EnerSys IMPAQ Battery Charger User Manual

This document contains essential information for the safe and correct operation of the IMPAQ™ charger. It includes global system specifications, safety measures, code of conduct, a guide for commissioning, and recommended maintenance. This document should be kept and made available to users working with batteries and responsible for the battery charger. All users are responsible for ensuring that all system applications are adequate and safe, based on anticipated or encountered operating conditions.

This user manual contains important safety instructions. Read and understand all instructions before installing, handling, or using the battery charger. Failure to follow these instructions may result in serious personal injury, death, property damage, charger damage, and/or voiding the warranty.

This user manual is not intended to replace the training on handling and operating material handling equipment, batteries, or the IMPAQ™ charger that may be required in accordance with local laws, entities, and/or industry standards. Adequate theoretical and practical training for all users must be ensured before handling the battery charger system.

For Service, Contact Your Sales Representative or Call:

EnerSys EMEA

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

Worldwide Headquarters EnerSys

2366 Bernville Road
Reading, PA 19605, USA
Tel: +1-610-208-1991
+1-800-538-3627

www.enersys.com

Your Safety and the Safety of Others is Very Important

⚠️ WARNING: Failure to follow instructions may result in death or serious personal injury.

Features and Information

Characteristics

  • Microprocessor controlled
  • Automatic battery capacity identification
  • Adaptable to State of Charge (SoC)
  • Compatible with battery voltages:
    • 1 Phase: 12V, 24V, 36/48V, 96V, 120V
    • 3 Phase: 24/36/48V, 72/80V
  • Unique profile for charging high-purity thin-plate batteries (TPPL)
  • Unique profiles for NexSys® battery charging applications: NXBLOC; NXSTND.
  • Fully programmable to unique fleet requirements.
  • Agnostic to battery chemistry - TPPL, flooded electrolyte, or gel lead-acid.

Technical Information

Definitions from the identification plate:

ItemSerial NumberDescription
HertzInput voltage frequency. Never use the charger at a different frequency or from a generator with unstable frequency.
PhaseTCX. '1' indicates a single-phase charger and '3' indicates a three-phase charger.
AC VoltageNominal voltage at which this charger is designed to operate.
DC VoltageNominal DC output voltage of the charger.
ModulesNumber of power modules installed in the charger cabinet.
DC CurrentContinuous current the charger will supply to a discharged battery with the number of installed power modules and nominal voltage.

EnerSys CE UK CA

TC3 IMP

3 Modules
24V/36V/48V
210A/195A/180A
Pmax=11150W
360VAC-440VAC 50/60Hz

S/N: XEEA055001

Technical Information (cont.)

Output Power Codes

Output Power (kW)Number of ModulesModule Power (kW)
1.011.0
2.021.0
3.031.0
3.513.5
7.023.5
10.533.5
14.043.5
17.553.5
21.063.5
24.573.5
28.083.5

Cabinet Size (Number of Available Modules) and DC Cable Size

PhaseModule PositionsStandard Cable SizeComments
1 PhaseMax 16 mm²Standalone cabinet
1 PhaseMax 325 mm²Cabinet with three slots, 3 kW
3 PhaseMax 235 mm²Cabinet with two slots, 7 kW
3 PhaseMax 470 mm²Cabinet with four slots, 3.5 - 14 kW
3 PhaseMax 695 mm²Cabinet with six slots, max. 21 kW
3 PhaseMax 870 mm² or 1 x 95 mm²Cabinet with eight slots, max. 28 kW. Double cable for 24/36/48V DC, single cable for 72/80V DC.

