EnerSys NexSys+ Battery Charger
Owner's Manual
Introduction
The information contained in this document is very important for the safe handling and correct use of NexSys®+ chargers. It contains a comprehensive system specification, as well as relevant safety measures, codes of conduct, a start-up guideline, and recommended maintenance. This document should be kept and made available to users who work with the battery charger and are responsible for it. All users are responsible for ensuring that all system applications are appropriate and safe, based on the conditions expected or encountered during operation.
This owner's manual contains important safety instructions. Read and understand all instructions before installing, operating, or servicing the battery charger. Failure to follow these instructions may result in serious injury, death, property damage, damage to the battery charger, and/or voiding of the warranty.
This user manual does not substitute any training regarding the handling and operation of material handling equipment, batteries, or the NexSys®+ charger, which may be required by local regulations, authorities, and/or industry standards. Before operating the battery charger system, ensure that all users receive appropriate training and qualification.
For service, contact your local sales representative or call:
EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Fax: +41 44 215 74 10
EnerSys APAC
No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333
www.enersys.com
Your safety and the safety of others is very important
⚠️ WARNING: Failure to follow instructions may result in death or serious injury.
Features
- Microprocessor-controlled operation.
- Automatic battery capacity recognition.
- Charging status (SoC) adaptation.
- Battery voltage compatibility:
- 1-phase: 12V, 24V, 36/48V
- 3-phase: 24/36/48V, 72/80V, 96V, 120V
- Wireless integration with Wi-iQ® battery monitoring devices.
- Individual battery bank recognition and automatic charger pairing.
- Unique charging profile for thin plate pure lead (TPPL) batteries.
- Unique charging profiles for the following NexSys® batteries: NXBLOC, NXSTND, NXSFAST, NXP2V, NXPBLC, ATP2V.
- Remote access via the E Connect™ mobile app for setting changes, charger monitoring, and data sharing.
- Controller Area Network (CAN) communication capability.
- Full programmability for unique vehicle fleet requirements.
- Independent of battery chemistry: EnerSys® Lithium-ion (Li-ion), TPPL, flooded, gel, and lead-acid batteries.
Technical Information
Nameplate Label Definitions
| Item | Description |
|---|---|
| Serial Number | Provides a date code. |
| Hertz | Input voltage frequency. The charger must not operate at a different frequency or from a generator with unstable frequency. |
| Phase | TCX. Where "1" indicates a single-phase charger and "3" indicates a three-phase charger. |
| AC Volts | Nominal voltage for which the specific charger is designed to operate. |
| DC Volts | Charger's nominal DC output voltage. |
| Modules | Actual number of power modules installed in the charger cabinet. |
| DC Amps | Continuous current output by the charger to a discharged battery based on the number of installed power modules and nominal voltage. |
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 Size (Available Module Count) and DC Cable Size
| Phase | Module Count | Typical Cable Size |
|---|---|---|
| 1ph | Max. 1 | 6 mm² |
| 1ph | Max. 3 | 25 mm² |
| 3ph | Max. 2 | 35 mm² |
| 3ph | Max. 4 | 70 mm² |
| 3ph | Max. 6 | 95 mm² |
| 3ph | Max. 8 | 70 mm² or 1 x 95 mm² |
Charging Profile Codes
| Profile Code | Charger Profile | Description | Comments |
|---|---|---|---|
| P19 | FAST | Fast charging profile for flooded type battery with Airmix. Charging rate up to 0.4 C5. Battery capacity, temperature, and equalization values must be set and a properly programmed Wi-iQ® battery monitoring device (FAST EU) must be installed. If Comm is not present or not installed, the charger will use the STDWL profile. An 8-hour weekly equalization is required. Recommended parameters for charger setting. | Standalone cabinet Three slots, 3 kW cabinet Two slots, 7 kW cabinet Four slots, 3.5 to 14 kW cabinet Six slots, max. 21 kW cabinet Eight slots, max. 28 kW cabinet. Dual cable for 24/36/48Vdc, single cable for 72/80Vdc |
| P22 | HDUTY | Heavy-duty flooded cell pulse profile. The charging profile diagnoses the battery condition throughout recharge and adjusts its parameters to optimize flooded battery charging. Max. 0.25 C5. Automatic battery capacity matching with DC loops. | |
