EnerSys 0624 Plus Outdoor Charger Owner’s Manual

EnerSys 0624 Plus Outdoor Charger

Product Information

Specifications

• Input Voltage: 1ph 12V 24V 36/48V, 3ph 24/36/48V 72/80V 96V 120V
• Phase: Single Phase (1ph) or Three Phase (3ph)
• Output Power: 3.5kW – 21kW
• Module Power: 3.5kW per module
• Module Positions: Up to 6 modules
• Cabinet Size: Max 6 modules, Standard Cable Gauge 95 mm2

Product Usage Instructions

Safety Precautions

Before using the charger, carefully read and follow all safety precautions mentioned in the manual to prevent any injuries or accidents.

Installation

• Ensure the input voltage matches the charger specifications.
• Connect the charger to a stable power source following the provided guidelines.

Operating Instructions

After installation, power on the charger and select the appropriate charging profile based on your battery type. Monitor the display for any alerts or notifications during the charging process.

Maintenance and Service

• Regularly inspect the charger for any signs of wear or damage.
• Follow the maintenance schedule outlined in the manual for optimal performance.

Frequently Asked Questions

Q: What should I do if the charger displays a fault code?

A: If a fault code appears on the display, refer to the troubleshooting section in the manual to identify and resolve the issue. If needed, contact customer service for further assistance.

Q: Can I manually set the battery capacity for charging?

A: Yes, certain charging profiles allow manual adjustment of battery capacity if required. Refer to the specific profile codes and instructions for details on setting battery capacity.

INTRODUCTION

• The information contained in this document is critical for safe handling and proper use of the NexSys®+ Outdoor charger(s).
• It contains a global system specification as well as related safety measures, codes of behavior, a guideline for commissioning, and recommended maintenance.
• This document must be retained and available for users working with and responsible for the battery charger.
• All users are responsible for ensuring that all applications of the system are appropriate and safe, based on conditions anticipated or encountered during operation.
• This owner’s manual contains important safety instructions. Read and understand all instructions before installing, handling or operating the battery charger.
• Failure to follow these instructions may result in serious injury, death, destruction of property, damage to the battery charger, and/or void the warranty.
• This owner’s manual is not intended as a substitute for any training on handling and operating material handling equipment, battery or NexSys®+ Outdoor charger that may be required by local laws, entities and/or industry standards.
• Proper instruction and training of all users must be ensured prior to handling of the battery charger system.
• For service, contact your sales representative or visit: https://www.enersys.com/en/sales-services/

Your Safety and the Safety of Others is Very Important

• WARNING You may be seriously injured if you don’t follow these and other related instructions.

FEATURES & INFORMATION

Features

• Microprocessor-controlled.
• Able to auto-identify battery’s capacity.
• Able to adapt to State of Charge (SoC).
• Compatible with battery voltages of.

• Wireless integration with Wi-iQ® battery monitoring devices.
• Individual battery pack recognition and automatic pairing with the charger.
• Rugged 6-bay IP54/NEMA3R rated enclosure (outdoor cabinet).
• Modular design (up to 21kW).
• Multi-voltage 24/48, 72/96V DC.
• HF modular technology with efficiency up to 94%.
• Internal heater, fans and filter.
• Unique profile for charging Thin Plate Pure Lead (TPPL).
• Unique profiles for NexSys® battery charge applications: NXBLOC; NXSTND; NXSFAST; NXP2V; NXPBLC.
• Remote access via E Connect™ mobile app to change settings, monitor charger and share data.
• Controller Area Network (CAN) communication capable.
• Fully programmable to unique fleet requirements.
• Battery chemistry agnostic—Lithium-ion (Li-ion), TPPL, Flooded and Gel-Lead Acid batteries.
• External START/STOP and EQUALIZE buttons.
• External main switch.

Technical Information

Name Plate Label Definitions

at a different frequency or from a generator with unstable frequency.
Phase| TCX. “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.

