EnerSys IMPAQ Battery Charger User Manual
IMPAQ Battery Charger
User Manual
Introduction
This document provides essential information for the safe operation and correct use of IMPAQ™ battery chargers. It includes a comprehensive system overview, safety measures, usage procedures, commissioning, and recommended maintenance guidelines. This manual should be kept and made available to all personnel working with and responsible for the charger. Users must ensure that all system applications are appropriate and safe based on established or encountered operating conditions.
This user manual contains important safety instructions. Read and follow all instructions before installing, handling, or using the charger. Failure to comply with these instructions may result in serious injury, death, property damage, charger damage, and/or voiding the warranty.
The user manual does not replace training on handling and using material handling equipment, batteries, or IMPAQ™ chargers, which may be required by local laws, authorities, or industry standards. Before using the charger system, ensure that all users receive adequate training and instruction.
For assistance, contact your sales representative or call:
- EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10 - EnerSys APAC
No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333
www.enersys.com - EnerSys Headquarters
2366 Bernville Road
Reading, PA 19605, USA
Tel: +1-610-208-1991
+1-800-538-3627
Your safety and the safety of others are very important. Failure to follow instructions can cause death or serious injury.
Features and Information
Features
- Microprocessor controlled
- Automatically identifies battery capacity
- Adapts to State of Charge (SoC)
- 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 profile for TPPL (Thin Plate Pure Lead) charging
- Unique profiles for NexSys® battery charging applications: NXBLOC, NXSTND
- Fully programmable to suit fleet requirements
- Independent of battery chemistry - TPPL, flooded lead-acid, and gel
Technical Data
Definitions of labels for identification plates:
| Characteristic | Description |
|---|---|
| Serial Number | Provides the data code. |
| Hertz | Input voltage frequency. Never use the charger at a different frequency or with an unstable generator frequency. |
| Phase | TCX. "1" indicates a single-phase charger, and "3" indicates a three-phase charger. |
| Volt AC | Nominal operating voltage of the charger. |
| Volt DC | Nominal DC output voltage of the charger. |
| Modules | Number of power modules installed in the charger cabinet. |
| Amp DC | DC current delivered by this charger to a discharged battery with the installed number of power modules and based on the nominal voltage. |
EnerSys
CE UK CA
EnerSys Sp.z o.o
ul.Leszczynska 73
43-300 Bielsko-Biala, Poland
TC3 IMP
3 Modules
24V/36V/48V
210A/195A/180A
Pmax=11150W
360VAC-440VAC 50/60Hz
S/N: XEEA055001
Technical Data (cont.)
Output power codes:
| Output Power (kW) | Number of 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 |
Cabinet size (available modules) and DC cable size:
| Phase | Module Positions | Standard Cable Size | Comments |
|---|---|---|---|
| Single-phase | Max 1 | 6 mm² | Stand-alone cabinet |
| Single-phase | Max 3 | 25 mm² | 3 kW three-slot cabinet |
| Three-phase | Max 2 | 35 mm² | 7 kW two-slot cabinet |
| Three-phase | Max 4 | 70 mm² | 3.5 to 14 kW four-slot cabinet |
| Three-phase | Max 6 | 95 mm² | Max 21 kW six-slot cabinet |
| Three-phase | Max 8 | 70 mm² or 1 x 95 mm² | Max 28 kW eight-slot cabinet. Double cable for 24/36/48 V DC, single cable for 72/80 V DC. |
Charging Profiles
| Profile Code | Charger Profile | Description |
|---|---|---|
| P22 | HDUTY | Heavy-duty single-cell wet battery pulse profile. The charging profile analyzes the battery state throughout the charging phase and adjusts parameters to optimize charging for flooded battery technology. Max 0.25 C5. Automatic battery capacity detection with DC current loop. |
| P21 | STDWL | Standard (non-water) single-cell profile. IUI profile Max 0.13 to 0.20 C5. Automatic battery capacity detection with single-phase current loop. If necessary, battery capacity can be manually set. Weekly equalization is required. |
| P02 | GEL | IUI profile. Max 0.17 to 0.22 C5. Automatic battery capacity with single-phase current loop. If necessary, battery capacity can be manually set. Weekly equalization is required. |
| P06 | AGM | IUI profile. Max 0.20 C5. Automatic battery capacity with single-phase current loop. End time limitation. If necessary, battery capacity can be manually set. Weekly equalization is required. |
| P07 | OPP (*) | PzQ cells with equalization. IU profile (main) and IUI pulse (daily) at 0.25 C5. Final current 5%. Daily full charge must be set. Weekly equalization is required. |
| P04 | AIRMIX | Pneumatic/Airmix profile. Requires the air kit to be installed. IUI profile Max 0.13 to 0.25 C5. Automatic battery capacity with single-phase current loop. If necessary, battery capacity can be manually set. Weekly equalization is required. |
| P25 | LOWCHG | Low discharge charging profile. IUI profile from 0.09 to 0.13 C5. If necessary, manually set battery capacity. Weekly equalization is required. |
| P31 | NXBLOC (*) | For NexSys® Core monobloc batteries in normal charging conditions. Charging speed from 0.18 to 0.70 C5. Battery capacity, temperature, and equalization values must be set (NexSys® MONOBLOC battery). Weekly equalization is required. |
| P29 | NXSTND (*) | For NexSys® Core 2 V batteries in normal charging conditions. Charging speed from 0.18 to 0.25 C5. Capacity, temperature, and equalization values must be set (NexSys® 2V battery). The same weekly value is required. |
(*) Equalization Profile Options
Daily Charging
This option can be set to increase the daily charging time if working hours allow. It should only be considered when daily work requires additional capacity.