| P21 | STDWL | Standard flooded cell profile (Water Less®). IUI profile Max. 0.13 to 0.20 C5. Automatic battery capacity matching with Ph1 loops. Battery capacity can be manually set if needed. Weekly equalization required. | |
| P02 | GEL | IUI profile. Max. 0.17 to 0.22 C5. Automatic battery capacity matching with Ph1 loops. Battery capacity can be manually set if needed. Weekly equalization required. | |
| P06 | AGM | IUI profile. Max. 0.20 C5. Automatic battery capacity matching with Ph1 loops. Termination time limitation. Battery capacity can be manually set if needed. Weekly equalization required. | |
| P07 | OPP (*) | Opportunistic charging of PzQ cells. IU (main) & IUI pulse (daily) profile at 0.25 C5. Termination current 5%. Daily full charge must be set. If a Wi-iQ® monitoring device is installed, it provides capacity, temperature, and voltage. However, for safety, in case of communication loss, you must manually set battery capacity, temperature, and voltage. Weekly equalization required. | |
| P04 | AIRMIX | Compressed air/Airmix profile. An air kit must be installed to use this profile. IUI profile Max. 0.13 to 0.25 C5. Automatic battery capacity matching with Ph1 loops. Battery capacity can be manually set if needed. Weekly equalization required. | |
| P09 | WL20 | Water Less® 20 battery, IUI profile (old WF200). Requires Airmix and Wi-iQ® battery monitoring device communication. Weekly equalization required. | |
| P25 | LOWCHG | Low rate charging profile. IUI profile 0.09 to 0.13 C5. Manual setting of battery capacity if needed. Weekly equalization required. | |
| P31 | NXBLOC (*) | For NexSys® TPPL Bloc battery under normal load. Charging rate 0.18 to 0.70 C5. Battery capacity, temperature, and equalization values must be set, or a properly programmed Wi-iQ® battery monitoring device (NexSys® BLOC battery) must be installed. If not installed or no communication, the charger will use manual Ah and temperature setting. Weekly equalization required. | |
| P29 | NXSTND (*) | For NexSys® TPPL 2V battery under normal load. Charging rate 0.18 to 0.25 C5. Battery capacity, temperature, and equalization values must be set, or a properly programmed Wi-iQ® battery monitoring device (NexSys® 2V battery) must be installed. If not installed or no communication, the charger will use manual Ah and temperature setting. Weekly equalization required. | |
| P30 | NXFAST (*) | For NexSys® TPPL 2V battery with fast, higher rate. Charging rate 0.25 to 0.40 C5. Properly programmed FAST Wi-iQ® battery monitoring device (NexSys® 2V battery). If not installed or no communication, the charger will use manual Ah and temperature setting. Weekly equalization required. | |
| P32 | NXP2V (*) | For NexSys® TPPL 2V battery with fast, higher rate. Charging rate 0.18 to 0.40 C5. Properly programmed Wi-iQ® battery monitoring device (NexSys® TPPL 2V battery). If not installed or no communication, the charger will use manual Ah and temperature setting. Weekly equalization required. | |
| P33 | NXPBLC (*) | For NexSys® TPPL Bloc battery under normal load. Charging rate 0.18 to 0.70 C5. Properly programmed Wi-iQ® battery monitoring device (NexSys® TPPL Bloc battery). If not installed or no communication, the charger will use manual Ah and temperature setting. Weekly equalization required. | |
| ATP2V | For NexSys® ATP 2V battery with fast, higher rate. Charging rate 0.2 to 0.5 C5. Properly programmed FAST Wi-iQ® battery monitoring device (NexSys® ATP 2V battery). If not installed or no communication, the user setting for Ah and temperature will be used. Float maintenance must be set. IFloat = Round ([Battery Voltage x Battery Capacity]/1000 x 0.1). | ||
| NXSION (*) | For EnerSys® Lithium battery only. The charger communicates with the EnerSys® lithium BMS, the BMS guides the charger, and then the charger setting is not mandatory. However, there are some recommended parameters for setting on the charger. |
Safety Precautions
- Opportunistic Charging Profile: In opportunistic charging mode, the user can charge the battery during breaks, lunch, or any available time during the work schedule. The opportunistic charging profile allows the battery to be safely charged while maintaining a partial charge state between 20% and 100% of C5 throughout the weekly work period. Sufficient time must be programmed after weekly equalization to allow the battery to cool and periodic electrolyte level checks to be performed.
