IMPAQ Battery Charger: Instructions for Use

Brand: EnerSys

1. Features

Microprocessor-controlled
Auto-identifies battery capacity
Adapts to State of Charge (SoC)
Compatible with battery voltages: 12V, 24V, 24/36/48V, 36/48V, 72/80V, 96V, 120V (for 1ph and 3ph configurations)
Unique profile for charging Thin Plate Pure Lead (TPPL)
Unique profiles for NexSys® battery charge applications (NXBLOC, NXSTND)
Fully programmable for fleet requirements
Battery chemistry agnostic: TPPL, Flooded, Gel Lead Acid

2. Technical Information

2.1. Name Plate Labels

2.1.1. Name Plate Label Definitions

Item	Description
Serial Number	Provides date code.
Hertz	Input voltage frequency. Do not operate at different frequencies or from unstable generators.
Phase	TCX: "1" for Single Phase, "3" for Three Phase Charger.
AC Volts	Nominal voltage for which the charger is rated.
DC Volts	Nominal DC output voltage.
Modules	Actual number of power modules installed in the charger cabinet.
DC Amps	DC current the charger delivers to a discharged battery based on installed modules and nominal voltage.

2.1.2. Output Power Letter Codes

Output Power (kW)	Number 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

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

Phases	Module Positions	Standard Cable Gauge	Comments
1ph	Max 1	6 mm²	Stand alone cabinet
1ph	Max 3	25 mm²	Three slot, 3 kW cabinet
3ph	Max 2	35 mm²	Two slot, 7 kW cabinet
3ph	Max 4	70 mm²	Four slot, 3.5 to 14 kW cabinet
3ph	Max 6	95 mm²	Six slot, max 21 kW cabinet
3ph	Max 8	70 mm² or 1 x 95 mm²	Eight slot, max 28 kW cabinet. Dual cable for 24/36/48Vdc, single cable for 72/80Vdc.

2.1.4. Charge Profile Codes

Profile Code	Charger Profile	Description
P22	HDUTY	Heavy Duty wet cell Pulse Profile. Diagnoses battery status and 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 Equalize needed.
P02	GEL	IUI profile. Max 0.17 to 0.22 C5. Auto battery capacity with Ph1 loops. Manual battery capacity setting possible. Weekly Equalize needed.
P06	AGM	IUI profile. Max 0.20 C5. Auto battery capacity with Ph1 loops. Finish time limitation. Manual battery capacity setting possible. Weekly Equalize needed.
P07	OPP (*)	Opportunity charge PzQ cells. IU (main) & IUI pulse (daily) profile @0.25 C5. Finish current 5%. Must set Daily Full charge. Weekly Equalize needed.
P04	AIRMIX	Pneumatic / Airmix profile. Requires Air kit. IUI profile Max 0.13 to 0.25 C5. Auto battery capacity with Ph1 loops. Manual battery capacity setting possible. Weekly Equalize needed.
P25	LOWCHG	Low rate charge profile. IUI profile 0.09 to 0.13 C5. Manual battery capacity setting possible. Weekly Equalize needed.
P31	NXBLOC (*)	For NexSys® core Bloc battery under normal charge. Charge rate 0.192 to 0.70 C5. Requires setting Battery Capacity, Temperature & Equalize values. Weekly Equalize needed.
P29	NXSTND (*)	For NexSys® core 2V battery under normal charge. Charge rate 0.192 to 0.25 C5. Requires setting Battery Capacity, Temperature & Equalize values. Weekly Equalize needed.

2.2. Opportunity Profile Options

2.2.1. Operation: In Opportunity charging mode, the user can charge the battery during breaks, lunch, or any available time during the work schedule. This allows safe charging while the battery remains in a partial state of charge (20%-80% of C6) throughout the work week. Sufficient time should be scheduled after the weekly equalize charge for battery cooling and electrolyte level checks.

2.2.2. Daily Charge: This option adds additional daily charging time if the work schedule requires it, particularly when daily work demands extra capacity.

2.3. Equalization Charging

2.3.1. Balances electrolyte densities in battery cells for traditional flooded lead acid batteries, performed after normal charging.

2.3.2. Note: Factory default is Daily Charge Disabled, 6-8 hours Equalize on Sunday at 00:00 for flooded batteries, and 2-hour week/maintenance charge for NexSys® battery profiles.

2.4. Block Out Time

2.4.1. Inhibits charging during a specified time window. If a charge cycle starts before the window, it pauses and restarts at the end of the window.

