EnerSys EI1-AK-3AT IMPAQ Battery Charger Instruction Manual

EnerSys EI1-AK-3AT IMPAQ Battery Charger

Product Information

The Battery Charger is a microprocessor-controlled device that is able to auto identify the battery’s capacity and adapt to the State of Charge (SoC). It is compatible with battery voltages of 1ph, 3ph, 12V, 24V, 24/36/48V, 36/48V, 72/80V, 96V, and 120V. The charger is fully programmable to unique fleet requirements and is battery chemistry agnostic, capable of charging TPPL, Flooded, and Gel Lead Acid batteries.

Technical Information

Name plate labels Name plate label definitions

at a different frequency or from a generator with unstable frequency.
Phase| TCX. When “1” indicates a Single Phase Charger and “3” indicates a Three Phase Charger.
AC Volts| Nominal voltage for which this charger is rated to operate.
DC Volts| Nominal DC output voltage of the charger
Modules| Actual number of power modules installed in the charger cabinet.
DC Amps| DC current that this charger will deliver to a discharged battery with the number of power modules installed and based on the Nominal Voltage

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

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

Charge profile codes

diagnoses the battery status throughout the recharge phase and adjusts its parameters to optimize the charge of 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. Can manually set battery capacity if required. Weekly Equal is needed.
P02| GEL| IUI profile. Max 0.17 to 0.22 C5. Auto battery capacity with Ph1 loops. Can manually set battery capacity if required. Weekly Equal is needed.
P06| AGM| IUI profile. Max 0.20 C5. Auto battery capacity with Ph1 loops. Finish time limitation. Can manually set battery capacity if required. Weekly Equal is 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 Equal is needed.
P04| AIRMIX| Pneumatic / Airmix profile. Must have Air kit fitted to use this profile. IUI profile Max 0.13 to 0.25 C5. Auto battery capacity with Ph1 loops. Can manually set battery capacity if required. Weekly Equal is needed.
P25| LOWCHG| Low rate charge profile. IUI profile 0.09 to 0.13 C5. Manually set battery capacity if required. Weekly Equal is needed.
P31| NXBLOC ()| For NexSys® core Bloc battery under normal charge. Charge rate 0.192 to 0.70 C5. Must set Battery Capacity, Temperature & Equalize values (NexSys® BLOC battery).Weekly Equal is needed.
P29| NXSTND (*)| For NexSys® core 2V battery under normal charge. Charge rate 0.192 to 0.25 C5. Must set Battery Capacity, Temperature & Equalize values
(NexSys® 2V battery). Weekly Equal is needed.

Opportunity 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 charge profile allows the battery to be safely charged while it
is kept in a partial state of charge between 20% and 80% of C5 throughout the work week. Sufficient time should be scheduled after the weekly equalize charge to allow battery cooling and to perform periodical electrolyte level checks.
Daily Charge : This option can be set to add additional daily charging time, if the work schedule allows. It should be considered only when the daily work demand requires additional capacity.

Equalization charging

1. Equalization charging for traditional flooded lead acid batteries, per-formed after normal charging, balances the electrolyte densities in the battery’s cells.
   NOTE: The factory default is Daily Charge DISABLE, 6-8 hours Equal-ize, Sunday at 00 hour for flooded, 2-hour week / maintenance charge for Nex-Sys® battery charge profiles.

Block out time

1. This function inhibits the charger from charging the battery during the block out time window. If a charge cycle has started before the block out window it is inhibited during the block out window and will automatically restart the charge cycle at the end of the block out window.

Refresh charging

1. Refresh or maintenance charging enables the charger to maintain the battery at maximum state of charge as long as it is attached to the charger.

Charger option list

Product Usage Instructions

To use the Battery Charger, follow these steps:

1. Ensure that the charger is connected to a power source with the correct voltage and frequency.
2. Identify the battery’s capacity and select the appropriate charge profile from the available options.
3. If required, manually set the battery capacity using the charger’s controls.
4. If necessary, connect any additional accessories or kits required for specific charging profiles.
5. Start the charging process by pressing the appropriate buttonsor following the instructions provided on the charger’s interface.
6. Monitor the charging progress and ensure that the battery is being charged within the recommended parameters.
7. If applicable, perform regular maintenance tasks such as weekly equalization as specified in the charger profile.

For more detailed instructions on using the Battery Charger, refer to the complete user manual available at www.enersys.com.

Features

1. Microprocessor-controlled
2. Able to auto identify battery’s capacity
3. Able to adapt to State of Charge (SoC)
4. Compatible with battery voltages of:
   1ph| 3ph
   ---|---
   12V|
   24V| 24/36/48V
   36/48V| 72/80V
   | 96V
   | 120V
5. Unique profile for charging Thin Plate Pure Lead (TPPL)
6. Unique profiles for NexSys® battery charge applications: NXBLOC; NXSTND.
7. Fully programmable to unique fleet requirements.
8. Battery chemistry agnostic – TPPL, Flooded and Gel Lead Acid.

