EnerSys NXSTND NexSys+ Charger User Manual
- May 15, 2024
- EnerSys
Table of Contents
Instructions for Use CHARGING
SOLUTIONS
Features
1.1. Microprocessor-controlled
1.2. Able to auto identify battery’s capacity
1.3. Able to adapt to State of Charge (SoC)
1.4. Compatible with battery voltages of:
| 1ph | 3ph |
|---|---|
| 12V | |
| 24V | 24/36/48V |
| 36/48V | 72/80V |
| 96V | |
| 120V |
1.5. Wireless integration with EnerSys® Wi-iQ® battery monitoring devices
1.6. Individual battery pack recognition and automatic pairing with the
charger
1 7. Unique profile for charging Thin Plate Pure Lead (TPPL)
1.8. Unique profiles for NexSys® battery charge applications: NXBLOC; NXSTND;
NXSFAST; NXP2V; NXPBLC.
1.9. Remote access via E Connect™ mobile app to change settings, monitor
charger and share data.
1.10. Controller Area Network (CAN) communication capable.
1.11. Fully programmable to unique fleet requirements.
1.12. Battery chemistry agnostic – EnerSys® Lithium-ion (Li-ion), TPPL,
Flooded and Gel Lead Acid batteries.
Technical Information
2.1. Name plate labels
****EnerSys Sp.z 0.0
ul.Leszczynska 73
43-300 Bielsko-Biala, Polandhttp://www.enersys-
hawker.com/english/index_ad.asp?lang=e
TC3 1Q
3 Modules
24V/26V/48V
210A/195A/180A
Pmax=11150W
360VAC-440VAC 50/60Hz
2.1.1. Name plate label definitions
| Item | Description |
|---|---|
| Serial Number | Provides date code. |
| Hertz | Input voltage frequency. Under no conditions operate the charger |
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
2.1.2. Output power letter codes
Output Power (kW)| Number Modules| Module Power
(kW)
---|---|---
1.0| 1| 1.0
2.0| 2| 1.0
3.0| 3| 1.0
3.5| 1| 3.5
7.0| 2| 3.5
10.5| 3| 3.5
14.0| 4| 3.5
17.5| 5| 3.5
21.0| 6| 3.5
24.5| 7| 3.5
28.0| 8| 3.5
2.1.3. Cabinet size (number of modules available) and DC cable size
Phases| Module Positions| Standard Cable Gauge|
Comments
---|---|---|---
1ph| Max 1| 6 mm2| Stand alone cabinet
1ph| Max 3| 25 mm2| Three slot, 3 kW cabinet
3ph| Max 2| 35 mm2| Two slot, 7 kW cabinet
3ph| Max 4| 70 mm2| Four slot, 3.5 to 14 kW cabinet
3ph| Max 6| 95 mm2| Six slot, max 21 kW cabinet
3ph| Max 8| 70 mm2 or 1 x 95 mm2| Eight slot, max 28 kW cabinet. Dual
cable for 24/36/48Vdc single cable for 72/80Vdc
2.1.4. Charge profile codes
| Profile Code | Charger Profile | Description |
|---|---|---|
| P19 | FAST | Fast profile for flooded battery equipped with airmix. |
Charger rate up to 0.4 C5. Must set Battery Capacity, Temperature & Equalize
values and fit properly programmed Wi-iQ® battery monitoring device (FAST EU).
If not installed or no Comm, charger will use STDWL profile. Weekly Equal of
8h is needed. Recommended parameters to set on the charger.
P22| HDUTY| Heavy Duty wet cell Pulse Profile. The charge profile
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. If
programmed Wi-iQ® battery monitoring device fitted, gives capacity, temp and
voltage, however for safety if no communication, should manually set Battery
Capacity, Temp and Voltage. 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.