- Daily Charging: This option can be set to add additional daily charging time if the work schedule requires it. It should only be considered when the daily work requirement necessitates additional capacity.
- Equalization Charging: Equalization charging for lead-acid batteries, performed after normal charging, equalizes the electrolyte density within the battery cells.
- NOTE: Factory default is: Daily charging disabled, Sunday at 00:00 for flooded type, 2 hours per week/maintenance charge for NexSys® charging profiles.
- WARNING: The transport pallet must be removed for proper and safe operation.
- This manual contains important safety instructions. Before using the battery charger, read all instructions, precautions, and warnings posted on the battery charger, the battery, and the product where the battery is used.
- Read and understand all setup and operating instructions before using the battery charger to avoid any damage to the battery and charger.
- Do not touch uninsulated parts of the output connector or battery terminals, as there is a risk of electric shock. Never open the equipment: High voltage may still be present even after the charger is switched off. Any adjustment, maintenance, or repair of the equipment while it is open must only be performed by appropriately qualified personnel who are aware of the associated hazards.
- During charging, lead-acid batteries produce hydrogen gas, which can be dangerous if ignited. Do not smoke, use open flames, or create sparks near the battery. Take all necessary precautions when the equipment is to be used in areas where there is a risk of accident. Ensure adequate ventilation according to EN 62485-3 standard or local regulations to allow for the escape of emitted gases. Never disconnect the battery during charging.
- If the charger does not have the LMEB function (Late Mate/Early Brake), do not connect or disconnect the battery plug while the charger is energized. Doing so will cause an electric arc and burn the plug contacts, resulting in damage to the charger or battery explosion.
- Lead-acid batteries contain sulfuric acid which can cause burns. It must not come into contact with eyes, skin, or clothing. In case of eye contact, rinse immediately with clean water for at least 15 minutes. Seek immediate medical attention.
- Installation, setup, and maintenance of this equipment must only be performed by factory-qualified personnel. Before servicing the charger, turn off all AC and DC power connections.
- Must be used according to the indicated protection level and never come into contact with water.
- Must not be installed on surfaces subject to vibration (near compressors, engines, motors).
- Must be installed so that gases from the charging battery are not sucked into the charger by its fans.
- The charger is not intended for outdoor use, only for indoor use.
- Do not expose the charger to moisture. Operating conditions should be 0°F (0°C) to 113°F (45°C), relative humidity 0 to 70%.
- Do not use the charger if it has been dropped, subjected to a severe impact, or suffered any other damage.
- For continuous protection and to reduce the risk of fire, install chargers on a non-flammable surface.
- For NexSys® iON batteries, use only EnerSys® battery packs that include the battery management system (BMS) and all necessary protection for the integrated pack.
- The charger's DC cables emit low-power magnetic fields into their surroundings (<5cm). Individuals with implanted medical devices should avoid being near the charger during charging.
