EnerSys NexSys+ Battery Charger

Introduction

The information contained in this document is of vital importance for the safe handling and proper use of NexSys®+ chargers. It includes general system specifications, associated safety measures, rules of conduct, an commissioning guide, and a maintenance recommendation. This document must be kept and made available to users who work with and are responsible for the charger. Each user is responsible for ensuring that the system is suitable and safe for the intended applications or the conditions prevailing during operation.

This operating manual contains important safety instructions. Read this manual completely before installing, handling, or using the charger. Failure to comply with these instructions can lead to serious injury, death, property damage, damage to the charger, and/or voiding of the warranty.

This operating manual is not intended as a substitute for instruction in the handling and operation of the industrial truck, batteries, or the NexSys®+ charger, which may be prescribed by local laws, authorities, and/or industry standards. Before handling the battery charging system, ensure that all users receive proper instruction and training.

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

www.enersys.com

⚠️ Your safety and the safety of others is very important. If you do not follow the instructions, you may be killed or seriously injured.

Features

• Microprocessor controlled.
• Automatic detection of battery capacity.
• Adaptation to the state of charge (SoC).
• Suitable for the following 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 pack recognition and automatic coupling with the charger.
• Unique profile for charging batteries in Thin Plate Pure Lead (TPPL) technology.
• Unique charging profiles for the following NexSys® batteries: NXBLOC; NXSTND; NXSFAST; NXP2V; NXPBLC; ATP2V.
• Remote access via the E Connect™™ App for mobile devices, for changing settings, monitoring chargers, and exchanging data.
• Controller Area Network (CAN) communication possible.
• Fully programmable for special fleet requirements.
• Independent of battery chemistry: EnerSys® Lithium-Ion batteries (Li-ion), TPPL, flooded electrolyte, and lead-acid gel batteries.

Technical Information

Type Plate Definitions

Output Power Coding

Cabinet Size and DC Cable Cross-section

Charge Profile Codes

Interim Charge Profile Options

Operation: In interim charge mode, the user can charge the battery during breaks, e.g., during lunch break or at another available time within the work schedule. The interim charge profile ensures that the battery is charged safely, maintaining a partial charge state of the battery between 20% and 100% of C5 throughout the work week. After the weekly equalization charge, sufficient time must be allocated for the battery to cool down and for regular checks of the electrolyte level.

Daily Charge: This option can be set to allow for additional daily charging times if the work schedule permits. It should only be considered when daily work requirements demand additional capacity.

Equalization Charge: An equalization charge for conventional lead-acid batteries, performed after the normal charging process, equalizes the electrolyte density in the battery cells.

NOTE: As factory settings, Daily Charge DEACTIVATED, 6-8 hours equalization charge, Sunday at 0:00 for lead-acid batteries, and 2 h weekly charge/maintenance charge for NexSys® battery profiles are set.

Lockout Period

This function prevents the charger from charging the battery during the lockout period. If a charging cycle was started before the lockout period, it will be paused during the lockout period and restarted after the lockout period expires.

Maintenance Charge

Through maintenance charging, the charger ensures that the battery remains as full as possible as long as it is connected to the charger.

