Introduction
This document provides essential information for the safe operation and correct use of NexSys®+ battery chargers. It contains global system specifications, safety measures, commissioning guidelines, and recommended maintenance. Keep this document accessible for users responsible for the charger's operation. Users must ensure all system applications are suitable and safe based on operating conditions.
This manual contains important safety instructions. Read and understand all instructions before installing, handling, or operating the charger. Failure to comply may result in serious injury, death, property damage, or warranty voidance.
This manual does not replace any required training for handling equipment, batteries, or NexSys®+ chargers as per local laws or standards. Ensure operators receive proper training before use.
⚠️ WARNING: Failure to follow instructions may lead to death or serious injury.
For service, contact your sales representative or call:
- EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10 - EnerSys APAC
No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333
Characteristics
- Microprocessor control.
- Automatic battery capacity detection.
- Adaptation to battery State of Charge (SoC).
- Compatibility with battery voltages:
- 1-phase: 12 V, 24 V, 36/48 V
- 3-phase: 24/36/48 V, 72/80 V, 96 V, 120 V
- Wireless integration with Wi-iQ® battery monitoring devices.
- Individual battery recognition and automatic pairing.
- Unique charging profile for Thin Plate Pure Lead (TPPL) batteries.
- Specific profiles for NexSys® batteries: NXBLOC, NXSTND, NXSFAST, NXP2V, NXPBLC, ATP2V.
- Connection via E Connect™ mobile app for settings and monitoring.
- Communication via Controller Area Network (CAN).
- Fully programmable for specific operating requirements.
- Independent of battery chemistry: Li-ion, TPPL, flooded, gel.
Technical Information
The charger's technical specifications are detailed below, including output power capabilities and charging profiles.
Output Power vs. Module Count
| 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 |
Housing Size vs. DC Cable Cross-section
| Phases | Module Positions | Standard Cable Cross-section | Comments |
|---|---|---|---|
| 1-phase | Max. 1 | 6 mm² | Single housing |
| 1-phase | Max. 3 | 25 mm² | Three slots, 3 kW housing |
| 3-phase | Max. 2 | 35 mm² | Two slots, 7 kW housing |
| 3-phase | Max. 4 | 70 mm² | Four slots, 3.5 to 14 kW housing |
| 3-phase | Max. 6 | 95 mm² | Six slots, max. 21 kW housing |
| 3-phase | Max. 8 | 70 mm² or 1 x 95 mm² | Eight slots, max. 28 kW housing. Dual cable for 24/36/48 Vdc, single cable for 72/80 Vdc |
Charging Profiles
The charger supports various charging profiles tailored for different battery types and operating conditions:
- P19 FAST: Fast charge for flooded batteries with airmix; up to 0.4 C5. Requires weekly equalization.
- P22 HDUTY: Pulse charging for heavy-duty flooded batteries; max 0.25 C5. Auto-adapts to battery capacity.
- P21 STDWL: Standard profile for Water Less® batteries (IUI profile); max 0.13 to 0.20 C5. Requires weekly equalization.
- P02 GEL: IUI profile for GEL batteries; max 0.17 to 0.22 C5. Requires weekly equalization.
- P06 AGM: IUI profile for AGM batteries; max 0.20 C5. Time limit for completion. Requires weekly equalization.
- P07 OPP: For PzQ cells; IU/IUI profiles; 0.25 C5. Requires daily full charge.
- P04 AIRMIX: Pneumatic/Airmix profile for batteries with air supply; IUI profile; max 0.13 to 0.25 C5. Requires weekly equalization.
- P09 WL20: Water Less® 20 batteries; IUI profile. Requires airmix and Wi-iQ®.
- P25 LOWCHG: Low charge current profile; IUI profile; 0.09 to 0.13 C5. Requires weekly equalization.
- P31 NXBLOC: For NexSys® TPPL Bloc batteries; 0.18 to 0.70 C5. Requires weekly equalization.
- P29 NXSTND: For NexSys® TPPL 2V batteries; 0.18 to 0.25 C5. Requires weekly equalization.
- P30 NXFAST: For NexSys® TPPL 2V batteries (high speed); 0.25 to 0.40 C5. Requires weekly equalization.