- Contact one of the company's trained technicians if a problem arises during charger commissioning. It is designed only for recharging EnerSys® lead-acid batteries for industrial motive power applications and NexSys® batteries in industrial installations. When the equipment is decommissioned, the casings and other internal components can be disposed of by specialized companies. Local legislation supersedes the instructions in this document and must be strictly adhered to (AHHE 2002/96 EC).
Installation
Location
For safe operation, choose a location free from excessive humidity, dust, flammable materials, and corrosive fumes. Also, avoid high temperatures (above 113°F [45°C]) or potential liquid spills onto the charger.
Do not obstruct the charger's ventilation openings.
Follow the charger's warning label when mounting in contact with or on top of a combustible surface.
It is recommended to install the charger within a radius of at least 72 cm from the nearest edge of the battery.
Cabinet Mounting
The charger must be mounted on a wall, rack, shelf, or floor in a vertical position. The minimum distance between two chargers must be 31 cm. For wall mounting, ensure the surface is vibration-free and the charger is mounted vertically. For floor mounting, ensure the surfaces are free from vibration, water, and moisture. Areas where chargers are at risk of water ingress must be avoided.
The charger must be secured by 2 or 4 supports suitable for the mounting type. The drilling pattern varies depending on the charger model (refer to the technical data sheet).
Electrical Connections
To avoid charger failure, ensure it is connected to the correct line voltage. Follow local, national standards and laws for making these connections.
⚠️ WARNING: Ensure the power source is switched off and the battery is disconnected before connecting the input power to the charger terminals.
To the mains power supply: You can connect only to a 1-phase 230Vac or 3-phase 400Vac mains power supply (depending on charger type) via a standard socket and appropriate circuit breaker (not supplied). Power consumption is listed on the charger's nameplate.
Battery Connection: The charger must be connected to the battery using the supplied cables:
- The RED cable: to the POSITIVE terminal of the battery.
- The BLACK cable: to the NEGATIVE terminal of the battery.
AC Circuit Protection
The user must provide appropriate branch circuit protection and a disconnect method from the AC power supply to the charger, to allow for safe servicing.
⚠️ CAUTION: Fire/Electric Shock Hazard. Use only on circuits that are provided with branch circuit protection in accordance with legislation and standards.
Applicable safety regulations must be observed. The system protection installed on the power supply to the charger must comply with the charger's electrical characteristics. Installation of an appropriate circuit breaker is recommended. When replacing fuses, it is imperative to ensure that only fuses of the specified type and correct size are used.
This equipment complies with Class 1 safety standards, meaning the device must be grounded and powered from a grounded supply.
Grounding the Charger
Connect the ground wire to the appropriate terminal, usually marked with one of the following symbols: ? [Ground Symbol].
⚠️ HAZARD: FAILURE TO GROUND THE CHARGER MAY RESULT IN FATAL ELECTRIC SHOCK. Follow the National Electrical Code for grounding conductor sizes.
DC Connector Polarity
The charging cables are connected to the charger's DC output: the red charging cable (POS) connects to the charger's positive supply line, and the black charging cable (NEG) connects to the charger's negative supply line. When connecting to the battery, the charger's output polarity must be considered. If connected incorrectly, the DC fuses in the power modules will blow.
