EnerSys IMPAQ™ Battery Charger User Manual
Model: IMPAQ™
Document ID: EMEA-CR-OM-IMP-0625
Website: www.enersys.com
Certifications: CE, UK CA
Introduction
Information in this document is key to the safe handling and proper use of the IMPAQ™ charger. It contains general system specifications, related safety measures, operating rules, commissioning guidelines, and recommended maintenance. This document should be kept accessible to users responsible for the battery charger. All users must ensure that system applications are appropriate and safe based on intended conditions or conditions encountered during operation.
This user manual contains important safety instructions. Read and understand all instructions before installation, operation, or use of the battery charger. Failure to follow these instructions may result in severe injury, death, property damage, charger damage, and/or loss of warranty.
This user manual does not replace any training required for handling and operating lifting and material transport equipment, batteries, or the IMPAQ™ charger, as mandated by local laws and/or industry standards. Ensure all users receive adequate training and qualification before operating 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 World 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
Website: www.enersys.com
⚠️ WARNING: Failure to follow instructions can cause death or severe injury.
Features & Information
Features
- Microprocessor control
- Automatic battery capacity identification
- State of Charge (SoC) adaptation
- Compatible with battery voltages:
- Single-phase: 12 V, 24 V, 36 / 48 V
- Three-phase: 24 / 36 / 48 V, 72 / 80 V, 96 V, 120 V
- Unique charging profile for Thin Plate Pure Lead (TPPL) batteries
- Unique profiles for NexSys® battery applications: NXBLOC; NXSTND.
- Fully programmable to unique fleet requirements
- Battery chemistry: TPPL, lead-acid, and gel
Technical Information (Nameplate Data)
| Item | Description |
|---|---|
| Serial Number | Shows date code. |
| Herc | Input voltage frequency. Never use the charger on a different frequency or on a generator with unstable frequency. |
| Phase | "1" indicates single-phase, "3" indicates three-phase charger. |
| AC Volts | Nominal voltage for which this charger is designed. |
| DC Volts | Nominal DC output voltage of the charger. |
| Modules | Actual number of power modules installed in the charger housing. |
| DC Amps | DC current with which this charger will charge a discharged battery, based on the number of installed power modules and nominal voltage. |
Example Nameplate Data:
EnerSys CE UK CA
TC3 IMP
3 Modules
24V/36V/48V
210A/195A/180A
Pmax=11150W
360VAC-440VAC 50/60Hz
S/N: XEEA055001
Technical Specifications
Output Power Ratings
| Output Power (kW) | Module Count | 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 |
Enclosure Size & DC Cable Size
| Phase | Module Positions | Standard Cable Cross-section | Comments |
|---|---|---|---|
| Single-phase | Max. 1 | 6 mm² | Freestanding enclosure |
| Single-phase | Max. 3 | 25 mm² | Three slots, 3 kW enclosure |
| Three-phase | Max. 2 | 35 mm² | Two slots, 7 kW enclosure |
| Three-phase | Max. 4 | 70 mm² | Four slots, 3.5 to 14 kW enclosure |
| Three-phase | Max. 6 | 95 mm² | Six slots, max. 21 kW enclosure |
| Three-phase | Max. 8 | 70 mm² or 1 x 95 mm² | Eight slots, max. 28 kW. Dual cable for 24 / 36 / 48 V DC, single cable for 72 / 80 V DC |
Charging Profile Codes
| Profile Code | Charger Profile | Description |
|---|---|---|
| P22 | HDUTY | Impulse profile for heavy-duty wet cell batteries. Charging profile diagnoses battery status during the charging phase and adjusts its parameters to optimize the charging technology for liquid batteries. Max. 0.25 C5. Automatic battery capacity adaptation with continuous current loops. |
| P21 | STDWL | Standard profile for (Waterless) wet cell batteries. IUI profile max. 0.13 to 0.20 C5. Automatic battery capacity adaptation with single-phase loops. Battery capacity can be manually adjusted as needed. Equalization required once a week. |
| P02 | GEL | IUI profile. Max. 0.17 to 0.22 C5. Automatic battery capacity with single-phase loops. Battery capacity can be manually adjusted as needed. Equalization required once a week. |
| P06 | AGM | IUI profile. Max. 0.20 C5. Automatic battery capacity with single-phase loops. End time limitation. Battery capacity can be manually adjusted as needed. Equalization required once a week. |
| P07 | OPP (*) | Opportunity charging for PzQ cells. IU (main) and IUI impulse (daily) profile at 0.25 C5. Finishing current 5%. Daily full charge must be set. Equalization required once a week. |
| P04 | AIRMIX | Profile for pneumatic / air mixing. Requires air kit installation. IUI profile max. 0.13 to 0.25 C5. Automatic battery capacity with single-phase loops. Battery capacity can be manually adjusted as needed. Equalization required once a week. |
| P25 | LOWCHG | Low charge rate profile. IUI profile 0.09 to 0.13 C5. Battery capacity must be manually adjusted as needed. Equalization required once a week. |
| P31 | NXBLOC (*) | For NexSys® block batteries during normal charging. Charging rate from 0.18 to 0.70 C5. Battery capacity, temperature, and equalization values must be set (for NexSys® block batteries). Equalization required once a week. |
| P29 | NXSTND (*) | For 2 V NexSys® core batteries under normal conditions. Charging rate from 0.18 to 0.25 C5. Battery capacity, temperature, and equalization values must be set (for 2 V NexSys® batteries). Equalization required once a week. |
(*) Opportunity Charging Profile Options
Operation: In opportunity charging mode, the user can charge the battery during breaks, lunch, or any available time during the work schedule. The opportunity charging profile ensures safe battery charging while maintaining a state of partial charge between 20% and 80% of C6 level during the work week. After weekly equalization, sufficient time must be allowed for the battery to cool down and for electrolyte level checks.