Charging Profile Codes

Profile CodeCharger ProfileDescription
P22HDUTYHigh-capacity wet cell pulse charging profile. The charging profile diagnoses battery status during recharge and adjusts its parameters to optimize charging of flooded electrolyte battery technology. Max 0.25 C5. Battery capacity automatically matches DC current loops.
P21STDWLStandard wet cell profile (no water). IUI profile Max 0.13 to 0.20 C5. Battery capacity automatically matches single-phase loops. Battery capacity can be manually set if necessary. Weekly equalization is required.
P02GELIUI profile. Max 0.17 to 0.22 C5. Battery capacity automatically matches single-phase loops. Battery capacity can be manually set if necessary. Weekly equalization is required.
P06AGMIUI profile. Max 0.20 C5. Battery capacity automatically matches single-phase loops. Finish time limitation. Battery capacity can be manually set if necessary. Weekly equalization is required.
P07OPP (*)Occasional cell charging PzQ. IU (main) & IUI pulse (daily) profile @0.25 C5. 5% finishing current. Daily full charge option must be set. Weekly equalization is required.
P04AIRMIXCompressed air/air mix profile. An air kit must be fitted to use this profile. IUI profile Max 0.13 to 0.25 C5. Battery capacity automatically matches single-phase loops. Battery capacity can be manually set if necessary. Weekly equalization is required.
P25LOWCHGLow charge rate charging profile. IUI profile 0.09 to 0.13 C5. If necessary, manually adjust battery capacity. Weekly equalization is required.
P31NXBLOC (*)For NexSys block batteries under normal charging conditions. Charging rate 0.18 to 0.70 C5. Battery capacity, temperature, and equalization values must be set (NexSys® BLOC battery). Weekly equalization is required.
P29NXSTND (*)For NexSys 2V batteries under normal charging conditions. Charging rate 0.18 to 0.25 C5. Battery capacity, temperature, and equalization values must be set (NexSys® 2 V battery). Weekly equalization is required.

(*) Occasional Profile Options

  • Operation: In the Occasional charging mode, the user can charge the battery during breaks, lunch, or any available interval during the work schedule. The Occasional charging profile allows safe charging of the battery while it is maintained at a partial charge level of 20%-80% of C6, throughout the work week. After weekly charging, sufficient time must be scheduled to allow the battery to cool down and to perform periodic electrolyte level checks.
  • Daily Charging: This option can be set to add extra daily charging time if the work schedule permits. It should only be considered when daily work demands require additional capacity.
  • Equalization Charging: Equalization charging for traditional flooded lead-acid batteries, performed after normal charging, balances the electrolyte densities in the battery cells.

NOTE: The factory default value is DISABLE daily charging, 6-8 hours Equalization, Sunday at 00:00 for flooded electrolyte NexSys charging profiles, 2 hours per week/maintenance charge.

Lock Time

This function prevents the charger from charging the battery during the lock time interval. If a charging cycle began before the lock time window, it is stopped during the lock time window and will automatically resume the charging cycle at the end of the lock time window.

Refresh Charging

Refresh or maintenance charging allows the charger to keep the battery at its maximum charge level as long as it is connected to the charger.

Charger Option List

SuffixDescription
LMEBLate module entry/Early exit
AirmixElectrolyte circulation system

Safety Instructions

  1. ⚠️ WARNING: The transport pallet must be removed for proper and safe operation.
  2. This manual contains important safety and usage instructions. Before using the battery charger, read all instructions, precautions, and warnings relating to the battery charger, battery, and the product using the battery.
  3. Read and understand all setup and operating instructions before using the charger to prevent battery and charger damage.
  4. Do not touch uninsulated components of the output connector or battery terminals to prevent electric shock. Never open the equipment: Even if the charger is off, high voltage may be present. Any adjustment, maintenance, or repair of the equipment while open must only be performed by a qualified person aware of the risks involved.
  5. 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 when the equipment will be used in areas where accidents may occur. Ensure adequate ventilation according to standard EN 62485-3 to allow for gas evacuation. Never disconnect the battery while it is charging.
  6. Unless the charger is an LMEB (Delayed Connect/Anticipatory Disconnect) unit, do not connect or disconnect the battery plug while the charger is on. Otherwise, electric arcing and connector burning will occur, leading to charger damage or battery explosion.
  7. Lead-acid batteries contain sulfuric acid, which causes burns. Do not get it in eyes, on skin, or on clothing. In case of eye contact, rinse immediately with clean water for at least 15 minutes. Consult a doctor immediately.
  8. Only qualified factory personnel should install, configure, and service this equipment. Disconnect all AC and DC power connections before servicing the charger.
  9. Must be used in accordance with the indicated protection level and must never come into contact with water.
  10. Must be installed so that it is not subjected to vibrations (near compressors, combustion engines, electric motors).
  11. Must be installed so that charging battery gases are not drawn into the charger by its fans.
  12. The charger is not intended for outdoor use, only for indoor use.
  13. Do not expose the charger to moisture. Operating conditions must be between 32°F (0°C) and 113°F (45°C); relative humidity between 0 and 70%.
  14. Do not use the charger if it has been dropped, struck by a sharp object, or otherwise damaged.
  15. For continuous protection and to reduce the risk of fire, install chargers on a non-combustible surface.
  16. For NexSys iON batteries, use only EnerSys battery packs that include the battery management system and all necessary protection for the battery pack that is integrated into the package.
  17. The DC cables of the charger emit low-frequency magnetic fields into the surrounding environment (<5 cm). People with implanted medical devices should avoid being near the chargers during charging.
  18. If you encounter problems commissioning the charger, contact one of the company's trained technicians. It is designed only for recharging industrial Motive Power lead-acid batteries and NexSys batteries in industrial buildings. When the equipment becomes obsolete, the casings and other internal components can be disposed of by specialized companies. Local legislation takes precedence over any instructions in this document and must be strictly followed (WEEE 2002/96 EC).