P09| WL20| Hawker Waterless 20 product, IUI profile (old
WF200). Requires Airmix and Wi-iQ® battery monitoring device comm. 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 or fit properly programmed Wi-iQ® battery monitoring device
(NexSys® BLOC battery). If not installed or no Comm, charger will use manual
setup Ah and temp. 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 or fit properly programmed Wi-iQ® battery monitoring device (NexSys® 2V
battery). If not installed or no Comm, charger will use manual setup Ah and
temp. Weekly Equal is needed.
P30| NXFAST ()| For NexSys® Core 2V battery under fast, higher rate.
Charge rate 0.251 – 0.40 C5. Properly FAST programmed Wi-iQ® battery
monitoring device (NexSys® 2V battery). If not installed or no Comm, charger
will use manual setup Ah and temp. Weekly Equal is needed.
P32| NXP2V ()| For NexSys® PURE 2V battery under fast, higher rate.
Charge rate 0.251 – 0.40C5. Properly programmed Wi-iQ® battery monitoring
device (NexSys® Pure 2V battery). If not installed or no Comm, charger will
use manual setup Ah and temp. Weekly Equal is needed.
P33| NXPBLC ()| For NexSys® PURE Bloc battery under normal charge.
charge rate 0.251 to 0.70 C5. Properly programmed Wi-iQ® battery monitoring
device (NexSys® Pure Bloc battery). If not installed or no Comm, charger will
use manual setup Ah and temp. Weekly Equal is needed.
–| NXSION ()| For Lithium Enersys® Battery only. The charger is
communicating with the Enersys® Lithium BMS through the CANBUS, the BMS is
driving the charger and then the setting of the charger is not compulsory.
Nevertheless, there is recommended parameters to set on the charger.
*2.2. () Opportunity profile options
2.2.1. Operation: In Opportunity charging mode, the user can charge the
battery during breaks, lunch, or any available time during the work schedule.
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.
2.2.2. 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.
2.3. Equalization charging
2.3.1. Equalization charging for traditional flooded lead acid batteries,
performed after normal charging, balances the electrolyte densities in the
battery’s cells.
2.3.2. NOTE: The factory default is Daily Charge DISABLE, 6-8 hours Equalize,
Sunday at 00 hour for flooded, 2-hour week / maintenance charge for NexSys®
charge profiles.
2.4. Block out time
2.4.1. 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.
2.5. Refresh charging
2.5.1. 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.
2.6. Charger option list**
| Suffix | Description |
|---|---|
| PLC | Programmable Logic Controller |
| LMEB | Late Make Early Break |
| CAN | Controller Area Network |
| Ethernet | Network Connection |
| Airmix | Electrolyte Circulation System |
Safety Precautions
3.1. Warning: The shipping pallet must be removed for proper and safe
operations.
3.2. 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.
3.3. Read and understand all setup and operating instructions before using the
battery charger to prevent damage to the battery and to the charger.
3.4. 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.
3.5. 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.
3.6. 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.
3.7. 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.
3.8. Only factory-qualified personnel should install, set up and service this
equipment. De-energize all AC and DC power connections before servicing the
charger.
3.9. Must be used in conformance with its indicated level of protection and
never come into contact with water.
3.10. Must not be installed on surfaces subject to vibration (near to
compressors, engines, motors).
3.11. Must be installed so that the gases from the battery being charged, do
not get sucked into the charger by its fans.
3.12. The charger is not for outdoor use, only indoor use.
3.13. Do not expose the charger to moisture. Operating conditions should be
32ºF (0ºC) to 113ºF (45ºC); 0 to 70% relative humidity.
3.14. Do not operate the charger if it has been dropped, received a sharp
impact, or otherwise damaged in any way.
3.15. For continued protection and to reduce the risk of fire, install
chargers on a non-combustible surface.
3.16. 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.
3.17. 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.
3.18. 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
4.1. Location
4.1.1. 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.
4.1.2. 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.
4.1.4. It is recommended to mount the charger at least 72 cm radial distance
away from the closest top edge of the battery.
4.2. Cabinet mounting
4.2.1. The charger must be mounted on a wall, stand, shelf or floor in a
vertical position. The minimum distance between two chargers must be 8 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.