EU Declaration
EnerSys® hereby declares that its NexSys®+ series chargers comply with the following UK and EU regulations:
- The Electrical Equipment (Safety) Regulations 2016 (S.I. 2016/1101)
- European Directive 2014/35/EU (Low Voltage Directive)
- Safety: BS EN IEC 62368-1: 2020 + A11:2020
- The EMC Regulations 2016 (S.I. 2016/1091)
- Directive 2014/30/EU (EMC Directive):
- Electromagnetic Compatibility: BS EN IEC 61000-6-2: 2019, BS EN IEC 61000-6-4: 2019
- Directive 2011/65/EU (ROHS)
- Electromagnetic Fields Control Regulations (S.I. 2016/588)
- Directive 2013/35/EU (EMF Directive):
- Electromagnetic Fields: BS EN IEC 62311: 2020
- Radio Equipment Regulations 2017 (S.I. 2017/1206)
- Directive 2014/53/EU (RED Directive):
- ETSI EN 301 489-1 V2.1.1 (2017-02)
- ETSI EN 301 489-17 V3.1.1 (2017-02)
- ETSI EN 300 328 V2.2.2 (2019-07)
NOTE: The charger's DC cables emit low-power magnetic fields into their surroundings (<5cm). Even if emissions are lower than typical limits, it is recommended that individuals with implanted medical devices avoid being near the charger during recharging.
Operating Instructions
Control Panel and Indicators
The charger features a graphical display, control buttons, and indicator LEDs.
- Display: Shows charger operating information and menus.
- GREEN Indicator: Off = Charger is off or no battery available. Flashing = Cooling phase. On = Battery is ready and available.
- YELLOW Indicator: Off = Charger is off or no battery available. Flashing = Charging in progress. On = Charging in progress.
- RED Indicator: Off = No fault. Flashing = Fault detected. On = Fault.
- BLUE Indicator: Off = AC power missing. On = AC power present.
Control Buttons
- 1. LEFT / ESC: Enter main menu / Scroll left / Exit menu.
- 2. UP: Navigate menus / Change values.
- 3. DOWN: Navigate menus / Change values.
- 4. RIGHT / EQUALIZE: Scroll right / Start equalization or desulfation.
- 5. ENTER/STOP/START: Select menu items / Enter values / Stop and restart battery charging.
Idle Charger Indication
When the charger is idle (no battery connected) and the ENTER/STOP/START button has not been pressed, the screen displays the following information:
- Item 1: Charger DC Voltage
- Item 2: Selected charging profile
- Item 3: Firmware version
- Item 4: Battery connection status
- Item 5: System time and date
(Diagram description: The control panel shows a screen displaying "CHARGING 10 A 2.44V RAB123456 +68°F 100% 02-18-21 11:17:24" with buttons labeled UP, DOWN, LEFT/ESC, RIGHT/EQUALIZE, ENTER/STOP/START, and indicator LEDs.)
Battery Connection
Ensure the charger connector(s) match the battery connector(s). Connect the charger connector(s) to the battery connector(s). For chargers with dual connectors, both must be connected for charging to begin. NexSys® iON lithium batteries come with a specific connector type. The NexSys®+ charger is supplied with one or two connectors (LI connector) depending on the charger model. When the charger has two connectors, both must be connected, otherwise the charging cycle will not start. Always connect connector 1 first. All NexSys® iON charger connectors are equipped with the "Late Mate/Early Break" feature to prevent arcing if the battery is disconnected during charging.
When CAN communication is established between the NexSys® iON battery and the charger, the display will show "BMS CONNECTED". If "BMS CONNECTED" is not displayed, the charging cycle will not start. Check the CAN wiring and the battery.
Starting Charge
When a battery is connected to the charger, the control board detects the voltage, and after a short delay, the charger automatically starts charging the battery if the auto-start setting is enabled. Press the ENTER/STOP/START button if the battery is already connected. During NexSys® iON battery charging, CAN communication is established between the battery and the charger, and the display shows "BMS CONNECTED". After a few seconds, the battery will close its charging contactor to initiate charging. The charger will start the countdown process and display charging information.
Delayed Start
If the charger is programmed for a delayed start, charging will begin after the programmed delay. When the battery is connected to the charger, the screen displays the remaining time until the programmed charge begins. (Diagram description: Screen shows a countdown timer.)
Charging without Wi-iQ®
If the Wi-iQ® monitoring device adapter is not enabled or no Wi-iQ® monitoring devices are within range, the charging process starts after the programmed delay. The charger uses the profile, capacity, and temperature settings programmed in the configuration menu.