Charging Time-out
This function prevents the charger from charging during the block-out time window. If a charging cycle starts before the block-out window, it will be interrupted during the block-out window and will resume automatically at the end of the block-out window.
Refresh Charge
Refresh or maintenance charging allows the charger to keep the battery at maximum charge while connected to the charger.
Equalization Charge
Equalization charge for flooded batteries, performed after normal charging, balances the electrolyte density in the battery cells.
NOTE: The factory default is Daily Charge DISABLED, 6-8 hours equalization, Sunday at 00:00 for flooded batteries, 2 hours weekly charge/maintenance charge for NexSys® charging profiles.
Charger Option List
| Suffix | Description |
|---|---|
| LMEB | Late Make/Early Break |
| Airmix | Electrolyte circulation system |
Safety Measures
Safety Precautions
- WARNING: Remove the shipping pallet to ensure correct and safe use.
- This manual contains important operating and safety rules. Before using the charger, read the instructions, precautions, and warnings related to the charger, battery, and the product using the battery thoroughly.
- Before using the charger, read and understand the configuration and usage instructions completely to prevent damage to the battery and the charger itself.
- Do not touch uninsulated parts of the output connector or battery terminals to avoid the risk of electric shock. Never open the equipment: high voltage may still be present even when the charger is off. Any adjustments, maintenance, or repairs of open equipment must be performed only by qualified personnel aware of the associated risks.
- During charging, lead-acid batteries produce hydrogen, which can explode if ignited. Smoking, using open flames, or producing sparks near the battery is strictly prohibited. Take all necessary precautions when using equipment in areas where a potential incident exists. Ensure adequate ventilation according to EN 62485-3 to allow for the escape of released gases. Never disconnect the battery while it is charging.
- Unless the charger is equipped with the LMEB (Late Make Early Break) function, do not connect or disconnect the battery connector while the charger is on. Otherwise, an electric arc will form, and the connector will burn, resulting in damage to the charger or battery explosion.
- Lead-acid batteries contain sulfuric acid, which can cause burns. Avoid contact with eyes, skin, or clothing. In case of eye contact, wash immediately with plenty of clean water for at least 15 minutes. Seek immediate medical attention.
- Installation, configuration, and maintenance of this equipment must be performed exclusively by qualified personnel. Before performing maintenance on the charger, disconnect power from all AC and DC electrical connections.
- Use in accordance with the indicated protection level and never come into contact with water.
- Do not install on surfaces subject to vibration (near compressors, power supplies, motors).
- Install so that charging battery gases are not drawn into the charger by the fans.
- The charger is not intended for outdoor use, only indoors.
- Do not expose the charger to humidity. Operating conditions must be between 0 °C (32 °F) and 45 °C (113 °F); relative humidity from 0 to 70%.
- Do not use the charger if it has been dropped, subjected to a strong impact, or otherwise damaged.
- For continuous protection and to reduce the risk of fire, chargers must be placed on a non-flammable surface.
- For NexSys® iON batteries, only use EnerSys® battery packs that include the battery management system and all necessary protection for the integrated battery pack.
- The DC cables of the charger emit low-power magnetic fields in the surrounding area (<5 cm). People with implanted medical devices should avoid being near the chargers during charging.
