NexSys+ Outdoor Charger

Owner's Manual

Brand: EnerSys

Introduction

This document is critical for the safe handling and proper use of the NexSys⁺ Outdoor charger(s). It contains global system specifications, safety measures, codes of behavior, commissioning guidelines, and recommended maintenance. Users must retain this document and ensure it is available to all responsible personnel. All users are responsible for ensuring system applications are appropriate and safe based on anticipated or encountered operational conditions.

This owner's manual contains important safety instructions. Read and understand all instructions before installing, handling, or operating the battery charger. Failure to follow these instructions may result in serious injury, death, destruction of property, damage to the battery charger, and/or void the warranty.

This manual is not a substitute for any required training on handling and operating material handling equipment, batteries, or NexSys⁺ Outdoor chargers, as mandated by local laws, entities, or industry standards. Proper instruction and training of all users must be ensured prior to handling the battery charger system.

For service, contact your sales representative or visit: https://www.enersys.com/en/sales-services/

⚠️ WARNING You may be seriously injured if you don't follow these and other related instructions.

Features

Microprocessor-controlled.
Able to auto-identify battery's capacity.
Able to adapt to State of Charge (SoC).
Compatible with battery voltages of:
- 1ph: 12V, 24V, 36/48V
- 3ph: 24/36/48V, 72/80V, 96V, 120V
Wireless integration with Wi-iQ^® battery monitoring devices.
Individual battery pack recognition and automatic pairing with the charger.
Rugged 6-bay IP54/NEMA3R rated enclosure (outdoor cabinet).
Modular design (up to 21kW).
Multi-voltage 24/48, 72/96V DC.
HF modular technology with efficiency up to 94%.
Internal heater, fans, and filter.
Unique profile for charging Thin Plate Pure Lead (TPPL).
Unique profiles for NexSys^® battery charge applications: NXBLOC; NXSTND; NXSFAST; NXP2V; NXPBLC.
Remote access via E Connect^™ mobile app to change settings, monitor charger, and share data.
Controller Area Network (CAN) communication capable.
Fully programmable to unique fleet requirements.
Battery chemistry agnostic: Lithium-ion (Li-ion), TPPL, Flooded, and Gel-Lead Acid batteries.
External START/STOP and EQUALIZE buttons.
External main switch.

Technical Information

Name Plate Label Definitions

Item	Description
Serial Number	Provides date code.
Hertz	Input voltage frequency. Under no conditions operate 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 Volts	Nominal voltage for which this charger is rated to operate.
DC Volts	Nominal DC output voltage of the charger.
Modules	Actual number of power modules installed in the charger cabinet.
DC Amps	DC current that this charger will deliver to a discharged battery with the number of power modules installed and based on the nominal voltage.

Name Plate Label Example

The example nameplate shows:

Manufacturer: EnerSys
Certifications: CE, UK CA
Model: TC3 NS+ODM
Configuration: 6 Modules, 72V/80V, 240A/216A, Pmax=22300W
AC Input: 360VAC-440VAC 50/60Hz
Serial Number: S/N: XEEA055001

Output Power Letter Codes

Output Power (kW)	Number Modules	Module Power (kW)
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

Cabinet Size (number of modules available) and DC Cable Size

Phases	Module Positions	Standard Cable Gauge	Comments
3ph	Max 6	95 mm²	Six slot, max 21 kW cabinet.