Charging with Wi-iQ®
If one or more Wi-iQ® monitoring devices are within range, the charger will activate and apply current to the battery. The display will show "SCAN" followed by "IQLINK". This routine determines which Wi-iQ® monitoring device within range is connected to the battery charger. Once this is determined on the charger, data is downloaded from the Wi-iQ® monitoring device, the battery serial number is displayed, the profile capacity and temperature are updated for charging, and the main charging begins.
Charge Interruption
Charging can be temporarily interrupted and restarted from where it left off at any time. Simply press the ENTER/STOP/START button (labeled as number 11 in the Control Panel Functions section).
Charge Completion
End of Charge: The GREEN charge completion indicator LED lights up after the charge is correctly completed. The GREEN charge completion indicator LED is on, and the display shows "CHARGE COMPLETE". The display alternates between:
- Total charging time
- Amp-hours recovered into the battery
Any other LED lit indicates a problem during charging. Refer to the "Control Panel Functions" section for more information.
(Diagram description: Screen shows "CHARGE COMPLETE 0Ah" with other indicators.)
If the battery remains connected and float charging is enabled, float charges will be performed to maintain optimal charge. The battery is now ready for use. Press the ENTER/STOP/START button before disconnecting the battery.
Equalization Charging
An equalization charge can be started manually or automatically.
Manual Equalization Start
At the end of charging (GREEN LED is on or flashing), press the RIGHT/EQUALIZE button. The equalize button can also be pressed at any time during charging, at which point an equalization charge will start after the charge is completed. The start of the equalization charge is indicated by a symbol. During equalization charging, the charger displays the output current and alternates between battery voltage, per-cell voltage, and remaining time.
NOTE: When equalization charging starts manually, the output is automatically set.
Automatic Equalization Start
If an equalization day is programmed in the Charger Configuration, the equalization charge will automatically start on the programmed day of the week after the charge is completed.
After equalization, the battery will be available when the GREEN LED lights up again and the display shows AVAIL. The battery is now ready for use. Press the ENTER/STOP/START button before disconnecting the battery.
AC Power Interruption
If AC power is interrupted while a battery is connected to the charger during a charging cycle, the charger will reset and start a new charging cycle once the power is restored. All charger settings, as well as the time and date, are retained.
Series Charging
In series charging, the voltages of both batteries are added and must match the charger's nominal DC voltage rating shown on the nameplate. The charger's nominal amperage rating must equal the nominal amperage rating of each battery. The charging cycle will not start if both batteries are not connected.
Menu and Display Information
Main Menu Display
When the charger is idle, press and hold ESC. The main menu will appear. The main menu will automatically exit after 60 seconds of inactivity, or you can voluntarily exit by pressing the ESC button.
Access to all menus is from the main menu. A detailed description of each menu is included in the following sections of this manual. Menus requiring a password will only appear after the correct password has been entered.
The menus provide access to the following functions:
- Logs (□): View status and memory contents.
- Charger (?️): View faults, alarms, etc.
- USB (?️): USB functions.
- Settings (⚙️): Set date, language, and other parameters.
- Password (?): Manage passwords (for service technicians only).
- Exit (?): Exit the main menu.
(Diagram description: The display shows the main menu with options like Settings, USB, Logs, Password, Charger, Exit.)
Logs
The charger can display details of the last 300 charge cycles. The screen shown here indicates that 3 charges have been stored in memory. Memory item 1 is the last charge stored in memory. After memorizing the three-hundredth charge, the oldest entry is deleted and replaced by the next oldest.
Displaying a Charge Cycle
- Select a memory entry (Memo x) using the Up/Down buttons.
- Display the first History screen by pressing the Enter button.
- Display the second History screen by pressing the Down button.
- Return to the main menu by pressing the ESC button. The charge history is displayed. Use the Up/Down buttons to navigate between parameters.