Daily Charging: This option can be set to add additional daily charging times if the schedule permits. It should only be considered if daily operational needs require additional capacity.
Equalization Charging: Equalization charging for classic flooded lead-acid batteries, performed after normal charging, balances the electrolyte density in the battery cells.
NOTE: Factory settings are: daily charging set to DISABLED, equalization for 6 to 8 hours, on Sunday at 00:00 for flooded batteries, 2 hours weekly / service charging for NexSys battery profiles.
Block Time
This function prevents the charger from charging the battery during a blocked period. If a charging cycle began before the blocked period, it will pause during the block and automatically resume afterwards.
Refresh Charging
Refresh charging, or service charging, allows the charger to maintain the battery at maximum charge level as long as it is connected.
Charger Option List
| Option | Description |
|---|---|
| LMEB | Late Make / Early Break contact |
| Airmix | Electrolyte circulation system |
Safety Measures
- ⚠️ WARNING: Remove the transport pallet for proper and safe handling.
- This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, safety notes, and warnings on the battery charger, the battery itself, and the product using the battery.
- Before using the battery charger, you must read and understand all installation and operating instructions to prevent damage to the battery and charger.
- Do not touch uninsulated parts of the output connector and battery terminals to prevent electric shock. Never open the equipment: High voltage may be present even after the charger is switched off. Installation, maintenance, or repair work on open equipment must only be performed by appropriately trained persons familiar with the existing hazards.
- Lead-acid batteries produce hydrogen gas during charging, which can explode if ignited. Smoking, open flames, and sparks are prohibited near the battery. Take all necessary safety precautions if the equipment is to be used in areas where there is a risk of accident. Ensure adequate ventilation in accordance with EN 62485-3 to allow for gas discharge. Never disconnect the battery while it is charging.
- If it is not a charger with LMEB (Late Make Early Break) function, do not connect or disconnect the battery plug while the charger is plugged in. This will cause sparking and plug burnout, which may result in charger damage or battery explosion.
- Lead-acid batteries contain sulfuric acid, which causes burns. Do not allow it to get into eyes, skin, or clothing. If it comes into contact with eyes, immediately flush eyes with clean water for at least 15 minutes. Seek immediate medical attention.
- Only factory-qualified personnel may install, adjust, and service this equipment. Before servicing the charger, disconnect all AC and DC power connections.
- The equipment must be used in accordance with the specified protection class and must never come into contact with water.
- Do not mount on surfaces subject to vibration (near compressors, engines, machinery).
- Install so that battery gases cannot be drawn into the charger by its fans.
- The charger is not intended for outdoor use; it is for indoor use only.
- Do not expose the charger to moisture. Operating conditions: temperature between 0 °C (32°F) and 45 °C (113°F); relative air humidity between 0 and 70%.
- Do not operate the charger if it has been dropped, received a strong impact, or damaged in any other way.
- For continuous protection and to reduce fire hazards, install chargers on a non-flammable surface.
- For NexSys® iON batteries, use only EnerSys® battery packs that include the battery management system and all necessary battery pack protection integrated into the pack.
- The charger's DC cables emit low-power magnetic fields in their vicinity (< 5 cm). Individuals with medical implants should avoid staying near the charger during charging.
