[PDF] Enforcer Impaq Model: EI1/EI3 Battery Charger Owners Manual



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AM-IMPAQ-OM

Rev AB October 2018

IMPORTANT

product.

DO NOT DESTROY THIS BOOK

Model: EI1/EI3

IMPAQΠBattery Charger

2RQHU·V Manual

To automatically be connected to your closest Service Center, call us toll-free at:

1-800-ENERSYS (1-800-363-7797)

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TABLE OF CONTENTS

Important Safety Instructions ............. 2

Technical Information .......................... 3

Part Number and UL Part Number .......... 3

Output Power Letter Codes .............. 4

Cabinet Size/Gauge Letter Codes .... 4

DC Voltage Number Codes .............. 5

AC Line Voltage Letter Codes .......... 5

Charge Profile Letter Codes ............. 5

Specialty Charger Option List ........... 6

Serial Number ......................................... 6 Battery Type ............................................ 6 Max AH .................................................... 6 No. Cells .................................................. 6 Max Modules ........................................... 6 Hertz ........................................................ 6 Phase ...................................................... 6 AC Volts .................................................. 6 Max AC Amps ......................................... 6 Max DC Amps ......................................... 7 DC Volts .................................................. 7 AH ........................................................... 7 Modules ................................................... 7 AC Amps ................................................. 7 DC Amps ................................................. 7 CEC ......................................................... 7 cULus ...................................................... 7 Installation ............................................ 8 Location ................................................... 8 Cabinet Mounting .................................... 8 Electrical Connections ............................. 8 Connecting Input Power .......................... 8 Grounding the Charger ........................... 8 AC Circuit Protection ............................... 9 Breaker/Fuse Chart ................................. 9 DC Plug Polarity ...................................... 10

Description of Operation ..................... 10

General .................................................... 10 Starting the Charge Cycle ....................... 10 Charging Current ..................................... 10 AC Power Fail ......................................... 10 Series Charging ...................................... 10 Glossary ............................................... 11 Charging Profile ...................................... 11 Cold Storage Profile ................................ 11 Gel-Bloc Profile ....................................... 11 NXBLOC Profile ...................................... 11 NXSTND Profile ...................................... 11 Opportunity Profile .................................. 11 Operation ............................................ 11 Daily Charge ....................................... 11 STD Flooded (IEI) Profile ........................ 11 VRLA Profile ............................................ 11 Equalization Charging ............................. 12 Refresh Charging .................................... 12 Operating Instructions ......................... 12 Control Panel ........................................ 13 Menu Access ........................................ 14 Main Menu ............................................... 14 Memorizations ...................................... 14

Memorizations Display Screen ................ 14

Displaying a Charge Cycle ...................... 14 Memorization Data .................................. 15 Status .................................................... 15 Status Screen .......................................... 15 USB ....................................................... 16 Update Software .................................... 16 Parameters ........................................... 16 Date/Hour .............................................. 16 Language ............................................... 16 Region ................................................... 16 Display ................................................... 16 Contrast .............................................. 16 Screen Saver ...................................... 16 Delay .................................................. 16 Daylight Savings .................................... 16 Password .............................................. 17 Charging the Battery ............................ 17 Charger Idle Display .............................. 17 Starting a Charge Cycle ........................ 17 Delayed Start ......................................... 17 Effective Charge .................................... 18

End of Charge without Equalization ...... 19

End of Charge with Equalization ........... 19

Automatic Equalization Start ................. 19

Fault Codes .......................................... 20 Fault Display .......................................... 20

Maintenance and Service ..................... 22

1 kW Stand Alone Cabinet Mounting

Dimensions ..................................... 23

1 kW 3 Bay Cabinet Mounting

Dimensions ..................................... 24

1 kW 6 Bay Cabinet Mounting

Dimensions ..................................... 25

3.5 kW 2 and 4 Bay Cabinet Mounting

Dimensions ..................................... 26

3.5 kW 6 Bay Cabinet Mounting

Dimensions ..................................... 27

3.5 kW 8 Bay Cabinet Mounting

Dimensions ..................................... 28

1kW Technical Specifications ............. 29

3.5kW Technical Specifications .......... 31

Maintenance Log .................................. 39

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IMPORTANT SAFETY INSTRUCTIONS

WARNING: THE SHIPPING PALLET MUST BE REMOVED FOR PROPER AND SAFE OPERATION.

1. 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.

2. This charger has been designed to only charge lead-acid batteries. Read and understand all setup and

operating instructions before using the battery charger to prevent damage to the battery and to the charger.

3. Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock.

4. During charge, batteries produce hydrogen gas which can explode if ignited. Never smoke, use an open flame

or create sparks in the vicinity of the battery. Ventilate well when the battery is in an enclosed space.

5. 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.

6. 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 15 minutes. Seek medical attention

immediately.

