EnerSys IMPAQ Battery Charger

Introduction

This manual provides essential information for the safe handling and proper use of IMPAQ™ battery chargers. It includes system specifications, safety measures, operating guidelines, and recommended maintenance. This document should be kept accessible to users responsible for operating the battery charger. All users must ensure that system applications are appropriate and safe for the operating conditions.

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

This user manual does not substitute for any training on the operation of material handling equipment, batteries, or the IMPAQ™ charger, which may be required by local regulations, authorities, or industry standards. Proper training and qualification of all users must be ensured before operating the battery charger system.

For service, contact your local sales representative or call:

EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Fax: +41 44 215 74 10

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

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.

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

Features and Information

Features

• Microprocessor controlled
• Automatic battery capacity recognition
• Charge status (SoC) adaptation
• Battery voltage compatibility: 12V, 24V, 36V/48V, 72/80V, 96V, 120V
• Unique charging profile for thin plate pure lead batteries (TPPL)
• Unique charging profiles for NexSys® batteries: NXBLOC, NXSTND
• Fully programmable for unique vehicle fleet requirements
• Independent of battery chemistry – TPPL, flooded, and GEL

Technical Information

Nameplate Definitions

EnerSys
EnerSys Sp.z 0.0
ul. Leszczynska 73
43-300 Bielsko-Biala, Poland

CE UK CA

TC3 IMP

Scan for manual

3 Modules
24V/36V/48V
210A/195A/180A
Pmax=11150W

360VAC-440VAC 50/60Hz

S/N: XEEA055001

Technical Information (cont.)

Output Power Codes

Cabinet Size (Number of Modules) and DC Cable Size

Charging Profile Codes

Technical Information (cont.)

Charging Profile Codes (cont.)

(*) Opportunity Charging Profile Options

Operation: In opportunity charging, the user can charge the battery during breaks, lunch, or any available time during the work schedule. The opportunity charging profile allows the battery to be safely charged while maintaining a partial charge between 20% and 80% of C6 throughout the weekly work time. Sufficient time should be scheduled after weekly equalization to allow the battery to cool and for periodic electrolyte level checks.

Daily Charging: This option can be set to add extra daily charging time if the work schedule allows. It should only be considered when the daily work demand requires additional capacity.

Equalization Charging: Equalization charging for traditional flooded lead-acid batteries, performed after normal charging, equalizes the electrolyte specific gravity within the battery cells.

NOTE: The factory default setting is: Daily charging disabled, 6-8 hours equalization, Sunday at 00:00 for flooded type, 2 hours per week/maintenance charge for NexSys charging profiles.

Non-operational Time: This feature prevents the battery from being charged by the charger during the non-operational time. If a charging cycle has started before the non-operational time, it will be interrupted during the non-operational time and will automatically restart at the end of this period.

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

Charger Option Codes

Safety Precautions

Safety Precautions

1. WARNING: The transport 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, battery, and the product where the battery is used.
3. Read and understand all setup and operating instructions before using the battery charger to avoid any damage to the battery and charger.
4. Do not touch uninsulated parts of the output connector or battery terminals, as there is a risk of electric shock. Never open the equipment: High voltage may still be present even after the charger is turned off. Any adjustment, maintenance, or repair of the equipment while open must be performed only by qualified personnel familiar with the associated hazards.
5. During charging, lead-acid batteries produce hydrogen gas, which can explode if ignited. Do not smoke, use open flames, or create sparks near the battery. Take all necessary precautions when the equipment is to be used in areas where there is a risk of accident. Ensure adequate ventilation according to standard EN 62485-3 to allow any released gases to escape. Never disconnect the battery during charging.
6. If the charger does not have the LMEB (Late Mate Early Break) safe connection and disconnection feature, do not connect or disconnect the battery plug while the charger is energized. Doing so will cause an electric arc and burn the plug contacts, resulting in charger damage or battery explosion.
7. Lead-acid batteries contain sulfuric acid, which causes burns. It should not come into contact with eyes, skin, or clothing. In case of eye contact, rinse immediately with clean water for at least 15 minutes. Seek immediate medical attention.
8. Installation, setup, and maintenance of this equipment must be performed only by factory-trained personnel. Before servicing the charger, turn off all AC and DC power connections.
9. It must be used according to the indicated protection level and never come into contact with water.
10. It should not be installed on surfaces subject to vibration (near compressors, engines, motors).
11. It must be installed so that gases from the charging battery 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 should be 0°C (32°F) to 45°C (113°F), relative humidity 0 to 70%.
14. Do not use the charger if it has been dropped, subjected to a severe impact, 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 (BMS) and all necessary protection for the integrated pack.
17. The charger's DC cables emit low-power magnetic fields in their surroundings (<5 cm). Individuals with implanted medical devices should avoid being near chargers during charging.
18. Contact one of the company's trained technicians if a problem arises during charger commissioning. It is designed only for recharging lead-acid and NexSys® batteries for industrial motive power applications in industrial facilities. When the equipment is decommissioned, the casings and other internal components can be disposed of by specialized companies. Local legislation supersedes the 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, flammable materials, and corrosive fumes. Also, avoid high temperatures [above 45°C (113°F)] or possible liquid spillage onto the charger.