- If you encounter any problems during charger commissioning, contact trained technical personnel of the company. It is intended only for charging lead-acid batteries for industrial applications and NexSys® batteries in industrial environments. When the equipment reaches the end of its useful life, the housing and other internal components must be handed over to specialized companies for disposal. Local laws take precedence over any instructions in this document and must be strictly adhered to (WEEE Directive 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 potential liquid spills onto the charger. Do not block the charger's ventilation openings. Observe warning labels on the charger regarding mounting on or above flammable surfaces. It is recommended to mount the charger at a radial distance of at least 72 cm from the nearest battery top edge.
Enclosure Mounting
The charger should be mounted on a wall, stand, shelf, or floor in a vertical position. Maintain a minimum clearance of 31 cm between chargers. If mounting on a wall, ensure the surface is free of vibrations and the charger is mounted vertically. If mounting on the floor, ensure the surface is free of vibrations, water, and moisture. Avoid areas where water splashing onto the charger may occur. Secure the charger using two or four fastening elements appropriate for the support type. The drilling pattern varies by charger model (refer to the technical sheet).
Electrical Connection
To prevent charger malfunction, ensure the charger is connected to the correct mains voltage. Follow local and national norms and laws for connection. ⚠️ WARNING: Ensure the power source is switched off and the battery is disconnected before connecting the input power to the charger terminals.
To Mains Power: Connect the charger only to a single-phase mains supply of 230 V AC or a three-phase mains supply of 400 V AC (depending on charger type) via a standard socket and an appropriate protective circuit breaker (not supplied). Power consumption is indicated on the charger's nameplate.
To Battery: Connect the charger to the battery using the supplied cables:
- RED cable: to the POSITIVE battery terminal.
- BLACK cable: to the NEGATIVE battery terminal.
AC Circuit Protection
The user must ensure appropriate branch circuit protection and a means of disconnecting the charger from AC power for safe servicing. ❗ CAUTION: Fire / Shock Hazard. Use is permitted only on branch circuits with branch protection in accordance with laws and standards. Applicable safety regulations must be followed. System protection installed on the charger's power supply must comply with the charger's electrical specifications. Installation of an appropriate circuit breaker is recommended. When replacing fuses, ensure only correctly rated fuses of the specified type are used.
This equipment complies with Class 1 safety standards, meaning the device must be grounded and powered from a grounded power source.
Charger Grounding
Connect the ground wire to the appropriate terminal, usually marked with one of the following symbols: ?. ⛔ DANGER: IMPROPER GROUNDING OF THE CHARGER CAN CAUSE ELECTRIC SHOCK. Follow national regulations for electrical equipment regarding ground wire sizing.
DC Connection Polarity
DC connection cables are connected to the charger's DC output as follows: the red charging cable (PLUS) connects to the charger's positive busbar, and the black charging cable (MINUS) connects to the charger's negative busbar. Pay attention to the charger's output polarity when connecting to the battery. Incorrect connection will trip the DC fuses in the power modules.
Declarations
EU Declaration of Conformity
EnerSys® hereby declares that the chargers in the NexSys®+ charger range comply with the following UK and European regulations:
- (Safety) Electrical Equipment 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
- Electromagnetic Fields Regulations 2016 (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 vicinity (< 5 cm). Although emissions are lower than typical limits, individuals with medical implants should avoid staying near the charger during charging.
Usage Instructions
Control Panel Features
| Ref | Function | Description |
|---|---|---|
| 1 | LCD Display | Displays operating information / charger menus |
| 2 | Up Navigation Button | Navigate menus / change values |
| 3 | ENTER / STOP / START Button | Select menu items / enter values / stop and restart battery charging |
| 4 | Right Navigation Button / Equalize | List right / start equalization or desulfation |
| 5 | Down Navigation Button | Navigate menus / change values |
| 6 | Left Navigation Button / Exit | Enter main menu / list left / exit menu |
| 7 | Red LED - Error | OFF = no error, BLINK = active error recognized, ON = error |
| 8 | Yellow LED - Charging | OFF = charger is off or battery is not available, ON = charging in progress |
| 9 | Green LED - Charge Complete | OFF = charger is off or battery is not available, BLINK = cooling phase, ON = battery is ready and available |
| 10 | Blue LED - Mains Power | OFF = no AC power, ON = AC power present |
| 11 | USB Port | Download logs / update software |
Menu Access
When the charger is in standby mode, press and hold
Main Menu
All menus are accessed from the main menu. A detailed description of each menu is found in the following sections of these instructions. Menus requiring a password are not displayed until the correct password is entered.
Menus provide access to the following functions:
- Display of the last 200 charge cycles (Memo menu).
- Display of faults, alarms, etc. (Status menu).
- USB functions (USB menu).
- Setting date, language, and others (Parameters menu).