Safety Precautions

1. Warning: The shipping pallet must be removed for proper and safe operations.
2. This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, cautions and warnings on the battery charger, the battery and the product using the battery.
3. Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger.
4. Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock. Never open the equipment: High voltage could be still present even turning off the charger. Any adjustment, maintenance or repairs to the equipment while it is open must only be carried out by an appropriately skilled person who is aware of the risks involved.
5. During charge, lead acid batteries produce hydrogen gas which can explode if ignited. Never smoke, use an open flame or create sparks in the vicinity of the battery. Take all necessary precautions when the equipment will be used in areas where there is the possible risk of an accident occurring. Ensure appropriate ventilation according to standard EN 62485-3 to allow any gases released to escape. Never disconnect the battery while it is being charged.
6. Unless charger is equipment with LMEB (Late Make Early Break) feature Do not connect or disconnect the battery plug while the charger is on. Doing so will cause arcing and burning of the connector resulting in charger damage or battery explosion.
7. Lead acid batteries contain sulfuric acid which causes burns. Do not get in eyes, on skin or on clothing. In cases of contact with eyes, flush immediately with clean water at least for 15 minutes. Seek medical attention immediately.
8. Only factory-qualified personnel should install, set up and service this equipment. De-energize all AC and DC power connections before servicing the charger.
9. Must be used in conformance with its indicated level of protection and never come into contact with water.
10. Must not be installed on surfaces subject to vibration (near to compressors, engines, motors).
11. Must be installed so that the gases from the battery being charged, do not get sucked into the charger by its fans.
12. The charger is not for outdoor use, only indoor use.
13. Do not expose the charger to moisture. Operating conditions should be  (0ºC) to 113ºF (45ºC); 0 to 70% relative humidity.
14. Do not operate the charger if it has been dropped, received a sharp impact, or otherwise damaged in any way.
15. For continued protection and to reduce the risk of fire, install chargers on a non-combustible surface.
16. For NexSys® iON batteries, use only EnerSys® battery packs that include the battery management system and all necessary protection for the battery pack integral to the pack.
17. The DC cables of the charger emit low power magnetic fields in their surroundings (<5cm). People with medical implant devices should avoid being near charger while charging.
18. Contact one of the company’s trained technicians if any problem is encountered when putting the charger into operation. It is only designed to recharge Industrial Motive Power lead acid and EnerSys® NexSys® batteries on industrial premises. When the equipment becomes obsolete, the casings and the other internal components can be disposed of by specialist companies. Local legislation takes precedence over any instructions in this document and must be scrupulously observed (WEEE 2002/96 EC).

Installation

Location

1. For safe operation, choose a location which is free of excess  moisture, dust, combustible material, and corrosive fumes. Also, avoid high temperature (above 113ºF (45ºC)) or potential liquid spill on the charger.
2. Do not obstruct the openings in the charger for air ventilation. 4.1.3. Follow charger warning label when mounting on or over a combustible surface.
3. It is recommended to mount the charger at least 72 cm radial distance away from the closest top edge of the battery.

Cabinet mounting

1. The charger must be mounted on a wall, stand, shelf or floor in a vertical position. The minimum distance between two chargers  must be 31 cm. If wall mounted, make sure that the surface is free of vibrations and the charger is mounted in a vertical position; if floor mounted, make sure that the surfaces are free of vibration, water, humidity. You must avoid areas where the chargers may be splashed with water.
2. The charger must be held by 2 or 4 fixings suitable for the type of support. The drilling pattern varies according to the model of charger (please refer to the technical data sheet).

Electrical connections

1. To prevent failure of the charger, make sure it is connected to the correct line voltage. Follow your local and local country standards and laws in making these connections.
2. WARNING: Make sure the power source is OFF and the battery is  disconnected before connecting the input power to the terminals of the charger.
3. To the mains supply: You may only connect to the 1-phase 230Vac  or 3-phase 400Vac mains supply (depending on the type of the charger) by means of a standard socket and an appropriate circuit breaker (not supplied). The current consumption is shown on the charger’s information plate.
4. Connection to battery: The charger must be connected to the battery by the cables supplied:
5. The RED cable: to the battery’s POSITIVE terminal.
6. The BLACK cable: to the battery’s NEGATIVE terminal.

AC circuit protection

1. The user must provide suitable branch circuit protection and a disconnect method from the AC power supply to the charger to allow for safe servicing
2. CAUTION: Risk of Fire/Electrick shock. Use only on circuits  provided with branch circuit protection in accordance with laws and standards.
3. The prevailing safety regulations must be observed. The system protection installed on the power supply to the charger must conform to the charger’s electrical characteristics. The installation of a suitable circuit breaker is recommended. It is imperative to ensure that when fuses are being replaced only fuses of the specified type and of the correct are used.
4. This equipment conforms to Class 1 safety standards, which means that the appliance must be earthed and requires to be powered from an earthed supply.