4.2.2. 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).
4.3. Electrical connections
4.3.1. 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.
4.3.2. WARNING: Make sure the power source is OFF and the battery is
disconnected before connecting the input power to the terminals of the
charger.
4.3.3. 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 in the charger’s information plate.
4.3.4. 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.
4.3.5. Connection to battery: The charger must be connected to the battery by
the cables supplied:
– The RED cable: to the battery’s POSITIVE terminal.
– The BLACK cable: to the battery’s NEGATIVE terminal.
4.4. AC circuit protection
4.4.1. 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
4.4.2. CAUTION: Risk of Fire/Electrick shock. Use only on circuits provided
with branch circuit protection in accordance with lows and standards.
4.4.3. 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.
4.4.4. 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.
4.5. Grounding the charger
4.5.1. Grounding the charger
4.5.2. Connect ground wire to the proper terminal usually marked with either
of the two symbols to the right.
4.5.3. DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC
SHOCK. Follow National Electric Code for ground wire sizing.
4.6. DC connector polarity
4.6.1. DC plug polarity
4.6.2. 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.
4.7. EU Declaration
EnerSys® hereby declares that the chargers in the NexSys + range 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 -
Radio Equipments Regulations 2017 (S.I. 2017/1206)
-
Directive 2014/53/EU®
ETSI EN 301 489-1 V2.1.1 (2017-02)
ETSI EN 301 489-17 V3.1.1 (2017-02)
ETSI EN 300 328 V2.2. 2 (2019-07)
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
5.1. Control panel features
| Reference | Function | Description |
|---|---|---|
| 1 | Graphical display | Display charger operation info/menus |
| 2 | Navigate UP button | Navigate menus / Change values |
| 3 | ENTER/STOP and START button | Select menu items / Enter values / Stop |
and restart battery charge
4| Navigate RIGHT/ EQUALIZE button| Scroll right / Start equalize or
desulfation
5| Navigate DOWN button| Navigate menus / Change values
---|---|---
6| Navigate LEFT/ ESC button| Enter main menu / Scroll left / Exit menus
7| RED fault indicator| OFF = no fault
FLASHING = ongoing fault 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
5.2. Charge operation
5.2.1. Charger idle display: With the charger in wait mode (no battery
connected) and without pressing the Stop/Start button, the display will show
the following information:
| Reference | Description |
|---|---|
| 1 | Charger DC Voltage |
| 2 | Firmware Version |
| 3 | Selected Charge Profile |
| 4 | System Time and Date |
| 5 | Connect Battery |
5.2.2. Connect battery: Make sure the charger connector(s) matches the battery
connector(s). Plug the charger connector(s) to the battery connector(s). For
chargers with dual connectors, both connectors must be connected in order to
start a charge.
5.2.3. NexSys
iON Li-ion batteries come with specific type of connector.
The NexSys® + charger comes with one or two connectors (LI Connector)
depending on the charger model. When the charger is equipped with two
connectors, both connectors must be connected, otherwise charge cycle will not
start. Always connect connector 1 first. All NexSys® iON charger connectors
are equipped with arcless option called Late Make Early Break to prevent
arcing if battery is disconnected while charging.
5.2.4. When CAN communication is established between the NexSysiON battery and
charger, “BMS CONNECTED” will appear on the display screen. If the text “BMS
CONNECTED” is NOT shown, the charge cycle will not start. Check CAN wiring and
battery.
5.3. Connectors for NexSys® iON Batteries®
Start charging
When a battery is connected to the charger, the control board senses the
voltage and after a short delay, the charger starts charging the battery
automatically if auto start is set to ON. Push the Stop/Start button if the
battery is already connected. When charging a NexSys® iON battery, the CAN
communication between the battery and charger is established and the message
“BMS CONNECTED” will be displayed on the screen.
After few seconds, the battery will close the charge contactor to initiate the
charge. The charger will start the countdown process and will start displaying
the charge information.