Name Plate Label

Output Power Letter Codes

Cabinet Size (number of modules available) and DC Cable Size

Phases| Module Positions| Standard Cable Gauge| Comments
---|---|---|---
3ph| Max 6| 95 mm2| Six slot, max 21 kW cabinet.

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 equalization 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 equalization is needed.
 | P06| AGM| IUI profile. Max 0.20 C5. Auto battery capacity with Ph1 loops. Finish time limitation. Can manually set battery.
 | 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 equalization is needed.

 | P25| LOWCHG| Low rate charge profile. IUI profile 0.09 to 0.13 C5. Manually set battery capacity if required. Weekly equalization is needed.
 | P31| NXBLOC (*)| For NexSys® TPPL 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® TPPL bloc battery). If not installed or no comm, charger will use manual setup Ah and temp. Weekly equalization is needed.
 | P29| NXSTND (*)| For NexSys® TPPL* 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® TPPL 2V battery). If not installed or no comm, charger will use manual setup Ah and temp. Weekly equalization is needed.
()| Opportunity Profile Options|
| Please also use this profile for older NexSys® CORE batteries

• Opportunity Profile Options
• Please also use this profile for older NexSys® CORE batteries

Charge rate 0.251 to 0.40 C5. Properly FAST programmed Wi-iQ® battery monitoring device (NexSys® TPPL 2V battery). If not installed or no comm, charger will use manual setup Ah and temp. Weekly equalization is needed.
P32| NXP2V ()| For NexSys® PURE 2V battery under fast, higher rate. Charge rate 0.251 to 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 equalization 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 equalization is needed.
–| NXSION (*)| For NexSys® iON batteries only. The charger is communicating with the lithium-ion battery’s BMS through CANbus, the BMS is driving the charger and setting the charger is not compulsory. Nevertheless, there are recommended parameters to set on the charger.

• Opportunity Profile Options
• Please also use this profile for older NexSys® CORE batteries

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 equalization 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

• Equalization charging for traditional flooded lead-acid batteries, performed after normal charging, balances the electrolyte densities in the battery’s cells.
• NOTE: The factory default is daily charge disabled, 6-8 hours equalize, Sunday at 00 hour for flooded, 2-hour week/maintenance charge for NexSys® charge profiles.

Block Out Time

• 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

• 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.

Output Power Letter Codes

SAFETY

Safety Precautions

• WARNING The shipping pallet must be removed for proper and safe operations.

• 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.

• Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger.

• 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
  after 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.

• 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.

• 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. To avoid arcing, please push START/STOP button before disconnecting the battery.

• 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 for at least 15 minutes. Seek medical attention immediately.

• Only factory-qualified personnel should install, set up and service this equipment. De-energize all AC and DC power connections before servicing the charger.

• Must be used in conformance with its indicated level of protection and never come into contact with water.

• Must not be installed on surfaces subject to vibration (near compressors, engines, motors).

• Must be installed so that the gases from the battery being charged do not get sucked into the charger by its fans.

• Do not expose the charger to moisture. Operating conditions should be -4°F to 113°F (-20°C to +45°C); 0 to 70% relative humidity.

• Do not operate the charger if it has been dropped, received a sharp impact, or otherwise damaged in any way.

• For continued protection and to reduce the risk of fire, install chargers on a non-combustible surface.

• 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.

• The DC cables of the charger emit low power magnetic fields in their surroundings (<5cm). People with medical implant devices should avoid being near the charger while charging.

• 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

• For safe operation, choose a location which is free of excess dust, combustible material, and corrosive fumes. Also, avoid high temperatures (above 113°F [45°C]) or potential liquid spill on the charger.
• Do not obstruct the openings in the charger for air ventilation. This includes air inlets on the front and underside of the charger as well as the air outlet grid on the back of the charger.
• Follow charger warning label when mounting on or over a combustible surface.
• It is recommended to mount the charger at least 28 inches (72 cm) radial distance away from the closest top edge of the battery.