7. Only factory qualified personnel can service this equipment. De-energize all AC and DC power connections

before servicing the charger.

8. The charger is not for outdoor use.

9. Do not expose the charger to moisture. Operating conditions should be 32º to 113º F (0º to 45º C); 0 to 70%

relative humidity.

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

11. For continued protection and to reduce the risk of fire, install chargers on a floor of non-combustible material

such as stone, brick or grounded metal.

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

The product(s)

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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TECHNICAL INFORMATION

There are two nameplates located on the outside of the charger and should be used to check this application before installation. meplate includes the Part number and the ratings of the cabinet as configured. The Configured Ratings nameplate label must be replaced when adding or removing modules permanently in the field.

Part Number and UL Model Number

The UL Model Number specifies the characteristics of a full cabinet charger, while the Part Number specifies the characteristics of the cabinet as configured, plus all options. The Part number is required in any discussion or correspondence regarding this unit.

Single Display Cabinet:

EI3 - GN - 4YOR

Model Type

Phase

Power Level Top

Cabinet Size

DC Voltage Code

Input Voltage Code

Charge Profile

Options

Dual Display Cabinet:

EI3GHR - 4YOR

Model Type

Phase

Power Level Top

Power Level Bottom

Cabinet Size

DC Voltage Code

Input Voltage Code

Charge Profile

Options

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Output Power Letter Codes

The following table describes the letter codes to be used in charger part numbers to indicate the Output Power of the charger.

Letter

Code

Output Power

(kW)

Number

Modules

Module Power

(kW)

A 1.0 1 1.0

B 2.0 2 1.0

C 3.0 3 1.0

D 4.0 4 1.0

E 5.0 5 1.0

F 6.0 6 1.0

G 3.5/2.5* 1 3.5/2.5*

H 7.0/5.0* 2 3.5/2.5*

I 10.5/7.5* 3 3.5/2.5*

J 14.0/10.0* 4 3.5/2.5*

K 17.5 5 3.5

L 21.0 6 3.5

M 24.5 7 3.5

N 28.0 8 3.5

Cabinet Size/Gauge Letter Codes

The following table describes the letter codes to be used in charger part numbers to indicate the number of slots and size of the DC cables.

Letter

Code

Module

Positions

Standard Cable

Gauge Comments

K 1 10 AWG One slot, 1 kW cabinet

L 2 1/0 Two slot, 3.5 kW cabinet

M 3 4 AWG Three slot, 1 kW cabinet

N 4 3/0 Four slot, 3.5 kW cabinet

P 6 2/0 Six slot, 1 kW cabinet

P 6 3/0 Six slot, 3.5 kW cabinet

R 8 3/0 Eight slot, 3.5 kW cabinet

*Three Phase/Single Phase

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DC Voltage Number Codes

The following table describes the number codes to be used in charger part numbers to indicate the DC output voltage(s) of the charger.

Number

Code

Output

Voltage(s)

1 12 2 24

3 36/48

4 24/36/48

5 72/80

6 64 7 60

AC Line Voltage Letter Codes

The following table describes the letter codes to be used in charger part numbers to indicate the AC line voltage(s) and AC line frequency at which the charger can be operated.

Letter

Code

Voltage(s)

(Volts RMS) Line

Frequency

(Hertz)

Comments

A 120 50/60 120 VAC only

C 600 50/60 600 VAC only

G 208/220/240 50/60 208/220/240 VAC

Y 480* 50/60 480 VAC

Charge Profile Letter Codes

The following table describes the letter codes to be used in charger part numbers to indicate the Charging profile of the charger.

Letter

Code Profile

C Cold Storage

E STD Flooded (IEI)

G Gel-Bloc

O Opportunity

T NXBLOC

T2 NXSTND

V VRLA

*For 480VAC chargers with line voltage of 400VAC, see specifications starting on page 32.

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Specialty Charger Options List

Suffix Description

C6 2AWG AC Cord

C10 10' of #12AWG AC Cord

C12 12' of #12AWG AC Cord

L10 10

L13 13' of DC cable

L15 15' of DC cable

L18 18' of DC cable

L20 20' of DC cable

L25 25' of DC cable

L30 30' of DC cable

S Series DC cable

Serial Number

This is the serial number that indicates complete information about the charger. It must be supplied with the part number on any correspondence or discussion regarding this charger.

Battery Type

The chemical content construction of the battery this unit is designed to charge is given in this part of the nameplate. (L-A = Lead Acid)

Max AH

This is the maximum amp-hours capacity of this cabinet.

No. Cells

This is the number of battery cells this unit will charge. This number must match exactly with any battery connected to the charger output.

Max Modules

This is the maximum number of modules the cabinet can hold. Hertz This gives the frequency in cycles per second of the AC input voltage. Under no conditions operate the charger at a different frequency or from a generator with unstable frequency. Phase

Number "3" indicates a Three Phase Charger and .