Charge Profile Codes

Profile Code	Charger Profile	Description
P22	HDUTY	Heavy duty wet cell pulse profile. Optimizes charge for flooded battery technology. Max 0.25 C5. Auto battery capacity matching with continuous current loops.
P21	STDWL	Standard (Waterless) wet cell profile. IUI profile Max 0.13 to 0.20 C5. Auto battery capacity matching with Ph1 loops. Manual battery capacity setting possible. Weekly equalization needed.
P02	GEL	IUI profile. Max 0.17 to 0.22 C5. Auto battery capacity with Ph1 loops. Manual battery capacity setting possible. Weekly equalization needed.
P06	AGM	IUI profile. Max 0.20 C5. Auto battery capacity with Ph1 loops. Finish time limitation. Manual battery setting possible.
P07	OPP (*)	Opportunity charge PzQ cells. IU (main) & IUI pulse (daily) profile @0.25 C5. Finish current 5%. Requires daily full charge setting. If Wi-iQ® is fitted, uses its data; otherwise, manual setup of capacity, temp, and voltage is required. Weekly equalization needed.
P25	LOWCHG	Low rate charge profile. IUI profile 0.09 to 0.13 C5. Manual battery capacity setting required. Weekly equalization needed.
P31	NXBLOC (*)	For NexSys® TPPL** bloc battery under normal charge. Charge rate 0.192 to 0.70 C5. Requires manual setup of battery capacity, temperature, and equalize values, or a programmed Wi-iQ® device. If no comm, uses manual setup. Weekly equalization needed.
P29	NXSTND (*)	For NexSys® TPPL** 2V battery under normal charge. Charge rate 0.192 to 0.25 C5. Requires manual setup of battery capacity, temperature, and equalize values, or a programmed Wi-iQ® device. If no comm, uses manual setup. Weekly equalization needed.
P30	NXFAST (*)	For NexSys® TPPL** 2V battery under fast, higher rate. Charge rate 0.251 to 0.40 C5. Requires FAST programmed Wi-iQ® device. If no comm, uses manual setup. Weekly equalization needed.
P32	NXP2V (*)	For NexSys® PURE 2V battery under fast, higher rate. Charge rate 0.251 to 0.40 C5. Requires programmed Wi-iQ® device. If no comm, uses manual setup. Weekly equalization needed.
P33	NXPBLC (*)	For NexSys® PURE bloc battery under normal charge. Charge rate 0.251 to 0.70 C5. Requires programmed Wi-iQ® device. If no comm, uses manual setup. Weekly equalization needed.
	NXSION (*)	For NexSys® iON batteries only. Communicates with the lithium-ion battery's BMS via CANbus. BMS drives the charger. Recommended parameters can be set.

(*) Opportunity Profile Options

(**) Please also use this profile for older NexSys® CORE batteries

Operation Modes

Opportunity Charging

Allows charging during breaks, lunch, or available times. Maintains battery in a partial state of charge (20%-80% of C5) throughout the work week. Schedule time after weekly equalization for cooling and electrolyte checks.

Daily Charge

Adds additional daily charging time if the work schedule requires. Consider only when daily work demand requires extra capacity.

Equalization Charging

For flooded lead-acid batteries, performed after normal charging to balance electrolyte densities. Factory default: daily charge disabled, 6-8 hours equalize on Sunday at 00:00 for flooded; 2-hour week/maintenance charge for NexSys® profiles.

Block Out Time

Inhibits charging during a specified window. If a cycle starts before the window, it pauses and resumes afterward.

Refresh Charging

Maintains the battery at maximum state of charge while attached to the charger.

Output Power Letter Codes (Suffix)

Suffix	Description
LMEB	Late Make Early Break
CAN	Controller Area Network
Ethernet	Network Connection

Safety Precautions

⚠️ WARNING The shipping pallet must be removed for proper and safe operations.

This manual contains important safety and operating instructions. Read all instructions, cautions, and warnings on the charger, battery, and product using the battery before use.
Read and understand all setup and operating instructions before using the charger to prevent damage to the battery and charger.
Do not touch non-insulated parts of the output connector or battery terminals to prevent electrical shock. Never open the equipment: High voltage may be present even after turning off the charger. Adjustments, maintenance, or repairs must only be performed by a skilled person aware of the risks.
During charging, lead-acid batteries produce hydrogen gas, which can explode if ignited. Never smoke, use open flames, or create sparks near the battery. Take all necessary precautions in areas with a risk of accident. Ensure appropriate ventilation (per EN 62485-3) for gas escape. Never disconnect the battery while charging.
Unless the charger has LMEB (Late Make Early Break), do not connect or disconnect the battery plug while the charger is on. This can cause arcing, connector burning, charger damage, or battery explosion. To avoid arcing, push START/STOP before disconnecting the battery.
Lead-acid batteries contain sulfuric acid, which causes burns. Avoid contact with eyes, skin, or clothing. In case of eye contact, flush immediately with clean water for at least 15 minutes and seek medical attention.
Only factory-qualified personnel should install, set up, and service this equipment. De-energize all AC and DC power connections before servicing.
Must be used in conformance with its indicated level of protection and never come into contact with water.
Must not be installed on surfaces subject to vibration (e.g., near compressors, engines, motors).
Must be installed so that gases from the battery being charged are not sucked into the charger by its fans.
Do not expose the charger to moisture. Operating conditions: -4°F to 113°F (-20°C to +45°C); 0 to 70% relative humidity.
Do not operate the charger if it has been dropped, received a sharp impact, or is otherwise damaged.
For fire protection, install chargers on a non-combustible surface.
For NexSys® iON batteries, use only EnerSys® battery packs with integrated battery management systems and protection.
The DC cables emit low power magnetic fields (<5cm). People with medical implant devices should avoid being near the charger while charging.
Contact trained EnerSys technicians if any problem is encountered during operation. The charger is designed for industrial motive power lead-acid and EnerSys® NexSys® batteries on industrial premises. When obsolete, dispose of components through specialist companies, adhering to local legislation (WEEE 2002/96 EC).