Grounding the charger

1. Grounding the charger
2. Connect ground wire to the proper terminal  usually marked with either of the two symbols to the right.
3. DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO  FATAL ELECTRIC SHOCK. Follow National Electric Code for ground wire sizing.

DC connector polarity

1. DC plug polarity
2. The charging cables are connected to the DC output of the charger:
   the red charging cable (POS) is connected to the positive busbar of the charger, and the black charging cable (NEG) is connected to the negative busbar of the charger. The output polarity of the charger must be observed when connecting to the battery. Improper connection will open the DC fuses in the power modules.

EU Declaration

EnerSys® hereby declares that the chargers in the IMPAQ™charger ranges are in conformity with the following UK and European regulations:

• 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 of the charger emit low power magnetic fields in their surroundings (<5cm). Even if emissions are below the standard limits, people bearing medical implants should avoid operating close to the charger during recharge.

Operating Instructions

Control panel features

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 detected 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

Menu access

When the charger is idle, press and hold , the Main Menu is then displayed. The main menu is automatically exited after 60 seconds of inactivity or can be exited voluntarily by pressing the button.
Main Menu
All menus are accessed from Main Menu; a detailed description of each menu is included in the next sections of this manual. The menus that require a password are not displayed until the correct password has been entered.
The menus provide access to the following functions:

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

MEMORIZATIONS

1. Memorizations Display Screen
   The charger can display the details of the last 200 charge cycles.
   The display below shows one charge stored in memory. MEMO 1 is the latest charge memorized. After memorizing the two-hundredth charge, the oldest record is deleted and replaced by the next oldest.

2. Displaying a Charge Cycle
   Proceed as follows:

   • 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 the Main Menu by pressing Esc.
     The charge history is displayed; use the to scroll through the parameters.

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

4. STATUS
   This menu displays the status of the charger’s internal counters (number of normal and partial charges, faults by type, etc.).

   • Status Screen
     

5. USB
   This menu provides access to the USB function to update software.

   • Update Software
     Updates charger’s internal software. The software is provided by EnerSys®.

6. PARAMETERS

   • Date/Hour
     Sets date and time of the charger. The clock has a battery backup which will preserve the time when power to the charger is off.

   • Language
     Selects the language displayed in the menus.

   • Region
     Selects the format for date, metric (EU) or imperial (US) units for temperature, length and cable gauge.

   • Display
     Set screen saver function.
     Contrast
     Modifies the display contrast level (20 to 29).

   • Screen Saver
     Enable or Disable the screen saver function.

   • Delay
     Set the time the screen stays illuminated. The delay time is adjustable in minutes up to one hour and 59 minutes.

   • Daylight Savings
     Enables or disables automatic clock adjustment for daylight savings time. When enabled, time will move ahead one hour at 02:00 on the second Sunday in March and will move back one hour at 02:00 on the first Sunday of November. The charger must be powered up at the time of the change for it to take effect.

7. PASSWORD
   This is where the password is entered to gain access to service level menus by authorized EnerSys® service personnel.

8. CHARGING THE BATTERY
   At this point, the charger should have been set up by a qualified service person. Charging can only begin when a battery of the proper type, capacity and voltage is connected to the charger.
   With the charger in wait mode (no battery connected) and without pressing the Stop/Start button, the display will show the following information:

   • Charger Idle Display**
     Ref.| Description
     ---|---
     1| Charge DC voltage/Charge current
     2| Firmware version
     3| Selected charge profile
     4| System time
     5| System date
     6**| Connect battery

   • Starting a Charge Cycle
     The charger will start automatically when a battery is connected or if the Stop/Start button is pushed if the battery is already connected.

   • Delayed Start
     If the charger was programmed for delayed start, charging will begin following that delay. When the battery is plugged in to the charger, the display shows the time remaining before the programmed charging starts.

   • Effective Charge
     A few moments into the effective charge, the display will begin alternating between the following charging information: 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

   • End of Charge without Equalization
     The green complete LED comes on after proper end of charge. The green complete LED is on and the display shows AVAIL.
     The display alternates between:

   • Total charging time

   • Amp/hrs restored to the battery

   • Any other lit LED indicates a problem during charging. Please refer to paragraph Control Panel for more information.
     If the battery remains plugged in and refresh charge has been enabled, refreshes will occur to maintain an optimal charge.
     The battery is now ready for use. Push the ON/OFF button before unplugging the battery.

   • End of Charge with Equalization
     An Equalize charge can be started manually or automatically.