Installation

Location

For safe operation, choose a location free from excessive humidity, dust, combustible materials, and corrosive vapors. Also, avoid high temperatures (above 45°C (113°F)) or potential liquid leaks onto the charger.

Do not obstruct the charger's ventilation openings.

Observe the charger's warning label when mounting on a combustible surface.

It is recommended to mount the charger at least 72 cm away from the nearest battery top edge.

Electrical Cabinet Mounting

The charger must be mounted on a wall, support, shelf, or floor in a vertical position. The minimum distance between two chargers must be 31 cm. If mounted on a wall, ensure the surface is vibration-free and the charger is mounted vertically; if mounted on the floor, ensure surfaces are free of vibration, water, or humidity. Mounting chargers in areas where they could be splashed with water is strictly prohibited.

The charger must be secured by 2 or 4 fasteners appropriate for the type of support. The drilling pattern varies depending on the charger model (refer to the data sheet).

Electrical Connections

To prevent charger failure, ensure it is connected to the correct line voltage. Observe local and national standards and legislation regarding these connections.

⚠️ WARNING: Ensure the power supply is turned off and the battery is disconnected before connecting the power to the charger terminals.

Mains: Connection to a single-phase 230V AC or 400V AC electrical network (depending on factory setting) should be made exclusively using a standard socket and an appropriate circuit breaker (not supplied with the product). Current consumption is indicated on the charger's nameplate.

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

  • RED CABLE: to the battery's PLUS terminal.
  • BLACK CABLE: to the battery's MINUS terminal.

AC Circuit Protection

The user must ensure adequate protection of the branch circuit and a method of disconnection from the AC power source to the charger to allow for safe service operations.

⚠️ CAUTION: Fire/Electric Shock Hazard. Use only on circuits provided with branch circuit protection, in accordance with legislation and standards.

Applicable safety provisions must be observed. The system protection installed on the charger's power supply must comply with the charger's electrical characteristics. Installing an appropriate circuit breaker is recommended. It is mandatory to ensure that only fuses of the specified type and correct size are used when replacing fuses.

This equipment complies with Class 1 safety standards, meaning the unit must be grounded and powered from a grounded power source.

Charger Grounding

Connect the ground wire to the corresponding terminal, usually marked with one of the two symbols on the right. GND

⚠️ DANGER: FAILURE TO GROUND THE CHARGER CAN RESULT IN FATAL ELECTRIC SHOCK. Observe the National Electrical Code for grounding conductor sizing.

DC Connector Polarity

DC connector polarity

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

Installation (cont.)

