if there is poor natural ventilation of the charger. Move the charger to a location with a lower ambient temperature. Follow installation and safety instructions. TH-Amb Ambient temperature is too high. Service call. DFMOD Faulty module (refer to Module Menu to know the type of fault). Clean the module or the rear panel connection. If it does not work, call service. MOD DEF Module is disconnected or not responding. Check the power supply. MOD DFC Faulty module converter, module cannot transmit maximum current (check AC phases and AC fuse). Check if the fan(s) are working correctly and/or if the ambient temperature is not too high or if there is poor natural ventilation of the charger. If all modules are in thermal fault state, a TH error will appear. MOD TH Module thermal fault (check air flow, ambient environment, refer to Module Status Description to check the internal temperature sensor). Service call. MOD FUS Damaged module output fuse. Service call (check module status description). MOD Err Internal module error. Service call (check voltage value from Module Status Description). MOD VBAT Battery voltage is corrupted vs. fuse voltage and VLMFB vs modules. Check the Exx,CDV file to take action before resetting the lockout or call service. TH-LOCK Module is locked due to repetitive thermal events. Service call. VERIFICARE MODUL Charger is locked due to repetitive internal errors. Check the ribbon cable, AC power supply, connected module, inactive = off or call service. MODUL DE ALIMENTARE OPRIT Lack of CANBUS communication between display and module. Service call (replace faulty module). DF-VREG Modules do not respect the regulation voltage setting. Use the correct module. DF-ID Menu setting does not match module type (e.g.: Cell setting = 12 V, module type 40 cells) Service call. CANBUSERROR CAN bus error. Service call. DEFEEP Memory access refused. Service call. DEFRTC Clock access refused. Service call. Maintenance and Service
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