2.5. Refresh Charging

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

2.6. Charger Option List

Suffix	Description
LMEB	Late Make Early Break
Airmix	Electrolyte Circulation System

3. Safety Precautions

Warning: Remove shipping pallet for proper and safe operations.
Read all instructions, cautions, and warnings on the charger, battery, and product using the battery.
Understand all setup and operating instructions before use to prevent damage.
Do not touch non-insulated output connectors or battery terminals to prevent electrical shock. High voltage may be present even when the charger is off. Service by qualified personnel only.
Lead acid batteries produce explosive hydrogen gas during charging. Never smoke, use open flames, or create sparks near the battery. Ensure adequate ventilation (per EN 62485-3). Never disconnect the battery while charging.
Do not connect/disconnect the battery plug while the charger is on, unless equipped with LMEB feature, to avoid arcing and connector damage.
Sulfuric acid in lead acid batteries causes burns. Avoid contact with eyes, skin, and clothing. Flush eyes with water for 15 minutes and seek medical attention if contact occurs.
Only factory-qualified personnel should install, set up, and service this equipment. De-energize all AC and DC power connections before servicing.
Use only in conformance with indicated protection level and avoid contact with water.
Do not install on surfaces subject to vibration (near compressors, engines, motors).
Ensure battery charging gases are not drawn into the charger by its fans.
Charger is for indoor use only.
Operating conditions: 0°C to 45°C (32°F to 113°F); 0-70% relative humidity.
Do not operate if dropped, impacted, or damaged.
Install chargers on non-combustible surfaces for fire protection.
For NexSys® iON batteries, use only EnerSys® battery packs with integrated battery management system and protection.
DC cables emit low power magnetic fields (<5cm). People with medical implants should avoid operating near the charger while charging.
Contact trained EnerSys technicians for operational problems. The charger is designed for industrial motive power lead acid and EnerSys® NexSys® batteries on industrial premises. Dispose of obsolete equipment components according to local legislation (WEEE 2002/96 EC).

4. Installation

4.1. Location

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

4.2. Cabinet Mounting

Mount charger vertically on a wall, stand, shelf, or floor.
Maintain a minimum distance of 31 cm between chargers.
Ensure mounting surfaces are free of vibration, water, and humidity. Avoid areas prone to splashing.
Use 2 or 4 fixings suitable for the support type. Refer to the technical data sheet for drilling patterns.

4.3. Electrical Connections

Connect to the correct line voltage. Follow local standards and laws.
Warning: Ensure power source is OFF and battery is disconnected before connecting input power.
Mains Supply: Connect to 1-phase 230Vac or 3-phase 400Vac supply via a standard socket and appropriate circuit breaker (not supplied). Check charger information plate for current consumption.
Connection to Battery: Use supplied cables. RED cable to POSITIVE terminal, BLACK cable to NEGATIVE terminal.

4.4. AC Circuit Protection

User must provide branch circuit protection and a disconnect method for safe servicing.
Caution: Risk of Fire/Electric Shock. Use only circuits with branch circuit protection per laws and standards.
Observe safety regulations. System protection must conform to charger's electrical characteristics. A suitable circuit breaker is recommended. Use only specified fuse types.
Equipment conforms to Class 1 safety standards; must be earthed and powered from an earthed supply.

4.5. Grounding the Charger

Connect ground wire to the proper terminal (marked with grounding symbols).
Danger: Failure to ground can lead to fatal electric shock. Follow National Electric Code for ground wire sizing.

4.6. DC Connector Polarity

Observe DC plug polarity. Red cable (POS) to charger positive busbar, black cable (NEG) to negative busbar.
Improper connection will open DC fuses in power modules.

4.7. EU Declaration

EnerSys® declares conformity with UK and European regulations, including:

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 Fields Regulations (S.I. 2016/588)
Directive 2013/35/EU (Electromagnetic fields)
BS EN IEC 62311:2020

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

5. Operating Instructions

5.1. Control Panel Features

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

5.2. Menu Access

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

5.2.1. Main Menu

Access all menus from the Main Menu. Password-protected menus are not displayed until the correct password is entered. Menus provide access to:

View last 200 charging cycles (Memo menu).
View faults, alarms, etc. (Status menu).
USB functions (USB menu).
Setting of date, language, and other parameters (Parameters menu).
Management of password (Password menu).

5.3. Memorizations

5.3.1. Memorizations Display Screen

The charger displays details of the last 200 charge cycles. MEMO 1 is the latest. The oldest record is deleted and replaced when the 200th charge is memorized.

5.3.2. 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 Main Menu by pressing ESC.
Use ▲/▼ to scroll through parameters.