Memory Data
| Memory Item | Description |
|---|---|
| S/N | Serial number of the Wi-iQ® monitoring device |
| I end | Current at the end of charging |
| Temp end | Battery temperature at the end of charging (°F) |
| Capacity | Nominal battery capacity (AH) |
| U batt | Nominal battery voltage (V) |
| Temp | Battery temperature at the end of charging (°F) |
| Techno | Battery technology |
| Chg Time | Charge cycle time (minutes) |
| Profile | Selected profile |
| Ah | Amp-hours recharged during the charge cycle |
| % init | Charge status at the start of charging (%) |
| kWh | Kilowatt-hours recharged during the charge cycle |
| U start | Battery voltage at the start of charging (Vpc) |
| Status | Partial or total |
| U end | Battery voltage at the end of charging (Vpc) |
| Default | Error codes |
| Warning | Wi-iQ® monitoring device warnings |
| SoC | Charge start date and time |
| DBa | Battery disconnection date and time |
| CFC | Termination code (for service technician) |
Service and Troubleshooting
Status
This menu displays the status of the internal meters of the charger (number of normal and partial charges, error codes, etc.).
| Status | Description |
|---|---|
| Charge | Total number of charges - corresponds to the total number of charges that terminated normally and charges that terminated with or due to errors. |
| Complete | Number of charges that terminated normally. |
| Partial | Number of charges that terminated abnormally. |
| TH | Number of charger temperature errors. |
| DF1 etc. | Number of errors recorded by the charger (see Error Codes). |
Parameter Settings
| Parameter | Description |
|---|---|
| Date/Time | Sets the charger's date and time. The clock has a backup battery that maintains the time when the charger is turned off. |
| Language | Selects the language displayed in the menus. |
| Region | Selects the format for date, metric (EU) or Anglo-Saxon (UK) system units for temperature, length, and cable size, in metric and American measurement systems (AWG). |
| Display | Setting of screen saver and display themes. |
| Screen Saver | Enables or disables the screen saver function. |
| Delay Savings | Sets the time for which the screen remains lit. The delay time can be set in minutes, up to one hour and 59 minutes. |
| Themes | Themes A and B are two different ways of displaying information during the charging cycle, as shown in the table below. Theme A is selected by default and will be used in this manual. |
| Daylight Savings | Enables or disables automatic clock adjustment for daylight saving time. When enabled, the time will change one hour forward at 02:00 on the second Sunday in March and move back one hour at 02:00 on the first Sunday in November. The charger must be powered at the time of the change for it to be implemented. |
USB
This menu provides access to the USB function for software updates. Software updates are provided by EnerSys®.
Password
Here, the password is entered to gain access to the service level menus by authorized EnerSys® service personnel.
Service and Troubleshooting
Error Indication
In case of an error, one of the corresponding error codes listed below will be displayed on the screen. If it is a critical error, charging will stop and the red error LED will light up.
(Diagram description: Screen shows "DF1" with a warning symbol ⚠️.)