   • Manual Equalization Start

   • At the end of charge (green LED on or flashing), press on the button. The equalize button can also be pressed any time during the charge and an equalize charge will be started after charging is complete.
     NOTE: When an Equalize is manually started, the output current will be set to the value saved in the charger configuration.

   • The start of the equalization charge is indicated by the message EQUAL. During the equalization charge, the charger displays the output current and alternates: the battery voltage, voltage per cell and remaining time.

   • Manual Equalization Start

   • The battery will be available when the green LED comes back on and the display shows AVAIL

   • The battery is now ready for use. If the battery remains plugged in and refresh charge has been enabled, refreshes will occur to maintain an optimal charge. Push the ON/OFF button before unplugging the battery.

   • Automatic Equalization Start
     If an equalization day has been programmed in Charger configurations the equalization charge will start automatically on the programmed day of the week after charging is complete.
     NOTE: The factory default IEI Equalize, 6 hour Equalize, Sunday at 00 hour.
     The battery will be available when the green LED comes back on and the display shows AVAIL. The battery is now ready for use. If the battery remains plugged in and refresh charge has been enabled, refreshes will occur to maintain an optimal charge. Push the ON/OFF button before unplugging the battery.

6. Fault codes

In case of a fault, one of the corresponding fault codes listed below will appear on the display. If it is a critical fault, charging will stop and the red Fault LED will be illuminated.
Fault Display

Service and Troubleshooting

7.1. Fault Display

connection of the battery (reversed polarity cables) and the 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| Battery or charger setting inspection (Ah security, charge timeout, negative voltage Dv/Dt)| DF5 appears when the charging profile has been achieved with a fault condition, that can be a current increase in regulation phase demonstrating a battery heating or a badly programmed regulation voltage, or the charging time is too long and has exceeded the safety limit. Check charging para meters: profile, temperature, capacity, cables. Check the battery (defective cells, high temperature, water level).
DF7| Air pressure pump fault. Current Di-Dt, thermal run away.| Call for Service
TH| Charger Thermal fault, all modules are on thermal fault (check air flow, and ambient temperature).| Verify the proper operation of the fans and/or absence of too high ambient temperature, or there is poor natural ventilation to the charger.
Error| Cause| Solution
---|---|---
TH- Amb| Ambient temperature too high| Move the charger in a place with lower ambient temperature. Follow instrucitons on installation and safety
DFMOD| Module faulty (refer to Module Menu to know the fault type)| Call for Service
MOD DEF| Module is unplugged or not answer| Clean the module or the backplane connection. If not working Call for Service
MOD DFC| Module Converter faulty, the module can’t output the maximum current (check the AC phases, and AC fuse)| Check power supply.
MOD TH| Module thermal fault (check the air flow, ambient, refer to Module Status Description to check the internal temperature sensor)| Check that the fan(s) is (are) working correctly and/or that the ambient temperature is not too high or whether there is poor natural ventilation to the charger. If all modules are in thermal fault, a TH fault will follow.
MOD FUS| Module output fuse damaged| Call for Service
MOD Err| Module internal error| Call for Service (check the Module status description)
MOD VBAT| Battery voltage is corrupted vs Fuse voltage and VLMFB vs Modules| Call for Service (check the voltage reading on the Module Status Description)
TH- LOCK| Module is locked because of repetive thermal events| Check the Exx,CDV file to make action before to reset the locking or Call for Service
POWER MODULE OFF| No CANBUS communication between display and module| Check ribbon cable, AC mains, Module plugged, idle = off or Call for Service
DF- VREG| Modules don’t follow the regulation voltage setting| Call for Service (replace the faulty module)
DF- ID| Menu setting does no match the module type (ie: 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

Maintenance and service

1. WARNING: THERE ARE DANGEROUS VOLTAGES WITHIN THE  BATTERY CHARGER CABINET. ONLY A QUALIFIED PERSON SHOULD  ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER.
2. The charger requires minimal maintenance. Connections and  terminals should be kept clean and tight. The unit (especially the heatsink) should be periodically cleaned with a low pressure air to prevent any excessive dirt build up on components. Care should be taken not to bump or move any adjustments during cleaning. Make sure that both the AC 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.
3. Any data, descriptions or specifications set forth herein are subject to change without notice. Before using the product(s), the user is advised and cautioned to make its own determination and assessment of the suitability of the product(s) for the specific use in question and is further advised against relying on the information contained herein as it may relate to any general use or indistinct application. It is the ultimate responsibility of the user to ensure that the product is suited, and the information is applicable to the user’s specific application. The product(s) featured herein will be used under conditions beyond the manufacturer’s control and therefore all warranties, either express or implied, concerning the fitness or suitability of such product(s) for any particular use or in any specific application, are disclaimed. The user expressly assumes all risk and liability, whether based in contract, tort or otherwise, in connection with the use of the information contained herein or the product itself.

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© 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

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