- P32 NXP2V: For NexSys® TPPL 2V batteries (high speed); 0.18 to 0.40 C5. Requires weekly equalization.
- P33 NXPBLC: For NexSys® TPPL Bloc batteries; 0.18 to 0.70 C5. Requires weekly equalization.
- ATP2V: For NexSys® ATP 2V batteries (high speed); 0.2 to 0.5 C5. Requires weekly equalization.
- NXSION: For EnerSys® Lithium batteries; communicates with BMS.
Safety Measures
Adherence to safety guidelines is critical for proper operation.
General Safety
- Remove transport pallet before use.
- Read all instructions, warnings, and precautions on the charger, battery, and equipment.
- Understand setup and operation instructions to prevent damage.
- Do not touch uninsulated parts of the output connector or battery terminals to avoid electric shock.
- Never open the equipment; hazardous voltage may be present even after power is disconnected. Service by qualified personnel only.
Environmental & Operational Safety
- Do not expose to water; use only indoors.
- Operating conditions: 0°C to 45°C (32°F to 113°F) and 0-70% relative humidity.
- Do not operate if dropped, struck, or damaged.
- Install on a non-flammable surface for fire protection.
- For NexSys® iON batteries, use only EnerSys® modules with integrated BMS.
- DC cables emit low-power magnetic fields (<5cm). Individuals with medical implants should avoid proximity.
- Contact trained technicians for issues. The charger is intended for EnerSys® industrial traction batteries.
- Follow local regulations for end-of-life disposal (e.g., WEEE directive).
Battery Safety
- Lead-acid batteries contain sulfuric acid; avoid contact with eyes, skin, clothing. Rinse immediately with water and seek medical attention if contact occurs.
- Charging batteries emits hydrogen gas, which is explosive. No smoking, open flames, or sparks near the battery. Ensure adequate ventilation per EN 62485-3 or local regulations.
- Never disconnect the battery while charging.
- Avoid connecting/disconnecting battery connectors if the charger is not equipped with LMEB (Late Make/Early Break) to prevent arcing.
Installation
Location
Choose a location free from high humidity, dust, flammable materials, and corrosive vapors. Avoid high temperatures (above 45°C / 113°F) or potential liquid spills. Do not block ventilation openings. Install on a non-flammable surface. Recommended clearance of 72 cm from the nearest battery edge.
Mounting
Mount vertically on a wall, shelf, or floor. Maintain a minimum 31 cm spacing between chargers. Ensure mounting surfaces are vibration-free. Avoid areas where units can be sprayed with water. Secure with 2 or 4 mounting elements, depending on the model.
Electrical Connections
Ensure connection to the correct mains voltage (230 Vac single-phase or 400 Vac three-phase). Ensure the power source is OFF and the battery is disconnected before making connections. Use appropriate circuit protection and fuses as per charger specifications. The unit must be grounded for Class 1 safety.
Grounding
⚠️ DANGER: FAILURE TO GROUND THE CHARGER CAN RESULT IN FATAL ELECTRIC SHOCK. Follow national electrical codes for grounding conductor sizing.
DC Connector Polarity
Connect the red cable to the positive (+) battery terminal and the black cable to the negative (-) terminal. Ensure correct polarity to prevent damage.
Operating Instructions
Control Panel Description
The charger features a graphic display and several indicators and buttons:
- 1. Graphic Display: Shows operational information and menus.
- 2. Green Indicator: Charge Complete (OFF: charger off/no battery; FLASHING: cooling; ON: battery ready).
- 3. Navigation Left/ESC: Enter main menu / scroll left / exit menus.
- 4. Navigation Up: Navigate menus / change values.
- 5. Yellow Indicator: Charging (OFF: charger off/no battery; ON: charging).
- 6. USB Port: Download logs / upload software.
- 7. Navigation Down: Navigate menus / change values.
- 8. Red Indicator: Fault (OFF: no fault; FLASHING: current fault; ON: fault).
- 9. Blue Indicator: AC Power (OFF: no AC; ON: AC present).
- 10. Navigation Right/EQUALIZE: Scroll right / start equalization or desulfation.
