Instructions for use - NexSys®+ charger ENGLISH

SafEty INStructIoNS aIM of tHIS MaNuaL

This manual is designed for use by any skilled worker wishing to use NexSys®+ chargers for recharging NexSys batteries. This manual provides details of:• Thechargers’functions.• Anyadjustmentsrequiredandhowtousethechargers.When producing this manual, EnerSys® has aimed to provide its information in as simple and precise a manner as possible but cannot assume any responsibility for any misinterpreta-tion. The owner of the equipment is required to retain thismanualthroughouttheequipment’s lifeandtopassitontoany purchaser in the event of its resale.The manufacturer covers the guarantee in accordance with the local regulations (contact local sales organization).

Recommended useThis manual should be read through carefully before using the equipment and also read by anyone likely to use theequipment.Theequipment:• Presentsnoobstaclestothefreecirculationofairthrough

the air inlet and outlet but, nevertheless, should be cleaned ofdusteverysixmonthsbyaqualifiedperson.

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

• Mustbeusedwithin the temperature limitsstated in thetechnical characteristics.

• Mustnotbeinstalledonsurfacessubjecttovibration(nearto compressors, engines, motors).

• Mustbeinstalledsothatthegasesfromthebatterybeingcharged, do not get sucked into the charger by its fan.

Operator safetyTake all necessary precautions when the equipment willbe used in areas where there is the possible risk of an accident occurring. Ensure appropriate ventilation according to standard DIN EN 50272-3 to allow any gases released to escape. Never disconnect the battery while it is being charged.

ELEctrIcaL SafEty

The prevailing safety regulations must be observed. The sys-tem protection installed on the power supply to the charger mustconform to thecharger’selectrical characteristics.Theinstallation of a suitable circuit breaker is recommended. It is imperative to ensure that when fuses are being replaced only fusesofthespecifiedtypeandofthecorrect areused. It isstrictly forbidden to use inappropriate fuses or to short-circuit thefuseholders.ThisequipmentconformstoClass1safetystandards, which means that the appliance must be earthed andrequirestobepoweredfromanearthedsupply.

Never open the equipment: High voltage could be still present even turning off the charger.Any adjustment, maintenance or repairs to the equipmen-while it is open must only be carried out by an appropriately skilled person who is aware of the risks involved.

Contact one of the company’s trained technicians if any prob-lem is encountered when putting the charger into operation.Thisequipmenthasbeendesignedfor indooruse. It isonlydesigned to recharge lead/acid batteries on industrial premises.Whentheequipmentbecomesobsolete,thecasingsandtheother internal components can be disposed of by specialist companies. Local legislation takes precedence over any inst-ructions in this document and must be scrupulously observed (WEEE2002/96EC).

EnerSys reserves the right to make any improvements and/or modificationstotheproductdescribedinthismanualatanytime and without prior notice and is not obliged under any circumstances whatsoever to update the contents of this manualnortheequipmentconcerned.Theequipment’sproductionnumbermustbesuppliedwhenrequiringaservice.

If the charger is to be stored before its use, it must be kept carefully sealed in its original packaging. It must be stored in a clean and dry location at a moderate tempera-ture (-20°C to+40°C).Equipmentstoredata temperatureof less than 15°C must be brought progressively to operating temperature(overaperiodof24hours)toavoidanyriskof condensation causing electrical faults (particularly short-circuits).

Ec DEcLaratIoN

EnerSys hereby declares that the chargers in the NexSys+ range covered by this declaration conform to the descriptions laid down in European Directives:

2014/30/EU:DINEN61000-6-2,DINEN61000-6-4:Immunityandemissionslimits for industrial electronics

2014/35/EU:DIN EN 60950, DIN EN 60335 (Low Voltage Directive)

RoHS 2011/65/EC

PrESENtatIoN & uSE INtroDuctIoN

The NexSys®+ range of chargers enable batteries to be recharged from the mains supply. The microprocessor control automaticallyrecognizesthebattery’svoltage,capacity,stateof charge, etc., providing optimum battery control from highly efficientanalysisofitscondition.

1ph 3ph12V24V 24/36/48V

36/48V 72/80V

The desulphation, equalizing and refreshing charges are integrated.

2 1 47

8 3 9

6

5

5

Ref Button/LED Function Function

1 Start/Stop button Start/Stop charge Cancelvalue(pressduring3s), select of active menu

2 Chargerstatusindicator Battery available 3 Chargerstatusindicator Battery in charge 4 Blue LED ACsupplyON(light) ACsupplyOFF(ACmissing)5 Arrows Navigation buttons Return to top of list (press for 2 sec)6 Equalizationbutton Startanequalization Accessasubmenu7 Esc Accessasubmenu Closewindows8 TFT multicolor screen Showsdetails(refertoTFTdisplaypar.)9 USB port Download memories Uploadfirmware

Single phase 3 bay & three phase

Ref Function1 ACinputcable2 DCoutputcable3 Optionport4 Ventilation openings5 TFTscreen6 Navigation buttons7 Cableholder(onlyonsinglephase)

1

3

2

1

3

2

5 6 5 6

44

7

MEcHaNIcaL INStaLLatIoN

The charger can be wall or floor mounted. If wall mounted, make sure that the surface is free of vibrations and the char-ger 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.Thechargermustbeheldby2or4fixingssuitableforthetypeof support. The drilling pattern varies according to the model of charger (please refer to the technical data sheet).