- Contact a qualified company technician in case of problems during the charger's commissioning. It is designed exclusively for charging Industrial Motive Power lead-acid batteries and NexSys® batteries in industrial environments. When equipment becomes obsolete, casings and other internal components can be disposed of by specialized companies. Local legislation takes precedence over any instruction contained in this document and must be strictly observed (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 potential liquid leaks onto the charger.
Do not obstruct the charger openings intended for ventilation.
Follow the charger warning label when mounting on a flammable surface.
It is recommended to mount the charger at a radial distance of at least 72 cm from the nearest upper edge of the battery.
Cabinet Mounting
The charger must be wall-mounted, on a bracket, shelf, or floor-mounted in a vertical position. There must be a minimum distance of 31 cm between two chargers. If wall-mounted, ensure the surface is vibration-free and the charger is mounted vertically; if floor-mounted, ensure surfaces are free from vibrations, water, and moisture. Do not install the charger in areas where it may be exposed to water splashes.
The charger must be secured with 2 or 4 fastening devices suitable for the type of support. The drilling pattern varies depending on the charger model (refer to the technical sheet).
Electrical Connections
To avoid damaging the charger, ensure it is connected to an adequate voltage electrical line. Comply with local and national regulations and laws for these connections.
WARNING: Before connecting the input power to the charger terminals, ensure it is not powered and the battery is disconnected.
Mains Power:
The charger can only be connected to a single-phase 230 VAC or three-phase 400 VAC mains supply (depending on the charger type) using a standard socket and an adequate circuit breaker (not supplied). The current draw is indicated on the charger's identification plate.
Battery Connection:
The charger must be connected to the battery using the supplied cables:
- The RED cable: to the POSITIVE terminal of the battery.
- The BLACK cable: to the NEGATIVE terminal of the battery.
AC Circuit Protection
For safe maintenance, the user must provide adequate protection for residual current circuits and a method to disconnect the charger from the AC supply.
WARNING: Risk of fire/electric shock. Use only on circuits equipped with residual current protection according to norms and standards.
Comply with current safety regulations. The protection system installed on the charger's power supply must comply with the charger's electrical characteristics. It is recommended to install an adequate circuit breaker. When replacing fuses, ensure you use only fuses of the indicated type and correct size.
This equipment complies with Class 1 safety standards, therefore the appliance must be connected to earth and powered by an earthed mains supply network.
Charger Grounding
Connect the ground wire to the correct terminal, generally marked with one of the following symbols.
GND
DANGER: FAILURE TO GROUND THE CHARGER CAN RESULT IN FATAL ELECTRIC SHOCK. For ground wire dimensions, consult the National Electric Code.
DC Connector Polarity
The charging 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. When connecting the charger to the battery, respect the charger's output polarity. Incorrect connection will cause the DC fuses in the power modules to blow.
EU Declaration
EnerSys® hereby declares that the NexSys®+ range chargers comply with the following European and British regulations:
- 2016 Regulations on Electrical Equipment Safety (S.I. 2016/1101)
- European Directive 2014/35/UE: Safety
BS EN IEC 62368-1: 2020 + A11:2020 - CEM Regulations 2016 (S.I. 2016/1091)
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 Directive (Restriction of the use of certain hazardous substances in electrical and electronic equipment) - Electromagnetic Fields Control Regulations
(S.I. 2016/588)
Directive 2013/35/UE: Electromagnetic Fields
BS EN IEC 62311: 2020
NOTE: DC cables from the charger emit low-power magnetic fields in the surrounding area (<5 cm). Although emissions are below the reference limits, people with medical implants should avoid being near the charger during the charging phase.
Instructions for Use
Control Panel Features
| Ref | Function | Description |
|---|---|---|
| 1 | LCD Display | Displays charger operating information/menus. |
| 2 | UP Navigation Button | Navigation menu/Modify values. |
| 3 | ENTER/STOP and START Button | Select menu items/Enter values/Stop and restart battery charging. |
| 4 | RIGHT Navigation Button / EQUALIZE | Scroll right/Start equalization or desulfation. |
| 5 | DOWN Navigation Button | Navigation menu/Modify values. |
| 6 | LEFT Navigation Button / ESC | Access main menu/Scroll left/Exit menu. |
| 7 | RED Error Indicator | OFF = no error FLASHING = error in progress detected ON = error |
| 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 Power Indicator | OFF = AC absent ON = AC present |
| 11 | USB Port | Download data/Upload software. |
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Accessing Menus
When the charger is inactive, press and hold
Main Menu
The Main Menu provides access to all menus. Subsequent sections of the manual provide a detailed description of each menu. Menus requiring a password will not be displayed until the correct password is entered.