Installation

Location

Choose a location free of excess dust, combustible material, and corrosive fumes. Avoid high temperatures (above 113°F [45°C]) or potential liquid spills. Do not obstruct air ventilation openings (inlets on front/underside, outlet on back). Follow charger warning labels when mounting on or over combustible surfaces. Mount at least 28 inches (72 cm) radial distance from the closest top edge of the battery.

Cabinet Mounting

Mount the charger vertically on a wall, stand, shelf, or floor. Maintain a minimum distance of 4 inches (10 cm) between chargers. If wall-mounted, ensure the surface is vibration-free. If floor-mounted, ensure surfaces are free of vibration, water, or humidity. Use 2 or 4 fixings suitable for the support type; drilling patterns vary by model (refer to technical data sheet).

Electrical Connections

Ensure connection to the correct line voltage. Follow local standards and laws. ⚠️ WARNING Make sure the power source is OFF and the battery is disconnected before connecting input power.

To the mains supply

Connect to a 3-phase 400Vac mains supply using a standard socket and an appropriate circuit breaker (not supplied). Current consumption is shown on the charger's information plate.

Connection to battery

Use supplied cables:

RED cable: to the battery's POSITIVE terminal.
BLACK cable: to the battery's NEGATIVE terminal.

AC Circuit Protection

The user must provide suitable branch circuit protection and a disconnect method from the AC power supply for safe servicing. ? CAUTION Risk of Fire/Electric Shock. Use only on circuits with branch circuit protection in accordance with laws and standards.

Observe prevailing safety regulations. System protection must conform to the charger's electrical characteristics. A suitable circuit breaker is recommended. Use only specified fuses of the correct size.

This equipment conforms to Class 1 safety standards, requiring earthing and power from an earthed supply.

Grounding the Charger

Connect ground wire to the proper terminal, usually marked with the ground symbol (⏚).

? DANGER FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC SHOCK. Follow National Electric Code for ground wire sizing.

DC Connector Polarity

The charging cables connect to the DC output: RED cable (POS) to the positive busbar, BLACK cable (NEG) to the negative busbar. Observe output polarity when connecting to the battery. Improper connection will open DC fuses in power modules.

Installation & Operation

Installation (cont.)

EU Declaration

EnerSys^® declares that NexSys⁺ Outdoor chargers conform to the following UK and European regulations:

Electrical Equipment (Safety) Regulations 2016 (S.I. 2016/1101)
European Directive 2014/35/EU Safety (BS EN IEC 62368-1: 2020 + A11:2020)
EMC Regulations 2016 (S.I. 2016/1091)
Directive 2014/30/EU: Electromagnetic Compatibility (BS EN IEC 61000-6-2: 2019, BS EN IEC 61000-6-4: 2019)
Directive 2011/65/EU RoHS
Control of Electromagnetic Field Regulations (S.I. 2016/588)
Directive 2013/35/EU: Electromagnetic fields (BS EN IEC 62311: 2020, Radio Equipment Regulations 2017 (S.I. 2017/1206))
Directive 2014/53/EU (ETSI EN 301 489-1 V2.1.1, ETSI EN 301 489-17 V3.1.1, ETSI EN 300 328 V2.2.2)

NOTE: DC cables emit low power magnetic fields (<5cm). People with medical implants should avoid being close to the charger during recharge.