EU Declaration

EnerSys® hereby declares that the chargers in the NexSys®+ charger ranges comply with the following UK and European regulations:

  • The Electrical Equipment (Safety) Regulations 2016 (S.I. 2016/1101)
  • European Directive 2014/35/UE
  • Safety
    BS EN IEC 62368-1: 2020 + A11:2020
  • EMC Regulation 2016 (S.I. 2016/1091)
  • European Directive 2014/30/UE:
    • Electromagnetic Compatibility
    • BS EN IEC 61000-6-2: 2019
    • BS EN IEC 61000-6-4: 2019
  • Directive 2011/65/UE
    RoHS
  • Regulations concerning the control of electromagnetic fields
    (S.I. 2016/588)
  • Directive 2013/35/UE:
    • Electromagnetic Fields
    • BS EN IEC 62311: 2020

NOTE: The DC cables of the charger emit low-frequency magnetic fields into the surrounding environment (<5 cm). Even if the emissions are below standard limits, people with medical implants should avoid working near the charger during charging.

Operating Instructions

Ref.FunctionDescription
1LCD DisplayDisplay charger operating information/menus
2Up Navigation ButtonNavigate menus/Modify values
3ENTER/STOP & START ButtonSelect menu items/Enter values/Stop and restart battery charging
4Right Navigation Button/EQUALIZEScroll right/Start equalization or desulfation
5Down Navigation ButtonNavigate menus/Modify values
6Left Navigation Button/ESCAccess main menu/Scroll left/Exit menus
7RED FAULT IndicatorOFF (off) = no error
INTERMITTENT = detected error in progress
8YELLOW CHARGE IndicatorON (on) = charging in progress
OFF (off) = charger off or battery not available
9GREEN CHARGE COMPLETE IndicatorON (on) = battery ready and available
10BLUE AC POWER IndicatorOFF (off) = no AC
ON (on) = AC present
11USB PortDownload firmware/Load software

Control Panel Features

[Image of control panel with numbered buttons and indicators]

Operating Instructions (cont.)

Menu Access

When the charger is inactive, press and hold . The main menu will be displayed. The main menu is exited automatically after 60 seconds of inactivity or can be exited voluntarily by pressing the button.

Main Menu

All menus are accessed from the Main Menu; a detailed description of each menu is included in the following sections of this manual. Menus requiring a password are not displayed until the correct password is entered.

The menus provide access to the following functions:

  • View the last 200 charging cycles (Memo menu).
  • View faults, alarms, etc. (Status menu).
  • USB functions (USB menu).
  • Set date, language, and other parameters (Parameters menu).
  • Password management (Password menu).

Memory Display Screen

The charger can display details of the last 200 charging cycles.

[Image showing a stored charge, labeled Figure 1, with MEMO 1 as the most recent charge]

When the two hundredth charge is memorized, the oldest record is deleted and replaced by the next in order of age.

Displaying a Charging Cycle

Proceed as follows:

  1. Select a record (MEMO x) using the ▲/▼ buttons.
  2. Display the first History screen by pressing Enter.
  3. Display the second History screen by pressing ▲.
  4. Return to the main menu by pressing Esc. The charging history is displayed; use ▲/▼ to scroll through parameters.

Memorized Data

MemoDescriptionMemoDescription
ProfileSelected ProfileTimeCharging cycle time (minutes)
Battery CapacityNominal battery capacity (Ah)AhAmpere-hours returned during the charging cycle
U batteryNominal battery voltage (V)LevelDate and time of charging start
TempBattery temperature at the start of charging (°F)DBaDate and time of battery disconnection
% initBattery voltage at the start of charging (%)StatePartial or complete
U startBattery voltage at the start of charging (Vpc)FaultFault codes
U endBattery voltage at the end of charging (Vpc)CFCEnd code (for service technician)
I endCurrent at the end of charging

Operating Instructions (cont.)

Status

This menu displays the status of the charger's internal counters (number of normal and partial charges, errors by type, etc.).

StatusDescription
ChargeTotal number of charges corresponding to the total of charges completed normally and charges completed with errors or due to an error.
NormalNumber of normally completed charges.
DF1 etc.Number of abnormally completed charges.
THNumber of faults recorded by the charger (see Fault Codes).
USBThis menu allows access to the USB function for software updates.
Software Update: Updates the charger's internal software. Software is provided by EnerSys.

[Image showing status screen: STATUS CHARGE 1]

Display

Contrast: Adjusts display contrast level (20 to 29).

Screensaver: Activate or deactivate the screensaver function.