List of Charger Options

Safety Precautions

1. ⚠️ WARNING The shipping pallet must be removed for proper and safe operation.
2. This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, precautions, and warnings on the battery charger, the battery, and the product using the battery.
3. Read all setting and operating instructions and ensure you understand them before using the battery charger. This will prevent damage to the battery and the charger.
4. Do not touch uninsulated parts of the output connector or the battery terminals! Otherwise, there is a risk of electric shock. Never open the unit: High voltage may still be present even after the charger is switched off. All setting, maintenance, or repair work on the opened unit must only be carried out by a qualified person familiar with the associated risks.
5. During charging, lead-acid batteries generate hydrogen gas, which can be dangerous if ignited. Therefore, never smoke, use open flames, or create sparks near the battery. Take all necessary precautions when using the unit in areas where there is a risk of accident. Ensure adequate ventilation according to EN 62485–3 or local legal requirements to allow any potentially released gases to escape. Never disconnect the battery from the charger during the charging process.
6. Except for chargers with the LMEB (late closing/early opening) feature, never connect or disconnect the battery plug while the charger is switched on. Otherwise, arcing and burns on the plug may occur, and the charger may be damaged or the battery may explode.
7. Lead-acid batteries contain sulfuric acid, which can cause burns. Avoid contact with eyes, skin, or clothing. If acid gets into the eyes, flush them immediately with clean water for at least 15 minutes. Consult a doctor immediately.
8. Only factory-trained personnel may install, set up, and maintain this unit. All AC and DC connections must be de-energized before the charger is serviced.
9. Use the unit in compliance with the specified protection level and never allow it to come into contact with water.
10. Do not install on surfaces subject to vibration (e.g., near compressors and internal combustion or electric motors).
11. Installation must be such that gases escaping from the battery being charged are not drawn into the unit by the charger's fans.
12. The charger is not intended for outdoor use, only for indoor use.
13. The charger must not be exposed to moisture. For operation, the temperature must be between 0 °C and 45 °C, and the relative humidity between 0 and 70%.
14. Do not operate the charger after it has been dropped, subjected to a strong impact, or otherwise damaged.
15. For continued safety and a low fire risk, chargers should be placed on a non-combustible surface.
16. For NexSys® iON batteries, use only EnerSys® battery packs with a battery management system and all necessary safety measures for the battery pack included in the package.
17. The charger's DC cables generate weak magnetic fields in their immediate vicinity (<5 cm). Persons with implanted medical devices should therefore not be in the vicinity of the charger during the charging process.
18. Contact one of the company's trained technicians if a problem occurs during the commissioning of the charger. This is exclusively designed for charging EnerSys® lead-acid batteries for industrial drives and NexSys® batteries in industrial applications. If the unit is obsolete, the housing and other internal components can be disposed of by specialized companies. Local legislation takes precedence over all instructions in this document and must be strictly adhered to (WEEE 2002/96 EC).

Installation

Installation Location

For safe operation, choose an installation location that is free from excessive moisture, dust, and aggressive vapors. Also avoid high temperatures (above 45 °C) and prevent liquids from reaching the charger.

Do not block the charger's ventilation openings.

Observe the warning label on the charger if the unit is mounted on or above a combustible surface.

It is recommended to mount the charger at a radial distance of at least 72 cm from the nearest battery top edge.

Cabinet Mounting

The charger must be mounted on a wall or placed in an upright position on a stand or shelf, or on the floor. The minimum distance between two chargers must be 31 cm. For wall mounting, ensure that the mounting surface is vibration-free and that the charger is mounted vertically. For floor mounting, ensure that the installation surfaces are free of vibration, water, and moisture. Avoid areas where the chargers could be splashed with water.

The charger must be secured with 2 or 4 suitable fastening elements. The drilling pattern varies depending on the charger model (see technical data sheet).

Electrical Connections

To prevent charger failure, it must be connected to the correct mains voltage. When making these connections, follow the laws and standards applicable in your country for electrical installations.

⚠️ WARNING Ensure that the power supply is switched OFF and the battery is disconnected before applying the input voltage to the charger terminals.

Connection to the mains: You may only connect the charger via a standard socket and a suitable disconnect switch (not supplied) to a single-phase 230 V mains or a three-phase 400 V AC mains (depending on the charger type). The power consumption is indicated on the device label.

Connection to the battery: The charger must be connected to the battery using the supplied cables:

• RED cable: to the battery's PLUS pole.
• BLACK cable: to the battery's MINUS pole.

AC Circuit Protection

The user must ensure adequate protection of the circuit branch and a method by which the charger's AC power supply can be disconnected for safe maintenance.

⚠️ CAUTION Fire/Electric Shock Hazard. Use only in circuits equipped with circuit protection in accordance with applicable laws and standards.

The applicable safety regulations must be observed. The system protection installed on the charger's power supply must correspond to the electrical characteristics of the charger. It is recommended to install a suitable disconnect switch. Under all circumstances, it must be ensured that when replacing fuses, only fuses of the prescribed type and correct size are used.

This unit is classified as Class 1 according to safety standards. The unit must be grounded accordingly and supplied from a grounded power supply.