Operating Instructions

Control Panel Features

The control panel has the following features:

Ref	Function	Description
1	Graphical display	Display charger operation info/menus
2	GREEN charge complete indicator	OFF = charger off or battery not available; FLASHING = cooling phase; ON = battery ready and available
3	Navigate LEFT/ESC button	Enter main menu/Scroll left/Exit menus
4	Navigate UP button	Navigate menus/Change values
5	YELLOW charging indicator	OFF = charger off or battery not available; ON = charging in progress
6	USB port	Download memos/Upload software
7	Navigate DOWN button	Navigate menus/Change values
8	RED fault indicator	OFF = no fault; FLASHING = ongoing fault detected; ON = fault
9	BLUE AC supply indicator	OFF = AC missing; ON = AC present
10	Navigate RIGHT/ EQUALIZE button	Scroll right/Start equalize or desulfation
11	ENTER/STOP and START button	Select menu items/Enter values/Stop and restart battery charge

Charge Operation

Operate with both doors locked for ingress protection. Connect charger terminals to battery terminals. Use front-accessible push buttons. Refer to "Maintenance and Service" for picture references.

Charger Idle Display

When the charger is in wait mode (no battery connected) and Stop/Start is not pressed, the display shows:

Reference	Description
1	Charger DC Voltage
2	Selected Charge Profile
3	Firmware Version
4	Connect Battery
5	System Time and Date

When charging a NexSys^® iON battery, CAN communication establishes, displaying "BMS CONNECTED". The battery then closes the charge contactor, initiating charge and countdown.

Delayed Start

If programmed, charging begins after a delay. When the battery is plugged in, the display shows time remaining before charging starts (See Figure 1).

Note: Without a Wi-iQ^® device, charging starts after programmed delay using Profile, Capacity, and Temperature settings from the Configuration menu.

Start Charging

When a battery is connected, the control board senses voltage. If auto-start is ON, charging begins automatically. Press the Stop/Start button if the battery is already connected.

PAIRING with a Wi-iQ^® battery monitoring device

If Wi-iQ^® adapters are in range, the charger applies current. The display shows "SCAN" then "IQLINK" to determine the connected device. It then downloads data, displays battery S/N, updates profile capacity/temperature, and starts charging.

Display Information During Charging (See Figure 2)

Reference	Description
1	Charge time
2	Charging current
3	Percent of charge
4	Wi-iQ^® battery monitoring device warnings
5	USB connection
6	Charge voltage (total V and V/c), alternates with Ah returned
7	Battery temperature, alternates with battery capacity
8	Battery S/N from Wi-iQ^® battery monitoring device
	Li-ion only: Max current and voltage requested by BMS
9	Wi-iQ^® battery monitoring device link

Charging current adjusts automatically as battery voltage rises. The display shows charge parameters, including battery capacity percentage.

For NexSys^® iON batteries, the BMS controls charge current and voltage via CAN. If CAN is lost, charging stops, and the "BMS CONNECTED" message disappears.

Pause Charging

Press the START/STOP button once to pause. Press again to resume (See Figure 3).

Charge Complete

The GREEN charge complete indicator illuminates, and the display shows "CHARGE COMPLETE". The display alternates between Total charging time and Amp-hours restored.

End of Charge Without Equalization: GREEN indicator ON, display shows "CHARGE COMPLETE". Alternates between total charging time and amp-hours restored.

Operating, Menu, & Display

Operating Instructions (cont.)

⚠️ WARNING Any other lit LED indicates a problem during charging. Refer to Control Panel chart. If battery remains plugged in and refresh charge is enabled, refreshes occur to maintain optimal charge.

The battery is now ready for use. Push the START/STOP button before unplugging.

End of Charge with Equalization

An equalize charge can be started manually or automatically.

Manual Equalization Start

Press the EQUALIZE button anytime during charge; equalization will be scheduled after charging completes. The start is indicated by a symbol. During equalization, the charger displays output current, battery voltage, cell voltage, and remaining time. NOTE: Output is set automatically when equalization is manually started.