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).
Memorization Screen
The charger can display details of the last 200 charging cycles.
The display in Figure 1 shows a recorded charge. MEMO 1 is the most recently recorded charge. Once the two hundredth charge is recorded, the oldest data is erased and replaced by the next one.
Viewing a Charging Cycle
Proceed as follows:
- Select a record (Memo x) using the ▲/▼ buttons.
- View the first Chronology screen by pressing Enter.
- View the second Chronology screen by pressing .
- Return to the Main Menu by pressing Esc. The charge chronology appears; use to scroll through the parameters.
Stored Data
| Memo | Description | Chg Time (Charge Duration) | Description |
|---|---|---|---|
| Profile | Selected profile | Minutes | Charging cycle duration (minutes) |
| Capacity | Nominal battery capacity (Ah) | Ah | Amperes/hours restored during the charging cycle |
| U batt | Nominal battery voltage (V) | SoC | Date and time of charge start |
| Temp | Battery temperature at charge start (°C) | DBa | Date and time of battery disconnection |
| % init | Battery voltage at charge start (%) | Status | Partial or complete |
| U start (U start) | Battery voltage at charge start (Vpc) | Error | Error codes |
| U end (U end) | Battery voltage at charge end (Vpc) | CFC | Termination code (for service technician) |
| I end (I end) | Current at end of charge |
Charging the Battery
At this point, the charger should have been configured by a qualified service technician. 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 shows the information shown in Figure 1 and Figure 2.
Starting a Charging Cycle
The charger starts automatically when a battery is connected or when the START/STOP button is pressed if a battery is already connected.
Delayed Start
If the charger is programmed for a delayed start, charging will begin after the delay has elapsed. When the battery is connected to the charger, the display shows the remaining time before the programmed charging starts.
Actual Charging
A few moments after the actual charge, the display will alternate between the charging information shown in Figures 3, 4, and 5.
| Ref | Description |
|---|---|
| 1 | Charging DC voltage/charging current |
| 2 | Charging current |
| 3 | Equalization pending symbol (if selected) |
| 4 | Ah charged |
| 5 | Charging voltage (Total V) |
| 6 | Charging time |
| 7 | Charging voltage (V/cell) |
| 8 | Estimated remaining charging time |
| 9 | Charge percentage |
End of Charge Without Equalization
At the end of a regular charge, the GREEN charge complete indicator lights up. The GREEN charge complete indicator is on, and the display shows AVAILABLE. The display alternates between: total charging time, ampere-hours restored to the battery. Any other illuminated LED indicates a problem during charging. For more information, consult the Control Panel on page 9.
If the battery remains connected and the refresh charge is activated, refreshes will occur to maintain optimal charge.
The battery is now ready for use. Press the START/STOP button before disconnecting the battery.
End of Charge With Equalization
You can start an equalization charge manually or automatically.
Manual Equalization Start
- At the end of the charge (GREEN charge complete indicator on or flashing), press the
button. You can also press this button at any time during charging; at the end of the charge, an equalization charge will start.
NOTE: When manually starting an equalization charge, the output current is set to the value saved in the charger's configuration.
- The start of the equalization charge is indicated by the message EQUAL. During the equalization charge, the charger display shows the output current and, alternating with it, the battery voltage, voltage per cell, and remaining time.
- The battery will be available when the GREEN charge complete indicator lights up again and the display shows AVAILABLE. The battery is now ready for use. If the battery remains connected and the refresh charge is activated, refreshes will occur to maintain optimal charge. Press the START/STOP button before disconnecting the battery.
Automatic Equalization Start
If the charger configuration includes a programmed day of the week for equalization, the equalization charge will start automatically on the programmed day, once the charge is complete.
NOTE: The factory default setting is IEI equalization, 6 hours equalization, Sunday at 00:00.
The battery will be available when the GREEN charge complete indicator lights up again and the display shows AVAILABLE. The battery is now ready for use. If the battery remains connected and the refresh charge is activated, refreshes will occur to maintain optimal charge. Press the START/STOP button before disconnecting the battery.