5.3.3. Memorization Data

Memo	Description	Memo	Description
Profile	Selected profile	Chg Time	Time of the charge cycle (minutes)
Capacity	Rated battery capacity (AH)	AH	Amp-hours returned during charge cycle
U batt	Rated battery voltage (V)	SoC	Start of charge date and time
Temp	Battery temperature at start of charge (F)	DBa	Battery disconnect date and time
% init	Battery voltage at start of charge (%)	Status	Partial or complete
U start	Battery voltage at start of charge (Vpc)	Fault	Fault Codes
U end	Battery voltage at end of charge (Vpc)	CFC	Termination code (for service tech)
I end	Current at end of charge

5.4. Status

Displays charger's internal counters (number of normal/partial charges, faults by type, etc.).

5.4.1. Status Screen

Status	Description
Charge	Total number of charges (normally terminated or terminated with faults).
	Number of charges normally terminated.
	Number of charges abnormally terminated.
DF1 etc.	Number of faults recorded (see Fault Codes).
TH	Number of charger temperature faults.

5.5. USB

Provides access to USB function for software updates.

5.5.1. Update Software

Updates charger's internal software provided by EnerSys®.

5.6. Parameters

5.6.1. Date/Hour: Sets charger's date and time. Clock has battery backup.
5.6.2. Language: Selects menu language.
5.6.3. Region: Selects format for date, metric (EU) or imperial (US) units for temperature, length, and cable gauge.
5.6.4. Display: Set screen saver function. Contrast: Modifies display contrast (20-29).
5.6.5. Screen Saver: Enable or disable screen saver.
5.6.6. Delay: Sets screen illumination time (up to 1 hour 59 minutes).
5.6.7. Daylight Savings: Enables automatic clock adjustment for daylight savings time.

5.7. Password

Enter password for access to service level menus by authorized EnerSys® service personnel.

5.8. Charging the Battery

Charger should be set up by a qualified service person. Charging begins when a battery of the proper type, capacity, and voltage is connected.

5.8.1. Charger Idle Display

When idle (no battery connected, Stop/Start button not pressed), the display shows:

Ref.	Description
1	Charge DC voltage/Charge current
2	Firmware version
3	Selected charge profile
4	System time
5	System date
6	Connect battery

5.8.2. Starting a Charge Cycle

The charger starts automatically when a battery is connected or if the Stop/Start button is pressed (if battery is already connected).

5.8.3. Delayed Start

If programmed, charging begins after a delay. The display shows the remaining time before charging starts.

5.8.4. Effective Charge

During effective charge, the display alternates between:

Ref.	Description
1	Charge profile
2	Pending equalize symbol (if selected)
3	Charge current
4	Charge AH
5	Charge voltage (total V)
6	Charge time
7	Charge voltage (V/c)
8	Percent of charge
9	Estimated remaining charge time

5.8.5. End of Charge without Equalization

The green complete LED illuminates, and the display shows "AVAIL", alternating between total charging time and Amp/hrs restored. Other lit LEDs indicate a problem. If refresh charge is enabled, refreshes occur to maintain optimal charge. Push the ON/OFF button before unplugging the battery.

5.8.6. End of Charge with Equalization

Equalize charge can be started manually or automatically.

5.8.7. Manual Equalization Start

At end of charge (green LED on/flashing), press EQUALIZE button. Can be pressed anytime during charge.
Start indicated by "EQUAL" message. Display shows output current, battery voltage, voltage per cell, and remaining time.
Battery available when green LED is on and display shows "AVAIL". Push ON/OFF before unplugging.

5.8.8. Automatic Equalization Start

If an equalization day is programmed, the charge starts automatically on that day after normal charging is complete. Factory default: IEI Equalize, 6 hours, Sunday at 00:00.

6. Fault Codes and Troubleshooting

6.1. Fault Display

In case of a fault, a code appears on the display. Critical faults stop charging and illuminate the red Fault LED.