Automatic Equalization Start

If an equalization day is programmed, it starts automatically on that day after charging is complete. After equalization, the battery is available when the green LED shows AVAIL. If the battery remains plugged in and refresh charge is enabled, refreshes occur. Push ENTER/STOP and START before unplugging.

AC Power Failure

If AC power fails during a charge cycle, the charger resets and restarts the cycle when power is restored. Settings, time, and date are preserved.

Series Charging

Voltages of both batteries add up and must match the charger's DC volts rating. Ampere-hour rating must equal each battery's rating. Charge cycle will not start unless both batteries are connected.

Menu and Display Information

Main Menu Display

When the charger is idle, press and hold the Exit button to display the Main Menu. It exits automatically after 60 seconds of inactivity or by pressing .

All menus are accessed from the Main Menu. Menus requiring a password are not displayed until the correct password is entered.

Menu Functions

Logs [View status and memorizations]
Charger [View faults, alarms, etc.]
USB [USB functions]
Settings [Set date, language, and others]
Password [Management of password (for service technicians only)]
Exit [Exit main menu]

Logs

Memorization Display Screen

The charger can display details of the last 300 charge cycles. The display shows stored charges; Memo 1 is the latest. After 300 charges, the oldest record is deleted.

Displaying a Charge Cycle

Select a record (Memo x) using the < / > buttons.
Display the first History screen by pressing Enter.
Display the second History screen by pressing ↓.
Return to the Main Menu by pressing ESC.

The charge history is displayed; use < / > to scroll through parameters.

Memorization Data

Memo	Description	Memo	Description
S/N	Wi-iQ^® battery monitoring device serial number	I end	Current at end of charge
Capacity	Rated battery capacity (Ah)	Temp end	Battery temperature at end of charge (°F)
U batt	Rated battery voltage (V)	Chg Time	Time of the charge cycle (minutes)
Temp	Battery temperature at State of Charge (°F)	Ah	Amp-hours returned during charge cycle
Techno	Battery technology	kWh	Kilowatt-hours returned during charge cycle
Profile	Selected profile	Status	Partial or Complete
% init	State of charge at State of Charge (%)	Default	Fault codes
U start	Battery voltage at State of Charge (Vpc)	SoC	Start of charge date and time
U end	Battery voltage at end of charge (Vpc)	DBa	Battery disconnect date and time
Warning	Wi-iQ^® battery monitoring device warnings	CFC	Termination code (for service tech)

Status

Status Menu

This menu displays the charger's internal counters (normal/partial charges, fault codes, etc.).

Status	Description
Charge	Total number of charges (normally terminated + charges terminated with/by faults).
Complete	Number of charges terminated normally.
Partial	Number of charges terminated abnormally.
TH	Number of charger temperature faults.
DF1 etc.	Number of faults recorded by the charger (see Fault Codes).

Status Screen Example: CHARGE: 0, COMPLETE: 0, PARTIAL: 0, DF1: 0, DF2: 0, DF3: 0, DF4: 0, DF5: 0

Setting Parameters

Parameter	Description
Date/Time	Sets date and time. Clock has battery backup.
Language	Selects menu language.
Region	Selects date format, 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 screen saver.
Delay Savings	Set screen illumination delay time (up to 1 hour 59 minutes).
Themes	Themes A and B offer different display styles. Theme A is default.
Daylight Savings	Enables/disables automatic clock adjustment for daylight savings time. Requires charger to be powered on at the time of change.

USB and Password

USB

Provides access to the USB function for software updates. Software updates are provided by EnerSys^®.

Password

Enter password here to gain access to service level menus by authorized EnerSys^® service personnel.

Service & Troubleshooting

Fault Display

In case of a fault, a corresponding code appears on the display. Critical faults stop charging and illuminate the red Fault LED. Example display shows "DF1" with date and time.