Cabinet Mounting

• The charger must be mounted on a wall, stand, shelf, or floor in a vertical position. The minimum distance between two chargers must be 4 inches (10 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, or humidity.
• 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

• To prevent failure of the charger, make sure it is connected to the correct line voltage. Follow your local and country standards and laws in making these connections.
• WARNING Make sure the power source is OFF and the battery is disconnected before connecting the input power to the terminals of the charger.
• To the mains supply: You may only connect to the 3-phase 400Vac mains supply by means of a standard socket and an appropriate circuit breaker (not supplied). The current consumption is shown on the charger’s information plate.
• 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.

AC Circuit Protection

• 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.
• CAUTION Risk of Fire/Electric Shock. Use only on circuits provided with branch circuit protection in accordance with laws and standards.
• 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 size are used.
• 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

• Connect ground wire to the proper terminal usually marked with either of the two symbols (below).
• DANGER FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC SHOCK. Follow National Electric Code for ground wire sizing.

DC Connector Polarity DC plug polarity

• 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.

INSTALLATION & OPERATION

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 Field Regulations (S.I. 2016/588)
• Directive 2013/35/EU: Electromagnetic fields BS EN IEC 62311: 2020 Radio Equipment 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 with medical implants should avoid being close to the charger during recharge.

Operating Instructions

battery not available

FLASHING = cooling phase ON = battery ready and available

3| Navigate LEFT/ESC button| Enter main menu/Scroll left/ Exit menus
4| Navigate UP button| Navigate menus/Change values
5| YELLOW charging indicator| OFF = charger off or battery not available

ON = charging in progress

6| USB port| Download memos/Upload software
7| Navigate DOWN button| Navigate menus/Change values
**8| ** RED fault indicator| OFF = no fault

FLASHING = ongoing fault detected

ON = fault

9| BLUE AC supply indicator| OFF = AC missing ON = AC present
10| Navigate RIGHT/ EQUALIZE button| Scroll right/Start equalize or desulfation
11| ENTER/STOP and START button| Select menu items/Enter values/Stop and restart battery charge

Charge Operation

• To provide the ingress protection specified by design, the charger needs to be operated with both doors locked. All battery charging operations can be accomplished without directly accessing the control panel by physically connecting charger terminals to the battery terminals and using push buttons accessible in the front of the charger. Please refer to “Maintenance and Service” section for picture references.
• 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.

• 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.
• NexSys® iON Li-ion batteries come with specific type of connector. The NexSys+ Outdoor 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.
• When CAN communication is established between the NexSys® iON 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.

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.
• 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. Figure 1.
• 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.

PAIRING with a Wi-iQ® battery monitoring device:

• If one or more 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.

Li-ion only: Max current and voltage requested by BMS

9| Wi-iQ® battery monitoring device link

• 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 (Figure 2).
• 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 off-charge display without the message “BMS CONNECTED”.

Pause Charging

• To pause charging, press the START/STOP button once. To resume charging, press the START/STOP button once more (Figure 3).

Charge Complete

• Figure 2: End of charge display

End of Charge Without Equalization

• The GREEN charge complete indicator comes on after proper end of charge. The GREEN charge complete indicator is on and the display shows “CHARGE COMPLETE”. The display alternates between:
• Total charging time
• Amp-hours restored to the battery
• Any other lit LED indicates a problem during charging. Please refer to Control Panel chart 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 START/STOP button before unplugging the battery.

End of Charge with Equalization

• An equalize charge can be started manually or automatically.

Manual Equalization Start

• The EQUALIZE button can also be pressed any time during the charge and an equalization charge will be scheduled after charging is complete.
• The start of the equalization charge is indicated by the symbol. During the equalization charge, the charger displays the output current and alternates, the battery voltage and voltage per cell and remaining time.
• NOTE: When an equalization charge is manually started, the output will be set automatically.

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.
• After the equalization, 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 ENTER/STOP and START button before unplugging the battery.

AC Power Failure

• If the AC power fails with a battery connected to the charger during a charge cycle, the charger will reset and start a new charge cycle when power is restored. All charger settings, as well as the time and date, are preserved.

Series Charging

• In series charging, the voltages of both batteries add up and must match charger’s nameplate DC volts rating. The charger’s ampere-hour rating must be equal to each battery’s ampere-hour rating.
• Charge cycle will not start unless both batteries are connected.