5.4.1. 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.
5.4.2. Without a Wi-iQ® battery monitoring device: If the Wi-iQ® battery
monitoring device adapter is not enabled or no Wi-iQ® battery monitoring
devices are in range, effective charging starts after the programmed delay.
The charger uses Profile, Capacity and Temperature settings programmed in the
Configuration menu.
5.4.3. PAIRING with a Wi-iQ® battery monitoring device adapters are in range,
the charger will turn on and apply current to the battery. The display will
show “SCAN” followed by “IQLINK”. This routine determines which Wi-iQ® battery
monitoring device in range is connected to the battery charger. Once the
charger makes the determination, it downloads data from Wi-iQ® battery
monitoring device, displays the battery S/N, updates the profile capacity, and
temperature for charging, and starts the main charge.
| Reference | Description |
|---|---|
| 1 | Charge voltage (total V and V/c), alternates with Ah returned |
| 2 | Charge current |
| 3 | Battery S/N from Wi-iQ® battery monitoring device Li-ion only: Max |
current and voltage requested by BMS
4| Battery temperature, alternates with battery capacity
5| Charge time
6| Percent of charge
7| USB connection
8| Wi-iQ® battery monitoring device link
9| Wi-iQ® battery monitoring device warnings
5.4.4. Charging current (2) is determined by the battery voltage and state of
the charge condition. Charging current declines automatically as battery
voltage rises during the charge. As the battery charges, the graphical display
will output various charge parameters including the percentage of battery
capacity (6).
When charging a NexSys® iON battery, the battery BMS controls the charge
current and voltage. During the charge cycle, the BMS through the CAN will
send information to the charger to start, stop and output the desired current
and voltage. If the CAN is lost during charge cycle, the charger will stop the
charge and show the offcharge display without the message “BMS CONNECTED”.
5.4. Stop charging
5.5.1. The charging can be paused and restarted where it left off at any time.
Just hit the center power button (marked as number 3 in control panel section)
Remote is available for controlling at a distance.
5.5. Charge complete
5.6.1. End of charge display 5.6.2. End of charge without equalization
5.6.2.1. The green complete LED comes on after proper end of charge. The green
complete LED is on and the display shows CHARGE COMPLETE. The display
alternates between:
- Total charging time
- Amp-Hours restored to the battery
5.6.2.2. Any other lit LED indicates a problem during charging.
Please refer to paragraph Control Panel for more information.
5.6.2.3. If the battery remains plugged in and refresh charge has been
enabled, refreshes will occur to maintain an optimal charge.
5.6.2.4. The battery is now ready for use. Push the ON/OFF button before
unplugging the battery.
5.6.3. End of charge with equalization
5.6.3.1. An Equalize charge can be started manually or automatically.
5.6.4. Manual equalization start
5.6.4.1. At the end of charge (green LED on or flashing), press on the
Menu and Display Information
6.1. Main menu display
6.1.1. When the charger is idle, press and hold
6.1.3. The menus provide access to the following functions:
- View status and memorizations (LOGS icon)
- Viewing of faults, alarms, etc. (CHARGER icon)
- USB functions (USB icon)
- Setting of date, language and others (SETTINGS icon)
- Management of password (For service technicians only)
- Exit main menu (EXIT icon)
6.2. Logs
6.2.1. Memory display screen
6.2.1.1. The charger can display the details of the last 300 charge cycles.
6.2.1.2. The display here shows 3 charges have been stored in memory. MEMO 1
is the latest charge memorized. After memorizing the three-hundredth charge,
the oldest record is deleted and replaced by the next oldest. 6.2.2. Display
a charge cycle
6.2.2.1. 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.