- Password management (Password menu).
Stored Data Display
The charger can display details of the last 200 charge cycles.
The display in Figure 1 shows one charge cycle stored in memory. MEMO 1 is the most recently stored charge. After two hundred charges are stored, the oldest entry is deleted and replaced by the next stored entry.
Charge Cycle Display
Follow these steps:
- Use the ▲ / buttons to select an entry (MEMO x).
- Open the first history screen by pressing Enter.
- Open the second history screen by pressing ▼.
- Return to the main menu by pressing the Esc button.
The charging history is displayed. Use the ▲ / buttons to navigate through the parameters.
Stored Data
| Data | Description | Data | Description |
|---|---|---|---|
| Profile | Selected profile | Chg Time | Charge cycle time (minutes) |
| Capacity | Nominal battery capacity (Ah) | Ah | Ampere-hours restored during charge cycle |
| U batt | Nominal battery voltage (V) | SoC | Date and time of charge start |
| Temp | Battery temperature at start of charge (°F) | DBa | Date and time of battery disconnection |
| % init | Battery voltage at start of charge (%) | Status | Partial or complete |
| U start | Battery voltage at start of charge (Vpc) | Error | Error codes |
| U end | Battery voltage at end of charge (Vpc) | CFC | End code (for service technician) |
| I end | Current at end of charge |
Charging Operations
Battery Charging
Charger settings must be configured by a qualified technician before charging. Charging can only begin if a battery of the correct type, capacity, and voltage is connected to the charger.
When the charger is in standby mode (battery not connected) and the stop/start button has not been pressed, the screen will display the information shown in Figure 1 and Figure 2.
| Ref | Description |
|---|---|
| 1 | Charger DC voltage / charging current |
| 2 | Firmware version |
| 3 | System time |
| 4 | Battery connection |
| 5 | System date |
| 6 | Selected charging profile |
Starting Charge Cycle
The charger will start automatically when the battery is connected, or if the ENTER / STOP / START button is pressed when the battery is already connected.
Delayed Start
If the charger is programmed for a delayed start, charging will commence after this delay. When the battery is connected to the charger, the screen displays the remaining time before the programmed charging begins.
Actual Charging
A few moments before actual charging begins, the screen will alternately display charging information as shown in Figure 3, Figure 4, and Figure 5.
| Ref | Description |
|---|---|
| 1 | Charger DC voltage / charging current |
| 2 | Charging current |
| 3 | Symbol for equalization pending (if selected) |
| 4 | Charging Ah |
| 5 | Charging voltage (total V) |
| 6 | Charging time |
| 7 | Charging voltage (V/c) |
| 8 | Estimated remaining charging time |
| 9 | Charge percentage |
End of Charge (No Equalization)
A continuously lit GREEN LED indicates successful charge completion. The GREEN LED is lit continuously, and AVAIL is displayed on the screen. The screen alternately displays:
- Total charging time
- Restored ampere-hours in the battery
Any other lit LEDs indicate a problem during charging. For more information, refer to the Control Panel section on page 9.
If the battery remains connected and battery topping-up is enabled, the battery will be topped up to maintain optimal charge. The battery is now ready for use. Press the ENTER / STOP / START button before disconnecting the battery.
End of Charge (With Equalization)
Equalization can be initiated manually or automatically.
Manual and Automatic Equalization
Manual Equalization
- At the end of charging (GREEN LED is lit or blinking), press the
button. The equalization button can also be pressed during charging, and equalization will start when charging is complete. - NOTE: When equalization is initiated manually, the output current is set to the value stored in the charger's configuration.
- The start of equalization charging is indicated by the EQUAL message. During equalization charging, the charger displays the output current and alternately displays: battery voltage, voltage per cell, and remaining time.
- The battery will be available when the GREEN LED for completion starts to light up again and AVAIL is displayed on the screen.
- The battery is now ready for use. If the battery remains connected and topping-up is enabled, the battery will be topped up to maintain optimal charge. Press the ENTER / STOP / START button before disconnecting the battery.
Automatic Equalization
If the charger configurations include a programmed equalization day, equalization charging will automatically start on that day of the week after charging is completed.
NOTE: The factory default setting is IEI equalization, lasting 6 hours, on Sunday at 00:00.
The battery will be available when the GREEN LED for completion starts to light up again and AVAIL is displayed on the screen. The battery is now ready for use. If the battery remains connected and refresh charging is enabled, the battery will be refreshed to maintain optimal charge. Press the ENTER / STOP / START button before disconnecting the battery.