Menu and Display Information

Main Menu Display

• When the charger is idle, press and hold the Exit button, 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.
• 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:

• Logs ( ): View status and memorizations
• Charger ( ): View faults, alarms, etc.
• USB ( ): USB functions
• Settings ( ): Setting date, language and others
• Password ( ): Management of password (for service technicians only)
• Exit ( ): Exit main menu

MENU & DISPLAY INFORMATION

Logs

Memorization Display Screen

• The charger can display the details of the last 300 charge cycles.
• The display here shows that 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.

Displaying a Charge Cycle Proceed as follows:

1. Select a record (Memo x) using the buttons.
2. Display the first History screen by pressing the Enter button.
3. Display the second History screen by pressing .
4. Return to the Main Menu by pressing the ESC button.
   • The charge history is displayed; use to scroll through the parameters.

Memorization Data

Status

This menu displays the status of the charger’s internal counters (number of normal and partial charges, fault code, etc.).

normally terminated charges and charges terminated with or by faults.
Complete| Number of charges terminated normally.
Partial| Number of charges terminated abnormally.
TH| Number of charger temperature faults.
DF1 etc.| Number of faults recorded by the charger (see Fault Codes).

Setting Parameters

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.

USB

• This menu provides access to the USB function to update software.
• Software updates are provided by EnerSys®.

Password

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

SERVICE & TROUBLESHOOTING

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.

Fault Codes

connection of the battery (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 1.6V 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 an increase in current during the regulation phase indicating battery heating or a badly 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: defective cells, high temperature, water level.

DF7| Air pressure pump fault. Current Di-Dt, thermal runaway.| 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 to a place with lower ambient temperature. Follow instructions 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 does 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.
Fault| Cause| Solution
---|---|---
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).
BAT TEMP| Wi-iQ® battery monitoring device battery temperature too high.| Battery needs to cool down.
TH-LOCK| Module is locked because of repetitive thermal events.| Check the Exx, CDV file 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-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| CANbus error.| Call for service.
DEFEEP| Memory access denied.| Call for service.
DEFRTC**| Clock access denied.| Call for service.

Maintenance and Service

• WARNING THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET. ONLY A QUALIFIED PERSON SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER.
• The charger requires maintenance. Connections and terminals should be kept clean and tight. The unit (especially the heatsink) should be periodically cleaned with low pressure air to prevent any excessive dirt buildup on components. Care should be taken not to bump unit or make 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.
• To ensure proper charger unit ventilation and protection against particulate matter intrusion, routine air filter inspection and maintenance is required. The filter is accessible from the front of the unit by unlocking and opening the two doors. Be sure to disconnect the charger from all power sources (AC grid, batteries) prior to opening any charger door.
• Intervals for inspection are application-specific, depending on the environmental conditions in which the unit operates. The maximum interval for inspection is 90 days, with more frequent inspection required in areas with higher levels of airborne dust, dirt, or other particulate contaminants, or if the filter routinely becomes wet or moist. Upon inspection, if the exterior-facing surface of the filter appears to be darkened or clogged with contaminant, is carrying contaminant on its surface, or if the filter appears to be damaged or compromised in any manner, it should be replaced with a new filter.
• 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 their 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.
• Figure 4: Control panel is accessible once outer cabinet door is opened.
• Figure 5: Air filter, heater and power modules are accessible once the second inner door is opened.
• Figure 6: Control panel not accessible when cabinet is closed. Use external buttons for Start/Stop, pause, and equalization functions.
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• © 2024 EnerSys. All rights reserved. Unauthorized distribution prohibited.
• Trademarks and logos are the property of EnerSys and its affiliates except CE and UK CA, which are not the property of EnerSys.
• Subject to revisions without prior notice. E. &O.E.
• EMEA-EN-OM-NEX-PLCH-OUTDOOR 0624

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0624 Plus, 0624 Plus Outdoor Charger, Outdoor Charger, Charger
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