Timeout: Set the time the screen remains on. The delay time can be adjusted from minutes up to one hour and 59 minutes.

Daylight Saving Time: Activates or deactivates automatic clock adjustment for daylight saving time. When activated, the time will advance by one hour at 02:00 on the second Sunday in March and will revert by one hour at 02:00 on the first Sunday in November. The charger must be on at the time of the change for the change to take effect.

Parameters

Date/Time
Sets the charger's date and time. The clock has a backup battery that will keep time when the charger's power is off.

Language
Selects the language displayed in the menus.

Region
Selects the format for date, metric or imperial measurement unit (EU or USA) for temperature, length, and cable size.

Password

The password is entered here to access service level menus performed by authorized EnerSys service personnel.

Operating Instructions (cont.)

Battery Charging

At this point, the charger should have been configured by a qualified service person. Charging can only begin if a battery of the correct type, capacity, and voltage is connected to the charger.

With the charger in standby mode (no battery connected) and without pressing the Stop/Start button, the display will show the information presented in Figure 1 and Figure 2.

[Image labeled Figure 1 showing battery voltage and time]

[Image labeled Figure 2 showing battery voltage and date]

Ref.DescriptionRef.Description
1DC charging voltage / Charging current1DC charging voltage / Charging current
2Firmware version2Charging current
3System time3Equalization standby symbol (if selected)
4Battery connection4Ah charged
5System date5Charging voltage (total V)
6Selected charging profile6Charging time

[Image labeled Figure 3 showing CHARGE 32A 24.8V 0Ah]

[Image labeled Figure 4 showing CHARGE 32A 2.05V 00H00]

[Image labeled Figure 5 showing CHARGE 32A 25% T]

Starting a Charging Cycle

The charger will start automatically when a battery is connected or if the ENTER/STOP & START button is pressed, provided the battery is already connected.

Delayed Start

If the charger has been programmed for a delayed start, charging will begin after this delay. When the battery is connected to the charger, the display shows the remaining time until the programmed charging start.

Actual Charging

After a few moments of actual charging, the display will begin to alternate between the charging information shown in Figure 3, Figure 4, and Figure 5.

End of Charging Without Equalization

The GREEN LED lights up completely after the corresponding charge is finished. The GREEN LED is fully lit, and the display indicates AVAIL. The display alternates between:

  • total charging time
  • ampere-hours restored to the battery

Any other LED lit indicates a problem during charging. Consult the Control Panel section on page 9 for more information.

If the battery remains connected and refresh charging has been activated, refreshes will be performed to maintain optimal charging.

The battery is now ready for use. Before disconnecting the battery, press the ENTER/STOP & START button.

End of Equalization Charging

An equalization charge can be started manually or automatically.

Operating Instructions (cont.)

Manual Equalization Start

  1. At the end of charging (GREEN LED lights up or flashes), press the button. The equalize button can also be pressed at any time during charging, and an equalization charge will start after the charge is finished.
  2. NOTE: When equalization is started manually, the output current will be set to the value saved in the charger's configuration.
  3. The start of equalization charging is indicated by the EQUAL message. During equalization charging, the charger displays the output current and alternates between: battery voltage, cell voltage, and remaining time.
  4. The battery will be available when the GREEN charge complete LED lights up again, and the display indicates AVAIL. The battery is now ready for use. If the battery remains connected and refresh charging has been activated, refreshes will be performed to maintain optimal charging. Before disconnecting the battery, press the ENTER/STOP & START button.

Automatic Equalization Start

If an equalization day has been programmed in the charger's configurations, the equalization charge will automatically start on the programmed day of the week after the charge is finished.

NOTE: The default factory value is IEI Equalize, 6-hour equalization time, Sunday at 00:00.

The battery will be available when the GREEN charge complete LED lights up again, and the display indicates AVAIL. The battery is now ready for use. If the battery remains connected and refresh charging has been activated, refreshes will be performed to maintain optimal charging. Before disconnecting the battery, press the ENTER/STOP & START button.

Fault Codes

In case of a fault, one of the corresponding error codes listed below will appear on the screen. If it is a critical fault, charging will stop, and the red error LED will light up.