ELEctrIcaL coNNEctIoN

To the mains supplyYou may only connect to the 1-phase 230Vac or 3-phase400Vacmainssupply(dependingonthetypeofthecharger)by means of a standard socket and an appropriate circuit breaker (not supplied). The current consumption is shown on thecharger’sinformationplate.

To the batteryPolaritymustbeobserved.Anyreversalofpolaritywillblowtheoutputfuse,preventchargingandcauseDF2faultcodetobedisplayed.PleaserefertotheMessagesandfaultcodes.

Connection to batteryThe charger must be connected to the battery by the cables supplied:• TheREDcable:tothebattery’sPOSITIVEterminal.• TheBLACKcable:tothebattery’sNEGATIVEterminal.

tft ScrEEN

Off-charge displayWith the charger in waiting mode, the display shows informa-tion concerning the charger(top and bottom lines):1.Chargertype2. Software version.3. Waiting indication.4.Dateandtimeofthecharge.

Ref Function1 Chargeinfo2 Chargevoltage(totalVandV/c)3 Chargetime4 Battery temp.5 Battery ID6 Wi-iQ warnings7 USB connection8 ChargeAh9 Chargertypeandchargingprofile10 % of charge11 Chargecurrent12 Equalmode13 Date/time14 Wi-iQ link

Initiating charging

1. Connect the battery. If default setting (auto start ON) then the charge will start automatically else press the Start/Stop button.

The charger will start the countdown process and will start displaying the following information.

Charge screens

Without Wi-iQ®

With Wi-iQ

Ref Function1 Non blocking faults2 Voltage3 Current4 Chargingprofile5 Chargingtime6 Warnings from Wi-iQ7 BatteryT°C8 Ahcharged9 Wi-iQ linked10 Date/time11 State of charge and progress

2 3 4

118

1

5 107

2 3 4

118

1

5 1076 9

1

3

2

45

6

9

11

10

1378

12

14

2. Completion of the charging processWhen the charger completes the charging process the message of AVAIL will appear.STOP the charger.Afterdisconnectionthebatterywillbereadyforuse.

3. Equalization chargeThestartoftheequalizationchargeisindicatedbythemessageEQUAL.Duringtheequalizationcharge,thechargerdisplaysthe current, the battery voltage, voltage per cell, remaining time

4. Faults

Fault Cause SolutionDF-CUR Appears before a DF1 fault is dis-

played.DF1* Chargerproblem. DF1appearswhenthechargerisnotabletosupplyitsoutputcurrent.DF2* Outputdefault. Checkthecorrectconnectionofthebattery(reversedpolaritycables)

and the output fuse.DF3* Wrong battery. Too high or too low battery voltage. Battery voltage must be between

1.6Vand2.4Vpercell.Useproperchargerforbattery.DF4 Batterydischargedmorethan80%

of its capacity.Chargecontinues.

DF5 Batteryrequiresinspection. 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.Checkthebattery(defectivecells,hightemperature,water level..).

TH* Thermal problem in charger resul-ting in charge interruption.

Verify the proper operation of the fans and/or absence of too high ambient temperature, or there is poor natural ventilation to the charger.

iQ SCAN Look for present. Wi-iQiQ LINK Set the link. Wi-iQ-chargerMOD TH Alternatingwithchargeparameters

- one or more modules in thermal fault - the charge process continu-es - the faulty module(s) is (are) displayed + red led flashing.

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 DFC Alternatingwithchargeparameters-oneormoremoduleinDF1fault-the charge process continues - the faulty module(s) is (are) displayed + red led flashing.

Checkpowersupply.IfallmodulesareinDF1fault,aDF1*faultwillfollow.

DEF ID Blocking fault - one or more mo-dule are not compatible with the chargerconfiguration(forexample24Vchargerwithone48Vmodule).This can happen if the user replaces one module with another one with a different voltage setting.

Use correct module.

Default of balance voltage detectedby the Wi-iQ

Check each battery cell during discharge. Control if the Wi-iQ is properlyadjusted(seeWi-iQinstructionsofmounting).

Subject to technical modification without any prior notice. E&OEwww.enersys.com 09.2016

MESSaGES aND fauLt coDES

(*)Ablockingfaultpreventingchargingfromcontinuing.PleasecontactEnerSys® Service.