Error Codes
In case of an error, one of the corresponding error codes listed below will be displayed. If it is a critical error, charging will stop and the red error LED will illuminate.
| Error | Cause | Solution |
|---|---|---|
| DF-CUR | Current error before DF1 (may be low mains voltage, missing phase, or faulty module). | Call for assistance. |
| DF1 | Critical current error, all modules are in DF1 error (check mains and missing phase). | Call for assistance. |
| DF2 | Output fuse error, battery polarity reversal. | Check that the battery and output fuse are correctly connected (non-reversed polarity cables). |
| DF3 | Incorrect battery voltage for charger setting. | Battery voltage is 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 | Excessive discharge. | Continuous charging. |
| DF5 | Battery or charger settings inspection (Ah safety, charging timeout, negative Dv/Dt voltage). | DF5 appears when the charging profile has been reached with an error condition, which may be an increase in current during the regulation phase showing battery heating or an incorrectly programmed regulation voltage, or the charging time is too long and has exceeded the safety limit. Check charging parameters: profile, temperature, capacity, cables. Check the battery (faulty cells, high temperature, water level). |
| DF7 | Air pressure error. Di-Dt current, thermal leak. | Call for assistance. |
| TH | Charger thermal error, all modules are in thermal error (check airflow and ambient temperature). | Check fan operation and/or absence of excessive ambient temperature or poor ventilation in the charger. |
| TH-Amb | Ambient temperature too high. | Move the charger to a location with a lower ambient temperature. Follow installation and safety instructions. |
| DFMOD | Module error (refer to the Module menu for the type of error). | Call for assistance. |
| MOD DEF | Module is disconnected or not responding. | Clean the module or backplane connection. If it does not work, call for assistance. |
| MOD DFC | Converter module is faulty and unable to deliver maximum current (check AC phases and AC fuse). | Check the power supply. |
| MOD TH | Module has a thermal fault (check airflow, environment, refer to the module status description for checking the internal temperature sensor). | Check that the fans are operating correctly and/or that the ambient temperature is not too high or that the charger's natural ventilation is poor. If all modules have a thermal fault, a TH error will follow. |
| MOD FUS | Module output fuse damaged. | Call for assistance. |
| MOD Err | Internal module error. | Call for assistance (check the module status description). |
| MOD VBAT | Battery voltage is damaged compared to the fuse voltage and VLMFB compared to the modules. | Call for assistance (check voltage reading in the module status description). |
| TH-LOCK | Module is blocked due to recurring thermal events. | Check the Exx file, CDV to intervene before restoring the block or call for assistance. |
| CONTROLLARE IL MODULO POWER | Charger is blocked due to recurring internal errors. | Call for assistance. |
| MODULE OFF | No CANbus communication between the display and the module. | Check the plate, AC mains, connected module, inactive = off or call for assistance. |
| DF-VREG | Modules are not following the regulation voltage setting. | Call for assistance (replace faulty module). |
| ID DF | Menu setting does not match the module type (e.g., Cell setting = 12 V, 40-cell module type). | Use the correct module. |
| CANBUSERROR | CAN bus error. | Call for assistance. |
| DEFEEP | Memory access denied. | Call for assistance. |
| DEFRTC | Clock access denied. | Call for assistance. |
Maintenance and Assistance
Maintenance and Assistance
WARNING: DANGEROUS VOLTAGES PRESENT INSIDE THE CHARGER CABINET. MAINTENANCE AND ASSISTANCE FOR THIS CHARGER ARE EXCLUSIVELY RESERVED FOR QUALIFIED PERSONNEL.
The charger requires minimal maintenance. Connections and terminals must be kept clean and tight. The equipment (especially the heat sink) must be regularly cleaned with low-pressure air to prevent excessive dirt buildup on components. Be careful not to knock or move the equipment's adjustments during cleaning. Before cleaning, ensure that the AC lines and the battery are disconnected. The frequency of this type of maintenance depends on the environment where the equipment is installed.
All data, descriptions, and specifications provided in this document are subject to change without notice. Before using the products, users are advised to personally evaluate the suitability of the products for the specific intended use and are discouraged from relying solely on the information contained in this document as it relates to general use or a non-specific application. It is the user's responsibility to ensure that the product is suitable and that the information is appropriate for their specific application. Products mentioned herein will be used under conditions beyond the manufacturer's control, and therefore all warranties, express or implied, relating to the suitability or adequacy of such products for a particular use or specific application are excluded. The user expressly assumes all risks and liabilities, whether defined by contract, tort, or otherwise, in relation to the use of the information contained in this document or the product itself.