6.2.2.2. The charge history is displayed; use the ▲/▼ to scroll through the parameters.
6.2.3. Memorization Data
| Memo | Description | Memo | Description |
|---|---|---|---|
| S/N | Wi-iQ® battery monitoring device serial number | I end |
Current at end of charge
Capacity| Rated battery capacity (Ah)| Temp end| Battery
temperature at end of charge (F)
U batt| Rated battery voltage (V)| Chg Time| Time of the charge
cycle (minutes)
Temp| Battery temperature at start of charge (F)| Ah| Amp-hours
returned during charge cycle
Techno| Battery technology| kWh| Kilowatt-hours returned during
charge cycle
Profile| Selected profile| Status| Partial or Complete
% init| State of charge at start of charge (%)| Default| Fault
codes
U start| Battery voltage at start of charge (Vpc)| SoC| Start of
charge date and time
U end| Battery voltage at end of charge (Vpc)| DBa| Battery
disconnect date and time
Warning| Wi-iQ® battery monitoring device warnings| CFC|
Termination code (for service tech)
6.2.4. Status
6.2.4.1. This menu displays the status of the charger’s internal counters
(number of normal and partial charges, fault code, etc.).
6.2.4.2. Status screen
| Status | Description |
|---|---|
| Charge | Total number of charges – corresponds to the total of normally |
terminated charges and charges terminated with or by faults
Complete| Number of charges normally terminated
Partial| Number of charges terminated abnormally
TH| Number of charger temperature faults
DF1 etc.| Number of faults recorded by the charger (see Fault Codes)
6.3. Setting parameters
| Parameter | Description |
|---|---|
| Date/Time | 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 in both metric and AWG.
Display| Set screen saver function and display Themes.
Screen Saver| Enables or Disables the screen saver function.
Delay Savings| Set the time the screen stays illuminated. The delay time
is adjustable in minutes up to one hour and 59 minutes.
Themes| Themes A and B are two different ways that information is
displayed throughout the charge cycle as seen in table below. Theme A is
selected by default and will be used in this manual.
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.
6.4. USB
6.4.1. This menu provides access to the USB function to update software.
6.4.2. Software Updates are provided by EnerSys®.
6.5. Password
6.5.1. This is where the password is entered to gain access to service level
menus by authorized EnerSys® service personnel.
Service and Troubleshooting
7. 1 . Fault Display
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.
7.2. Fault Codes
| Error | Cause | Solution |
|---|---|---|
| DF-CUR | Current fault before DF1 (can be low mains, phase missing or | |
| faulty module) | Call for Service | |
| DF1 | Critical current fault, all modules are on DF1 fault (check the | |
| mains and phase missing) | Call for Service | |
| DF2 | Output fuse fault, battery reverse polarity | Check the correct |
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.
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.
7.2. Fault Codes (cont.)
| Error | Cause | Solution |
|---|---|---|
| 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)
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)
BAT TEMP| Wi-iQ® battery monitoring device battery temperature too
high| Battery needs to cool down
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 MOD- ULE OFF| No CANBUS communication between display and module|
Check ribbon cable, AC mains, Module plugged, idle = off or Call for Service
DF-TECHNO| Wi-iQ® battery monitoring device setting does not match the
charger type| Check Charger and Wi-iQ® battery monitoring device Settings
(example Wi-iQ® battery monitoring device set for NexSys® Fast battery with
IMPAQ)
DF- VREG| Modules do not follow the regulation voltage setting| Call
for Service (replace the faulty module)
DF-ID| Menu setting does not match the module type (ie: Cell setting =
12V, Module type 40 cells)| Use correct module.
| Default of balance voltage detected by the Wi-iQ ® battery monitoring
device| Check each battery cell during discharge.
Control if the Wi-iQ ® battery monitoring device is properly
adjusted (see Wi-iQ ® battery monitoring device
instructions of mounting).
CANBUSERROR| CAN bus error| Call for Service
DEFEEP| Memory access denied| Call for Service
DEFRTC| clock access denied| Call For Service
7.3. Maintenance and service
7.3.1. WARNING: THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER
CABINET. ONLY A QUALIFIED PERSON SHOULD ATTEMPT TO ADJUST OR SERVICE THIS
BATTERY CHARGER.
7.3.2. 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.
7.3.3. 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.