Error Codes
| Error Code | Cause | Solution |
|---|---|---|
| DF-CUR | Current error before DF1 (may be low network current, phase absence, or faulty module). | Call for service. |
| DF1 | Critical current error, all modules are in DF1 error (check network and phase that is missing). | Call for service. |
| DF2 | Output fuse error, reverse battery polarity. | Check correct battery connection (reversed polarity cables) and output fuse. |
| DF3 | Incorrect battery voltage relative to charger setting. | Battery voltage too high or too low. Battery voltage must be between 1.6V and 2.4V per cell for lead-acid batteries. Use a suitable charger for the battery. |
| DF4 | Overcharge. | Charging continues. |
| DF5 | Battery or charger setting check (fuse Ah, battery heating indication, or incorrectly programmed charging time limit, negative Dv/Dt voltage). DF5 appears when the charging profile is met with an error state. This may be a current increase during the setting phase (constant charging voltage) indicating battery heating or incorrectly programmed charging time limit or that 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. | Call for service. |
| DF7 | Air pressure pump error. Di-Dt current, thermal instability. | Verify correct operation of the fans and/or absence of excessively high ambient temperatures or poor charger ventilation. |
| TH | Charger thermal error, all modules show thermal error (check airflow and ambient temperature). | Move the charger to a location with a lower ambient temperature. Follow installation and safety guidelines. |
| TH-Amb | Ambient temperature too high. | Call for service. |
| DFMOD | Faulty module (refer to module status menu for error type). | Call for service. |
| MOD DEF | Module is disconnected or not responding. | Clean the module or motherboard connection. If it does not work, call for service. |
| MOD DFC | Faulty module converter, the module cannot deliver the maximum current (check AC phases and AC fuse). | Check the mains power supply. |
| MOD TH | Module thermal error (check airflow, environment, refer to "Module Status Description" for checking internal temperature sensor). If all modules show thermal error, a TH error will follow. | Check that the fan(s) is/are operating correctly and/or that the ambient temperature is not too high or if the charger's ventilation is adequate or not. If all modules show thermal error, a TH error will follow. |
| MOD FUS | Damage to the module's output fuse. | Call for service. |
| MOD Err | Internal module error. | Call for service (refer to module status description). |
| MOD VBAT | Battery voltage is incorrect compared to the fuse voltage and VLMFB for the modules. | Call for service (refer to voltage indication in module status description). |
| BAT TEMP | Battery temperature too high in the Wi-iQ® monitoring device. | The battery needs to cool down. |
| TH-LOCK | The module is locked due to repeated thermal events. | Refer to Exx, CDV file to unlock or call for service. |
| UNIT CHECK | The charger is locked due to repeated internal errors. | Call for service. |
| POWER MODULE OFF | No CANbus communication between display and module. | Check the cable, AC network, connected module, idle = off or call for service. |
| DF-TECHNO | Wi-iQ® monitoring device setting does not match the charger type. | Check charger and Wi-iQ® monitoring device settings (e.g., Wi-iQ® monitoring device set for NexSys® charger with IMPAQ charger). |
| DF-VREG | Modules do not follow the preset voltage in the setting phase (constant charging voltage). | Call for service (replace faulty module). |
| DF-ID | The menu setting does not match the module type (i.e., voltage setting = 12 V, module type for 40 cells). | Use the correct module. |
| CANBUSERROR | CANbus error. | Call for service. |
| DEFEEP | Memory access is not permitted. | Call for service. |
| DEFRTC | Clock access is not permitted. | Call for service. |
⚠️ WARNING: HAZARDOUS VOLTAGES EXIST INSIDE THE BATTERY CHARGER CABINET. CHARGER ADJUSTMENT OR SERVICE IS TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY.
The charger requires minimal maintenance. Connectors and terminals should be kept clean and sealed. The unit (especially the heat sink) should be regularly cleaned with low-pressure air to prevent excessive dust accumulation on components. Care must be taken not to strike or dislodge adjustments during cleaning. Ensure both 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.
Check each battery cell during discharge. Check if the Wi-iQ® monitoring device is correctly configured (see Wi-iQ® monitoring device installation instructions).
Any data, descriptions, or specifications provided herein are subject to change without notice. Before using the product(s), the user shall determine and verify the suitability of the product(s) for the intended use and further shall not rely on the information contained herein as it may relate to any general use or vague application. It is the user's sole responsibility to ensure that the product is suitable and that the information is applicable to the user's specific application. Products contained herein will be used under conditions beyond the manufacturer's control and, therefore, all warranties, express or implied, as to the applicability or fitness of such product(s) for any particular use or purpose or in any specific application are excluded. The user assumes all risks and liability, whether based on contract, tort, or otherwise, in relation to the use of the information contained herein or the product itself.