Grounding

Connect the ground cable to the correct terminal, which is usually marked with one of the two symbols shown below. ⏚

DANGER IF THE CHARGER IS NOT GROUNDED, THIS CAN LEAD TO FATAL ELECTRIC SHOCKS. The dimensioning of the grounding conductor must comply with the laws and regulations applicable in the respective country for electrical installations.

DC Connector Polarity

The charging cables are connected to the charger's DC voltage output as follows: the red charging cable (POS) to the charger's positive busbar and the black charging cable (NEG) to the charger's negative busbar. The charger's output polarity must be observed when connecting to the battery. Incorrect connection will cause the DC fuses in the power modules to blow.

EU Declaration

EnerSys® hereby declares that the chargers of the NexSys®+ series comply with the following British and European regulations:

• (Safety) Regulations concerning the operation of electrical equipment 2016 (S.I. 2016/1101)
• European Directive 2014/35/EU (Safety)
• DIN EN IEC 62368-1: 2020 + A11:2020
• EMC Directives 2016 (S.I. 2016/1091)
• Directive 2014/30/EU (Electromagnetic Compatibility)
• DIN EN IEC 61000-6-2: 2019
• DIN EN IEC 61000-6-4: 2019
• Directive 2011/65/EU (RoHS)
• Control of Electromagnetic Fields Regulations (S.I. 2016/588) for Great Britain
• Directive 2013/35/EU (Electromagnetic Fields)
• DIN EN IEC 62311: 2020
• Radio Equipment Regulations 2017 (S.I. 2017/1206)
• Directive 2014/53/EU
• 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 generate weak magnetic fields in their immediate vicinity (<5 cm). Although the emissions are below the limit values specified in the standards, persons with implanted medical devices should not be in the vicinity of the charger during the charging process.

Operation Manual

Control Panel Description

The control panel features a graphical display showing charger information and menus. Navigation is done via dedicated buttons: 'Left/ESC' to open the main menu or go back, 'Up' and 'Down' to navigate menus or change values, and 'Right/EQUALIZE' to scroll right or start equalization/desulfation. 'ENTER/STOP' and 'START' buttons are used to select menu items, enter values, and stop/restart charging. Indicator lights show the status: Green indicates charge completion, Yellow indicates charging is in progress, and Red indicates an error.

The charger displays information such as charging current, charge status (percentage), charging voltage, battery temperature, and battery serial number (when using Wi-iQ®). When the battery is connected and idle, the display shows the charger's DC voltage, selected charge profile, firmware version, and system time/date.

Charging Operation

Starting Charge: When a battery is connected, the control board detects the voltage, and if Autostart is enabled, the charger begins charging automatically after a short wait. If Autostart is not enabled, press the ENTER/STOP and START buttons to initiate charging. For NexSys® iON batteries, CAN communication is established, displaying "BMS CONNECTED". The charger then closes the contactor to start the main charge.

Delayed Start: If programmed, the charger will begin charging after a specified delay. When the battery is plugged in, the display shows the remaining time until the programmed charging starts.

Wi-iQ® Integration

If a Wi-iQ® battery monitor is within range, the charger will power on and apply voltage to the battery. The display will show "SCAN" followed by "IQLINK". This program determines which Wi-iQ® monitor in range is connected. Once detected, the charger downloads data from the Wi-iQ® monitor, displays the battery's serial number, updates profile capacity and temperature for charging, and begins the main charging process.

Without Wi-iQ® Monitor: If the Wi-iQ® monitor is not active or not in range, charging begins after the programmed delay using profile, capacity, and temperature settings from the configuration menu.

Stopping Charge

The charging process can be interrupted and restarted at any point. Simply press the ENTER/STOP and START buttons. Remote control is also available.

Charge Completion

Completion without Equalization: The GREEN "Charge Complete" indicator lights up after the charging process has properly finished. The GREEN LED for charge completion illuminates, and the display shows "CHARGE COMPLETE". The display alternates between total charging time and the Ah charged into the battery. Another illuminated LED indicates a problem during charging (refer to the "Control Panel" section for details).

If the battery remains connected and maintenance charge is activated, maintenance charges will be performed to maintain optimal charge. Press the ENTER/STOP and START buttons before disconnecting the battery terminals.