AC Volts

This is the nominal voltage this charger is rated for. The charger will only operate on this voltage.

Max AC Amps

This is the maximum AC Amps for which this cabinet is rated.

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Max DC Amps

This is the maximum output DC Amps for which this charger is rated.

DC Volts

This gives the nominal DC output voltage of the charger. AH This number indicates the largest Amperes-Hours (AH) capacity of the battery this charger is designed to charge proficiently as configured.

Modules

This is the actual number of power modules installed in the charger cabinet.

AC Amps

This is the AC current that this charger will draw with the number of power modules shown in

Configured Ratings nameplate.

DC Amps

This is the DC current that this charger will deliver to a discharged battery with the number of power modules installed. CEC This logo is applied to chargers that are certified with the California Energy Commission in compliance with Appliance Efficiency Regulations: cULus This logo is applied to chargers that have been tested to applicable standards and requirements by Underwriters Laboratories (UL) and the Canadian Standards Association (CSA):

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INSTALLATION

WARNING: The shipping pallet must be removed for proper and safe operation.

Location

For maximum safe operation, choose a location which is free of excess moisture, dust, combustible material and corrosive fumes. Also, avoid locations where temperatures are high or where liquids will drip on the charger. Do not obstruct the ventilation openings. Follow charger warning label when mounting on or over a combustible surface. The recommended charger mounting location should provide a radial distance of at least 28 inches 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 12 inches. The charger will be installed with four 5/16 inch bolts or with the bracket supplied. See the Mounting Dimensions section at the end of this manual for proper bolt pattern. Charger should be permanently fastened in place. For shelf mounting, part number 159-6LA22723 is required two per charger. NOTE: Ambient temperature at all levels cannot exceed 113°F (45°C).

Electrical Connections

To prevent failure of the charger, make sure it is connected to the correct line voltage. Follow your local and National Electric Code (NEC) in making these connections. WARNING: Make sure the power to the charger is OFF and the battery is disconnected before connecting the input power to the terminals of the charger.

Connecting Input Power

Connect the input power to the appropriate terminals and apply appropriate torque as follow: Phase Power (kW) Cabinet (Bay) Terminals Torque (in-lbs)

1 1 1 and 3 L* N* 6

1 2.5/3.5 4 L2 L3 15

3 2.5/3.5 4 and 6 L1 L2 L3 15

3 2.5/3.5 8 L1 L2 L3 25

* For 208/220/240V 1kW single phase, connect L1 to terminal L and L2 to terminal N.

Grounding the Charger

Connect ground wire to terminal marked with either of the two symbols below and apply same torque value per table above:

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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. Use only on circuits provided with branch circuit protection in accordance with the Breaker/Fuse Chart table in this manual, and the National Electrical Code, NFPA 70.

Breaker/Fuse Chart

AC Amps

(A)

Breaker/Fuse size

(A)

1 - 12 15

12.1 - 16 20

16.1 - 20 25

20.1 - 24 30

24.1 -28 35

28.1 - 32 40

32.1 - 36 45

36.1 - 40 50

40.1 - 48 60

48.1 - 56 70

56.1 - 64 80

64.1 - 72 90

72.1 - 80 100

80.1 - 88 110

88.1 - 100 125

DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC SHOCK. Follow National Electric Code for ground wire sizing.

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DC Plug Polarity

The charging cables are connected to the DC output of the charger with the red cable to the positive bussbar, and the black cable to the negative bussbar. The red cable is terminated into connector. The output polarity of the charger must be observed when connecting to the battery (read warning above). Improper connection will open the DC fuses in the power modules.

DESCRIPTION OF OPERATION

General

IMPAQ chargers are microprocessor-controlled. The processor is programmable to adapt to a wide range of battery capacities so that the charging profile can accurately adjust for any battery size. The charging coefficient is maintained absolutely on all types of batteries at various discharge levels. IMPAQ chargers are designed to charge NexSys®, GelBloc, flooded and sealed lead-acid batteries within the range of the cell and ampere-hour rating marked on the nameplate. Attempting to charge other battery designs with this charger could cause damage to the battery.

Starting the Charge Cycle

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.

Charging Current

Charging current is determined by the battery voltage and its state of charge condition. Charging current declines automatically as battery voltage rises during the charge. As the battery charges, the LCD display will output various charge parameters including the percentage of battery capacity.

AC Power Fail

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 DC Volts -hour rating must be equal to each of the batterys ampere-hour rating. Charge cycle will not start unless both batteries are connected.

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GLOSSARY

Charging Profile

The charging profile defines the rate of current charge over time. The charger adapts to the

Cold Storage Profile

This is a charging profile that allows the configuration of the charger for use with batteries in cold

storage application. The profile is an IEI (constant current, constant voltage, constant current) type with a number of user configurable parameters.

Gel-Bloc Profile

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