- 11. ENTER/STOP/START Button: Select menu items / enter values / stop and restart charging.
Charging Process
Idle Display: When no battery is connected, the display shows DC voltage, selected profile, firmware version, "Connect Battery", and system time/date.
Connecting Battery: Ensure correct connectors are used. For NexSys® iON batteries, CAN communication ("BMS CONNECTED") is required for charging to begin. The charger will then initiate the charging process.
Starting Charge: Charging starts automatically if enabled, or by pressing the ENTER/STOP/START button.
Delayed Start: Charging can be programmed to start after a delay.
Operation without Wi-iQ®: The charger uses programmed settings.
Operation with Wi-iQ®: The charger scans for Wi-iQ® devices, links to one, downloads battery data (serial number, capacity, temperature), and starts charging.
Charging Status
The display shows charging time, current, percentage of charge, voltage, temperature, battery serial number, etc.
Stopping Charge
Press the ENTER/STOP/START button to pause or resume the charging process at any time.
Charge Completion
When charging is complete, the Green LED illuminates, and the display shows "CHARGE COMPLETE". The display cycles through total charge time and Ah returned.
Recharge/Float: If the battery remains connected and float charge is enabled, the charger will maintain optimal charge level.
Equalization Charge: Can be started manually by pressing the RIGHT/EQUALIZE button or automatically. A symbol indicates equalization is active.
Menu and Display Information
Main Menu
Access the main menu by pressing and holding the ESC button. The menu auto-hides after 60 seconds of inactivity or can be exited by pressing ESC.
Menu Navigation
Use the navigation buttons (Up, Down, Left, Right) and the ENTER button to navigate menus and select options.
Menu Items:
- Logs: View up to 300 recent charge cycles.
- Charger: View errors, alarms, and status.
- USB: Access USB functions for software updates.
- Settings: Configure Date/Time, Language, Region (units), Display, Screen Saver, Delay Savings, Themes, and Daylight Savings.
- Password: Access service-level menus (requires password).
- Exit: Leave the main menu.
Status Screen
Displays counts for total charges, completed charges, partial charges, temperature faults (TH), and other faults (DF1 etc.).
Parameter Settings
Configure date, time, language, measurement units (metric/imperial), display settings, and daylight saving time.
USB Function
Used for software updates provided by EnerSys.
Password
Used by authorized service personnel to access advanced settings.
Service and Troubleshooting
Fault Codes
When a fault occurs, a code is displayed (e.g., DF1, DF2). Critical faults stop charging and activate the red fault indicator LED.
Faults, Causes, and Solutions
| Fault | Cause | Solution |
|---|---|---|
| DF-CUR, DF1, DF2, DFMOD | Current fault, module fault, phase loss | Call for service. Check connections, voltage, phase. |
| DF3 | Incorrect battery voltage | Check battery voltage (1.6-2.4V per cell for flooded lead-acid). Use appropriate charger. |
| DF4 | Over-discharge | Charging continues. |
| DF5 | Fault condition during charging profile | Check charging parameters (profile, temperature, capacity, cables), battery for defects. |
| DF7 | Air pump fault, thermal condition | Check air pump, ambient temperature, ventilation. |
| TH | Charger thermal fault | Check fans, ambient temperature, ventilation. |
| TH-Amb | High ambient temperature | Move charger to a cooler location. Follow installation guidelines. |
| MOD DEF | Module disconnected or not responding | Clean module/connection. Call for service if issue persists. |
| MOD DFC | Converter fault | Check power supply. |
| DF-TECHNO | Wi-iQ® setting mismatch | Verify Wi-iQ® settings against charger type. |
| DF-ID | Module type mismatch | Use correct module type. |
| CANBUSERROR | CANbus communication error | Call for service. |
| DEFEEP | Memory access denied | Call for service. |
| DEFRTC | Clock access denied | Call for service. |
General Maintenance
Keep connections clean and tight. Periodically clean radiators with low-pressure air. Disconnect power before cleaning. Maintenance frequency depends on the environment.
⚠️ WARNING: HAZARDOUS VOLTAGES INSIDE THE CHARGER HOUSING. Only qualified personnel should attempt to service this equipment.