Completion with Equalization: Equalization can be started manually or automatically. For manual start, press the RIGHT/EQUALIZE navigation button at the end of the charging process (when the green LED is lit or flashing). This button can also be pressed during charging; equalization will then start after the charging process is properly completed. The start of equalization is indicated by a symbol. During equalization, the charger displays the output current and alternates with battery voltage, voltage per cell, and remaining time.

Automatic Equalization Start

If a specific day for equalization is programmed in the charger's configuration, the equalization will start automatically on the programmed day after the charging process is completed. After equalization, the battery is ready for use when the green LED lights up again and the display shows "READY" (Operational readiness). If the battery remains connected and maintenance charge is activated, maintenance charges will be performed to maintain optimal charge. Press the ENTER/STOP and START buttons before disconnecting the battery terminals.

Power Failure

If the power supply fails during a charging cycle with the battery connected, the charger will reset. Once the power supply is restored, a new charging cycle will begin. All charger settings, as well as the time and date, will be retained.

Series Charging

For series charging, the voltages of the two batteries must match each other and the nominal DC voltage of the charger indicated on the nameplate. The charger's charging capacity (in Ah) must be equal to the capacity of each individual battery (in Ah). The charging cycle begins only when both batteries are connected.

Menu and Display Information

Main Menu Display

When the charger is idle, press and hold ESC to display the main menu. The main menu automatically closes after 60 seconds of inactivity, but can also be closed by pressing the ESC button.

All menus are accessed via the main menu. A detailed description of each menu can be found in the following sections of this manual. Password-protected menus are not displayed until the correct password has been entered.

The menus provide access to the following functions:

• Protocols (): View status and stored data.
• Charger (): View errors, alarms, etc.
• USB (): USB functions.
• Settings (): Set date, language, and more.
• Password (): Password management (for service technicians only).
• Exit (): Exit the main menu.

Logs

Memory Display Screen: The charger can display data from the last 300 charging cycles. The display shows that 3 charges have been stored. Memo 1 refers to the last stored charging cycle. When 300 charging cycles have been stored, the oldest dataset will be deleted and replaced by the preceding one.

Viewing a Charging Cycle:

1. Select a dataset (Memo x) using the [Up/Down Arrows] buttons.
2. Press the Enter button to display the first history screen.

To display the second history screen, press [Down Arrow]. With ESC, you return to the main menu. The charging cycle history is displayed. Use [Up/Down Arrows] to scroll through the parameters.

Stored Data

Status

This menu shows the status of the charger's internal counters (number of normal and partial charging cycles, error codes, etc.).

Parameter Settings

USB and Password

USB: This menu is used to access the USB function for software updates. Software updates are provided by EnerSys®.

Password: The password is entered here to gain access to the service menus for authorized EnerSys® service personnel.

Service and Troubleshooting

Error Display

When an error occurs, one of the corresponding error codes listed below is displayed. If it is a critical error, the charging process is stopped and the red error LED lights up.

Error Codes

⚠️ WARNING DANGEROUS VOLTAGES ARE PRESENT INSIDE THE CHARGER HOUSING. MAINTENANCE AND PROGRAMMING OF THE CHARGER MUST ONLY BE PERFORMED BY QUALIFIED PERSONNEL.

The charger requires little maintenance. Connections and terminals must be kept clean and securely fastened. The unit (especially the heat sink) must be cleaned periodically with low-pressure compressed air to prevent dirt buildup on the components. Ensure that no settings are changed during cleaning. Disconnect the charging system from both the mains voltage and the battery before cleaning. The frequency of this maintenance step depends on the environment in which the unit is installed.

All data, descriptions, or specifications contained herein are subject to change without prior notice. The user is strongly advised to determine and verify the suitability of the product/products for the intended use themselves before using this product/these products. Furthermore, the user is advised not to rely solely on the information contained herein, as it may refer to general use or to a use not described in detail. Ultimately, it is the user's responsibility to ensure the suitability of the product and the validity of the information provided for the user's specific application. The product(s) described herein will be used under conditions beyond the manufacturer's control. Therefore, all express or implied warranties regarding the suitability or fitness of this product/these products for a particular purpose or a specific application are excluded. The user expressly assumes all risks and liabilities associated with the product itself, as well as with the use of the information contained herein, whether based on contract, tort, or any other legal theory.