Do not obstruct the charger's ventilation openings.

Follow the charger's warning label when mounting on or near a combustible surface.

It is recommended to install the charger within a radius of at least 72 cm from the nearest battery rack.

Cabinet Mounting

The charger must be wall-mounted, on a support base, shelf, or floor, in a vertical position. The minimum distance between two chargers must be 31 cm. When wall-mounting, ensure the surface is vibration-free and the charger is mounted vertically. When floor-mounting, ensure the surfaces are free from vibration, water, and humidity. Avoid areas where chargers are at risk of water ingress.

The charger must be secured by 2 or 4 supports suitable for the mounting type. The drilling pattern varies depending on the charger model (refer to the technical data sheet).

Electrical Connections

To prevent charger failure, ensure it is connected to the correct line voltage. Follow local and national standards and regulations for making these connections.

⚠️ WARNING: Ensure the power source is turned off and the battery is disconnected before connecting the input power to the charger's terminals.

Mains Power Supply: You can connect to a 1-phase 230 VAC or 3-phase 400 VAC mains supply (depending on the charger type) using a standard plug and an appropriate circuit breaker (not supplied). Power consumption is listed on the charger's nameplate.

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

• The RED cable: to the POSITIVE battery terminal.
• The BLACK cable: to the NEGATIVE battery terminal.

AC Circuit Protection

The user must provide suitable branch circuit protection and a means of disconnecting from the AC supply to the charger to allow for safe servicing.

CAUTION: Fire/Electric Shock Hazard. Use only on circuits that are provided with branch circuit protection in accordance with applicable codes and standards.

Applicable safety regulations must be observed. The system protection installed on the power supply to the charger must comply with the charger's electrical characteristics. Installing an appropriate circuit breaker is recommended. When replacing fuses, it is imperative to ensure that only fuses of the specified type and correct rating are used.

This equipment complies with Class 1 safety standards, meaning the unit must be grounded and supplied from a grounded supply.

Charger Grounding

Connect the ground wire to the appropriate terminal, usually marked with one of the following two symbols.

GND

⚠️ DANGER: FAILURE TO GROUND THE CHARGER MAY RESULT IN FATAL ELECTRIC SHOCK. Follow the National Electrical Code for grounding conductor sizes.

DC Connector Polarity

DC Connector Polarity

The charging cables are connected to the charger's DC output: the red charging cable (POS) connects to the charger's positive supply line, and the black charging cable (NEG) connects to the charger's negative supply line. When connecting to the battery, the charger's output polarity must be observed. If connected incorrectly, the DC circuit breakers on the power modules will trip.

Installation (cont.)

EU Declaration

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

• The Electrical Equipment (Safety) Regulations 2016 (S.I. 2016/1101)
• Directive 2014/35/EU
• Low Voltage: BS EN IEC 62368-1: 2020 + A11:2020
• The 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: The charger's DC cables emit low-power magnetic fields in their surroundings (<5 cm). Even if emissions are lower than typical limits, it is recommended that individuals with implanted medical devices avoid being near the charger during recharging.

Operating Instructions

Operating Instructions

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

Control Panel Functions

Accessing the Menu

When the charger is in standby mode, press and hold the <ESC> button. The main menu will appear. The main menu will automatically exit after 60 seconds of inactivity, or you can exit intentionally by pressing the <ESC> button.