Fault Codes

Fault	Cause	Solution
DF-CUR	Current fault before DF1 (low mains, phase missing, or faulty module).	Call for service.
DF1	Critical current fault, all modules on DF1 (check mains and phase).	Call for service.
DF2	Output fuse fault, battery reverse polarity.	Check battery connection (reversed polarity cables) and output fuse.
DF3	Incorrect battery voltage for charger setting.	Battery voltage too high or too low. Must be between 1.6V and 2.4V per cell for lead-acid. Use proper charger for battery.
DF4	Overdischarge.	Charge continues.
DF5	Battery or charger setting inspection (Ah security, charge timeout, negative voltage Dv/Dt).	DF5 appears when charging profile achieved with fault. Check charging parameters: profile, temperature, capacity, cables. Check battery: defective cells, high temp, water level.
DF7	Air pressure pump fault. Current Di-Dt, thermal runaway.	Call for service.
TH	Charger thermal fault, all modules on thermal fault (check air flow and ambient temp).	Verify fan operation, absence of high ambient temp, or poor natural ventilation.
TH-Amb	Ambient temperature too high.	Move charger to a place with lower ambient temperature. Follow installation and safety instructions.
DFMOD	Module faulty (refer to module menu for type).	Call for service.
MOD DEF	Module unplugged or does not answer.	Clean module or backplane connection. If not working, call for service.
MOD DFC	Module converter faulty; cannot output max current (check AC phases, AC fuse).	Check power supply.
MOD TH	Module thermal fault (check air flow, ambient, internal temp sensor).	Check fan(s) operation and ambient temperature. Poor ventilation can lead to TH fault.
MOD FUS	Module output fuse damaged.	Call for service.
MOD Err	Module internal error.	Call for service (check module status description).
MOD VBAT	Battery voltage corrupted vs fuse voltage and VLMFB vs Modules.	Call for service (check voltage reading on module status description).
BAT TEMP	Wi-iQ® battery monitoring device battery temperature too high.	Battery needs to cool down.
TH-LOCK	Module locked due to repetitive thermal events.	Check Exx, CDV file to reset locking or call for service.
POWER MODULE OFF	No CANbus communication between display and module.	Check ribbon cable, AC mains, module plugged, idle=off, or call for service.
DF-TECHNO	Wi-iQ® battery monitoring device setting does not match charger type.	Check charger and Wi-iQ® device settings.
DF-VREG	Modules do not follow regulation voltage setting.	Call for service (replace faulty module).
DF-ID	Menu setting does not match module type (e.g., cell setting = 12V, module type 40 cells).	Use correct module.
	Default balance voltage detected by Wi-iQ® battery monitoring device.	Check each battery cell during discharge. Ensure Wi-iQ® device is properly adjusted.
CANBUSERROR	CANbus error.	Call for service.
DEFEEP	Memory access denied.	Call for service.
DEFRTC	Clock access denied.	Call for service.

Maintenance and Service

⚠️ WARNING DANGEROUS VOLTAGES INSIDE. ONLY QUALIFIED PERSONNEL SHOULD ADJUST OR SERVICE THIS CHARGER.

Connections and terminals must be kept clean and tight. Periodically clean the unit (especially heatsink) with low-pressure air. Avoid bumping or making adjustments during cleaning. Disconnect AC lines and battery before cleaning. Maintenance frequency depends on the environment.

To ensure proper ventilation and protection against particulate matter, routine air filter inspection and maintenance is required. The filter is accessible from the front by unlocking and opening the two doors. Disconnect all power sources (AC grid, batteries) before opening any door.

Maintenance Intervals

Inspection intervals are application-specific. Maximum interval is 90 days, with more frequent inspection in dusty/dirty areas or if the filter becomes wet. If the filter surface is darkened, clogged, contaminated, or damaged, replace it.

Disclaimer

Data, descriptions, and specifications are subject to change without notice. Users must determine product suitability for their specific use. EnerSys disclaims all warranties concerning fitness or suitability for any particular use. The user assumes all risk and liability associated with the use of the information or product.

Figure Descriptions

Figure 4: Control panel accessible once outer cabinet door is opened.
Figure 5: Air filter, heater, and power modules accessible once the second inner door is opened.
Figure 6: Control panel not accessible when cabinet is closed. Use external buttons for Start/Stop, pause, and equalization functions.

Notes

This section is intentionally left blank for user notes.

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