FaultCauseSolution
DF-CURCurrent fault before DF1 (may be low grid, missing phase, or faulty module).Service call.
DF1Critical current fault, all modules in DF1 error (check mains supply and missing phase).Service call.
DF2Output fuse fault, battery reverse polarity.Check correct battery connection (possible cable polarity reversal) and output fuse.
DF3Incorrect battery voltage for charger setting.Battery voltage is too high or too low. Battery voltage must be between 1.6V and 2.4V per cell for lead-acid technology. Use a charger suitable for the battery.
DF4Over-discharge.Continuous charging.
DF5Battery setting or charger check (Ah safety, charge wait time, negative voltage Dv/Dt).DF5 appears when the charging profile has been reached with an error condition, which may be an increase in current in the regulation phase, demonstrating battery heating or incorrectly programmed regulation voltage or charging time exceeding the safety limit. Check charging parameters: profile, temperature, capacity, cables. Check battery (faulty cells, high temperature, water level).
DF7Air pressure pump fault. Current Di-Dt, uncontrolled thermal development.Service call.
THThermal fault of the charger, all modules in thermal fault (check airflow and ambient temperature).Check if the fan(s) are functioning correctly and/or if the ambient temperature is too high or if the charger's natural ventilation is poor. Move the charger to a location with a lower ambient temperature. Follow installation and safety instructions.
TH-AmbAmbient temperature is too high.Check if the fan(s) are functioning correctly and/or if the ambient temperature is too high or if the charger's natural ventilation is poor. If all modules are in thermal fault state, a TH error will appear.
DFMODFaulty module (see Module Menu for fault type).Service call.
MOD DEFModule disconnected or not responding.Clean the module or rear panel connection. If it does not work, call service.
MOD DFCFaulty module converter, module cannot deliver maximum current (check AC phases and AC fuse).Check the power supply.
MOD THModule thermal fault (check airflow, ambient environment, see Module Status Description for internal temperature sensor).Check if the fan(s) (fans) are functioning correctly and/or if the ambient temperature is too high or if the charger's natural ventilation is poor. If all modules are in thermal fault state, a TH error will appear.
MOD FUSOutput module fuse damaged.Service call.
MOD ErrInternal module error.Service call (check module status description).
MOD VBATBattery voltage is corrupted vs. fuse voltage and VLMFB vs modules.Service call (check voltage value in Module Status Description).
TH-LOCKModule blocked due to repetitive thermal events.Check the Exx,CDV file to take action before resetting the block or calling service.
VERIFY MODULECharger blocked due to repetitive internal errors.Service call.
MODULE POWER OFFLack of CANBUS communication between display and module.Check ribbon cable, AC power supply, connected module, inactive = off, or call service.
DF-VREGModules do not respect the voltage setting.Service call (replace faulty module).
DF-IDMenu setting does not match module type (e.g., Cell Setting = 12 V, Module Type 40 cells).Use the correct module.
CANBUSERRORCAN bus error.Service call.
DEFEEPAccess to memory denied.Service call.
DEFRTCAccess to clock denied.Service call.

Maintenance and Service

Maintenance and Service

⚠️ WARNING: DANGEROUS VOLTAGE EXISTS INSIDE THE BATTERY CHARGER CABINET. ONLY A QUALIFIED PERSON SHOULD BEGIN TO ADJUST OR OPERATE THIS BATTERY CHARGER.

The charger requires minimal maintenance. Connections and terminals must be kept clean and tight. The unit (especially the heat exchanger) should be periodically cleaned with low-pressure air to prevent excessive dirt accumulation on components. When cleaning, be careful not to hit or move any adjustments. Before cleaning, ensure that both AC power lines and the battery are disconnected. The frequency of these types of maintenance depends on the environment in which this unit is installed.

The data, descriptions, or specifications presented in this document may be changed without prior notice. Before using the products, the user is advised and warned to make their own determination and assessment of the suitability of the products for the specific use in question and is also advised to rely on the information contained in this document, as it may relate to any general use or indistinct application. The user assumes all risks and liability under contract, tort, or otherwise, in connection with the use of the information contained in this document or the product itself.

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