Main Menu

All menus are accessed from the main menu. A detailed description of each menu is provided in the following sections. Menus requiring a password will only appear after the correct password has been 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 others (Parameters menu).
• Password management (Password menu).

Display of Stored Data in Memory

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

Memory Data

Displaying a Charging Cycle

Proceed as follows:

1. Select a record (MEMO x) using the directional buttons.
2. Display the first History screen by pressing Enter.
3. Display the second History screen by pressing the button.
4. Return to the main menu by pressing Esc. The charging history is displayed. Use the buttons to scroll between parameters.

The screen in Figure 1 shows a charge stored in memory. The MEMO 1 indicator indicates the last charge stored in memory. After storing the 200th charge, the oldest record is deleted and replaced by the next oldest.

Operating Instructions (cont.)

Battery Charging

At this point, the charger must have been configured by a qualified service technician. Charging can only begin with a battery of the correct type, capacity, and voltage 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 shown in Figure 1 and Figure 2.

Starting a Charging Cycle

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

Delayed Start

If the charger is programmed for a delayed start, charging will begin with the specified delay. When the battery is connected to the charger, the display will show the remaining time until the programmed charging starts.

Charging in Progress

A few minutes after charging begins, the display will alternately show the charging information shown in Figures 3, 4, and 5.

End of Charging Without Equalization

The GREEN charging completion indicator lights up after the charging is correctly completed. The GREEN charging completion indicator is on, and the display shows AVAIL. The display alternately shows the following:

• Total charging time
• Ampere-hours recovered in the battery

Any other LED that lights up indicates a problem during charging. Refer to the 'Control Panel Functions' section on page 9 for more information.

If the battery remains connected and refresh charging is enabled, refresh charges will be performed to maintain optimal charge. Press the ENTER/STOP & START button before disconnecting the battery.

End of Charging With Equalization

An equalization charge can be initiated manually or automatically.

Operating Instructions (cont.)

Manual Equalization Start

1. At the end of charging (GREEN charging completion indicator is on or flashing), press the <EQUALIZE> button. The equalize button can also be pressed at any time during charging, and an equalization charge will begin after the charging is completed.
2. NOTE: When equalization charging starts manually, the output current is adjusted to the value stored in the charger's configuration.
3. The start of equalization charging is indicated by the message EQUAL. During equalization charging, the charger displays the output current alternately with the following: battery voltage, voltage per cell, and remaining time.
4. The battery will be available when the GREEN charging completion indicator lights up again and the display shows AVAIL.
5. The battery is now ready for use. If the battery remains connected and refresh charging is enabled, refresh charges will be performed to maintain optimal charge. Press the ENTER/STOP & START button before disconnecting the battery.

Automatic Equalization Start

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

NOTE: The default factory setting is: Equalization IEI, 6 hours equalization, Sunday at 00:00.

The battery will be available when the GREEN charging completion indicator lights up again and the display shows AVAIL. The battery is now ready for use. If the battery remains connected and refresh charging is enabled, refresh charges will be performed to maintain optimal charge. Press the ENTER/STOP & START button before disconnecting the battery.

Fault Codes

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

Fault Codes (cont.)

Maintenance and Service

WARNING: HAZARDOUS VOLTAGES EXIST INSIDE THE BATTERY CHARGER CABINET. SETTING OR SERVICING THE BATTERY CHARGER IS TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY.

The charger requires minimal maintenance. Connectors and terminals must be kept clean and dry. The unit (especially the heat sink) should be regularly cleaned with low-pressure air to prevent excessive dust accumulation on components. Care must be taken not to strike or dislodge fittings during cleaning. Ensure that both AC power lines and the battery are disconnected before cleaning. The frequency of this type of maintenance depends on the environment in which this unit is installed.

Any data, descriptions, or specifications provided herein are subject to change without notice. Before using the product(s), the user shall determine the suitability and fitness of the product(s) for the user's intended use and shall not rely on any data, specifications, or other information provided herein, as it may relate to any general use or unspecified application. The user assumes all responsibility and liability for the use of the product(s) in accordance with applicable laws and regulations.