Error	Cause	Solution
DF-CUR	Current fault before DF1 (low mains, phase missing, faulty module).	Call for Service
DF1	Critical current fault, all modules on DF1 fault (check mains, phase missing).	Call for Service
DF2	Output fuse fault, battery reverse polarity.	Check correct battery connection (reversed polarity cables) and output fuse.
DF3	Incorrect Battery voltage for charger setting.	Too high or too low battery voltage. Battery voltage must be between 1.6V and 2.4V per cell for Lead Acid technology. Use proper charger for battery.
DF4	Overdischarge.	Charge continues. DF5 appears when charging profile achieved with fault: current increase in regulation phase (battery heating), badly programmed regulation voltage, or charging time exceeded safety limit. Check charging parameters (profile, temperature, capacity, cables). Check battery (defective cells, high temperature, water level).
DF5	Battery or charger setting inspection (Ah security, charge timeout, negative voltage Dv/Dt).	Call for Service
DF7	Air pressure pump fault. Current Di-Dt, thermal run away.	Call for Service
TH	Charger Thermal fault, all modules on thermal fault (check air flow, ambient temperature).	Verify fan operation, ambient temperature, and natural ventilation.
TH-Amb	Ambient temperature too high.	Move charger to a location with lower ambient temperature. Follow installation and safety instructions.
DFMOD	Module faulty (refer to Module Menu for fault type).	Call for Service
MOD DEF	Module is unplugged or not answering.	Clean module or backplane connection. If not working, Call for Service.
MOD DFC	Module Converter faulty, cannot output maximum current (check AC phases, AC fuse).	Check power supply. Check fans, ambient temperature, and natural ventilation. If all modules have thermal fault, a TH fault will follow.
MOD TH	Module thermal fault (check air flow, ambient, refer to Module Status Description for internal temperature sensor).	Call for Service.
MOD FUS	Module output fuse damaged.	Call for Service (check Module status description).
MOD Err	Module internal error.	Call for Service (check voltage reading on Module Status Description).
MOD VBAT	Battery voltage corrupted vs Fuse voltage and VLMFB vs Modules.	Check the Exx,CDV file to reset locking or Call for Service.
TH-LOCK	Module locked due to repetitive thermal events.	Check ribbon cable, AC mains, module connection, idle=off or Call for Service.
POWER MODULE OFF	No CANBUS communication between display and module.	Call for Service.
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.
CANBUSERROR	CAN bus error.	Call for Service.
DEFEEP	Memory access denied.	Call for Service.
DEFRTC	Clock access denied.	Call For Service.

7. Service and Maintenance

7.1. Warning

Dangerous voltages are present within the battery charger cabinet. Only qualified persons should adjust or service this charger.

7.2. Maintenance

The charger requires minimal maintenance. Keep connections and terminals clean and tight. Periodically clean the unit (especially the heatsink) with low-pressure air to prevent dirt buildup. Avoid bumping or moving adjustments during cleaning. Disconnect AC lines and battery before cleaning. Maintenance frequency depends on the environment.

7.3. Disclaimer

Any data, descriptions, or specifications are subject to change without notice. Users must determine the suitability of the product for their specific use and are advised against relying solely on the information provided. The user assumes all risk and liability for the use of the product and information contained herein.

© 2022 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates, except UL®, which is not the property of EnerSys. Subject to revisions without prior notice. E.&O.E.

EMEA-EN-OM-IMPAQ-1022

	EnerSys IMPAQ Battery Charger User Manual This user manual provides essential information for the safe and correct operation of the EnerSys IMPAQ battery charger. It covers system specifications, safety measures, operating procedures, installation, and troubleshooting.
	IMPAQ Karikues i baterisë Manuali i Përdoruesit Ky manual përdorimi ofron udhëzime thelbësore për trajtimin e sigurt dhe përdorimin korrekt të karikuesve të baterive IMPAQ™. Ai përmban specifikime të sistemit, masa sigurie, udhëzime funksionimi dhe rekomandime mirëmbajtjeje.
	EnerSys IMPAQ™ Battery Charger User Manual Comprehensive user manual for the EnerSys IMPAQ™ battery charger, covering features, technical specifications, safety measures, installation, operation, error codes, and maintenance. This guide provides essential information for the safe and efficient use of the IMPAQ™ charger.
	EnerSys IMPAQ Battery Charger Owner's Manual Comprehensive owner's manual for the EnerSys IMPAQ Battery Charger, detailing features, technical specifications, safety precautions, installation, operation, fault codes, and maintenance.
	EnerSys IMPAQ Battery Charger Owner's Manual This manual provides essential information for the safe handling, installation, operation, and maintenance of the EnerSys IMPAQ Battery Charger. It covers features, technical specifications, safety precautions, and troubleshooting.
	EnerSys IMPAQ™ Battery Charger User Manual Comprehensive user manual for the EnerSys IMPAQ™ battery charger, covering installation, operation, safety, technical specifications, and troubleshooting. Provides detailed guidance for safe and efficient use of the IMPAQ™ charger.
	EnerSys IMPAQ Battery Charger Owner's Manual This owner's manual provides comprehensive information on the safe installation, operation, and maintenance of the EnerSys IMPAQ battery charger. It covers features, technical specifications, safety precautions, fault codes, and service guidelines.
	NexSys+ Battery Charger User Manual - EnerSys Comprehensive user manual for the EnerSys NexSys+ battery charger, covering features, technical specifications, safety instructions, installation, operation, and troubleshooting.