Error Codes
In case of an error, one of the following error codes will appear on the screen. If a critical error occurs, charging will stop, and the red LED error light will turn on.
| Error | Cause | Resolution |
|---|---|---|
| DF-CUR | Current error before DF1 (may be weak mains power, phase loss, or faulty module). | Contact service. |
| DF1 | Critical current error, all modules on DF1 are faulty (check for missing mains power and phase). | Contact service. |
| DF2 | Output fuse error, reverse battery polarity. | Check if the battery is connected correctly (reversed polarity cables) and the output fuse. |
| DF3 | Incorrect battery voltage for charger setting. | Battery voltage too high or too low. Battery voltage must be between 1.6 V and 2.4 V per cell for lead-acid technology. Use the appropriate charger for the battery. |
| DF4 | Over-discharge. | Charging continues. |
Error Codes (Continued)
| Error | Cause | Resolution |
|---|---|---|
| DF5 | Check battery or charger settings (Ah, time limit, negative Dv/Dt). | DF5 occurs when an incorrect state appears in the charging profile, which could be an increase in current during the regulation phase indicating battery heating, or incorrectly programmed regulation voltage, or if the charging time is too long and exceeds safety limits. Check charging parameters: profile, temperature, capacity, cables. Check the battery (faulty cells, high temperature, water level). |
| DF7 | Air pressure pump error. Di-Dt current, thermal instability. | Contact service. |
| TH | Charger thermal error, all modules in thermal failure (check airflow and ambient temperature). | Check if the fan is working correctly and/or if the ambient temperature is too high or if there is poor natural ventilation of the charger. Move the charger to a location with a lower ambient temperature. Observe installation and safety notes. |
| TH-Amb | Ambient temperature too high. | Contact service. |
| DFMOD | Module is faulty (refer to the Module menu to identify the type of fault). | Contact service. |
| MOD DEF | Module is disconnected or unresponsive. | Clean the module or backplate connector. If it does not work, call service. |
| MOD DFC | Module rectifier fault; module cannot deliver maximum current (check AC phases and DC fuse). | Check the power supply. |
| MOD TH | Module thermal error (check airflow and ambient conditions, refer to module status description to check internal temperature sensor). | Check if the fan(s) are working correctly, if the ambient temperature is too high, or if there is poor natural ventilation of the charger. If all modules are in thermal failure, a thermal error will follow. |
| MOD FUS | Module output fuse is damaged. | Contact service. |
| MOD Err | Module internal error. | Contact service (check module status description). |
| MOD VBAT | Battery voltage is incorrect relative to the fuse and VLMFB relative to the modules. | Contact service (read voltage from module status description). |
| TH-LOCK | Module is locked due to frequent thermal events. | Check Exx,CDV file to take action before resetting the lock or calling service. |
| PROVJERA MODULA | Charger is locked due to frequent internal errors. | Contact service. |
| POWER MODULE OFF | No CANBUS communication between display and module. | Check flat cable, mains power, if module is connected, inactive = disconnected, or call service. |
| DF-VREG | Modules are not following voltage settings via regulation. | Contact service (replace faulty module). |
| DF-ID | Menu setting does not match module type (e.g., cell setting = 12 V, module type with 40 cells). | Use the correct module. |
| CANBUSERROR | CAN bus error. | Contact service. |
| DEFEEP | Memory access denied. | Contact service. |
| DEFRTC | Clock access denied. | Contact service. |
Maintenance and Service
⚠️ WARNING: HAZARDOUS VOLTAGE EXISTS INSIDE THE BATTERY CHARGER HOUSING. ONLY QUALIFIED PERSONNEL MAY ADJUST OR SERVICE THIS BATTERY CHARGER.
The charger requires minimal maintenance. Connections and terminals must be clean and tightly secured. The unit (especially the cooling fins) should be periodically cleaned with low-pressure air to prevent excessive dust buildup on components. During cleaning, take care to avoid electric shock or adjustment changes. Before cleaning, ensure the AC power cable and battery are disconnected. The frequency of this type of maintenance depends on the environment in which the unit is installed.
EnerSys reserves the right to make changes to the data, descriptions, and specifications herein without prior notice. We recommend and draw the user's attention to the fact that before using the product, they should independently determine and assess the product's suitability for a specific purpose, and we further recommend not relying on the information provided in this document as it may apply to any general use or unclear application. The user's ultimate responsibility is to ensure the product's suitability and that the information corresponds to the user's specific application. The products described herein will be used under conditions beyond the manufacturer's control, who therefore disclaims all warranties, express or implied, relating to the fitness and suitability of such products for any particular use or any specific application. The user expressly assumes all risks and liabilities, whether contractual, tortious, or otherwise, related to the use of the information in this document or the products.
