Technical Manual GB

Hawker® Life IQTM

Single phase and 3-phase
chargers

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 Technical manual Life IQ TM - Single phase and 3-phase chargers

CONTENTS INFORMATION
AIMS OF THIS MANUAL................................................................................2 GOALS OF THIS MANUAL
INFORMATION................................................................................................ 2
This manual is aimed at any authorized personnel wanting to use a
WARRANTY..................................................................................................... 2 single phase and 3-phase Life IQTM charger to recharge lead acid
motive power batteries (vented, Hawker XFCTM, Gel or Water Less®/
RECOMMENDATIONS....................................................................................2 Water Less® 20 ranges)
This manual contains information on:
ELECTRICAL SAFETY..................................................................................... 2 • Charger functionality.
• Use and setting of charger parameters.
LIMITATIONS OF USE.................................................................................... 3
• Technical specifications of the Life IQ chargers.
PRODUCT RECYCLING – DESTRUCTION.....................................................3 EnerSys® intends to provide clear and simple information in this manual,
and assumes no responsibility for misunderstanding or improper inter-
MODIFICATIONS AND IMPROVEMENTS .....................................................3 pretation of the information.
The owner of the equipment is required to preserve this manual during
RECEIVING – STORAGE.................................................................................3 the life of the equipment and to transfer said manual to any subsequent
purchaser.
SPARE PARTS................................................................................................ 3
INFORMATION PLATE................................................................................... 3 WARRANTY

GLOSSARY...................................................................................................... 3 Warranty is offered by the manufacturer based on local regulations.

Please contact your local distributor for further information.
EEC DECLARATION OF CONFORMITY......................................................... 3
DESCRIPTION............................................................................................. 4 RECOMMENDATIONS

INTRODUCTION............................................................................................. 4
Recommendations for safe operation
FEATURES...................................................................................................... 4 This manual should be carefully read, prior to using the equipment,
by anyone intending to use the charger. The Life IQ:
EXTERNAL COMPONENTS........................................................................... 4 • Must not have its air circulation impaired in any way, primarily
around the air inlet areas.
CONTROL PANEL........................................................................................... 4
• Dust accumulation must be removed every 12 months.
THE MENUS................................................................................................... 5 • Must be used within its protection norms, and never be directly in
contact with water.
ACCESS TO THE MENUS.............................................................................. 5 • Must be used only within the temperature range specified in the
technical specifications.
MEMORISED DATA........................................................................................ 5 • Internal connection torques must be checked once a year.
• Must not be installed on a surface subject to high vibration levels
STATUS........................................................................................................... 5
(proximity of motors, compressors, etc.).
USB................................................................................................................. 5 • Must not be installed close to the batteries in order to avoid any
gassing that could damage it prematurely.
CONFIGURATION........................................................................................... 5 • Must not be installed in arduous environments such as:
• Harbour applications (saline air)
PARAMETERS................................................................................................. 6 • Close to cold stores
• External locations with exposure to wind and rain.
PASSWORD.................................................................................................... 6
INFORMATION............................................................................................... 6 Operator safety
All proper precautions must be observed when the equipment is used
USING THE CHARGER................................................................................... 6 in areas where accidents are possible. Ensure proper ventilation when
the charger is used with lead-acid batteries, due to gassing.
UNPACKING....................................................................................................6 Never disconnect the battery during the charging process.
MECHANICAL INSTALLATION...................................................................... 6
General warnings
ELECTRICAL CONNECTIONS........................................................................ 7 Requirements for use:
• The equipment must be properly grounded (earthed).
FACTORY SETUP............................................................................................ 8 • The input voltage must match the charger requirements.
• The battery voltage must match the charger’s capabilities.
CHARGING THE BATTERY............................................................................. 8 • The battery capacity is within the charger’s range.
HISTORICAL DATA PER CHARGE ................................................................ 9
ELECTRICAL SAFETY
CHARGER HISTORICAL DATA....................................................................... 9
Safety regulations and requirements must be observed.
MESSAGES AND FAULT CODES................................................................. 9
Safety devices installed on the electrical supply to the chargers must be
of the proper type and rating. It is important to ensure that only fuses of
the proper capacity be used, should they need to be replaced.

This charger meets the Class 1 Electrical Safety requirements, and

therefore needs to be properly grounded during installation. It must be
connected to a power supply equipped with a ground cable, and the
ground connection should be as short as possible.

The equipment must be totally disconnected from all power sources

(main supply and battery) before it can be opened for inspection or
servicing. The battery can only be disconnected after the STOP/START
button has been pushed. Access to the inside of the charger should be
restricted to authorized maintenance personnel.

Please consult a qualified factory representative about any problems or

questions related to the installation of this unit.

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 LIMITS OF USE Mixing enables faster charging of the battery and eliminates the
differences in density by homogenizing the electrolyte throughout
This charger is designed to be used in a sheltered area. It is designed the cells. The ionic profile doesn’t require weekly equalisation charge.
exclusively to recharge lead batteries in an industrial environment.
Gel battery profile
PRODUCT RECYCLING - DESTRUCTION The procedure for charging sealed, maintenance-free batteries has
been optimised to ensure that the particular requirements necessary for
When this charger becomes obsolete, it can be recycled or destroyed by recharging are observed. The main advantages of these batteries are
authorized facilities. Local regulations will prevail and must be followed. that there is no necessity to add water, thus reducing maintenance costs,
and no necessity for special charging rooms (subject to local regulations)
MODIFICATIONS AND IMPROVEMENTS with ventilation and water demineralisation units.

EnerSys® reserves the right, at any time, to modify or improve its Water Less®/Water Less® 20 battery profile
products, without any obligation to update this product or this manual The charging procedure for Water Less batteries has been optimised in
accordingly. order to provide more flexibility and more time due to longer topping
up intervals.
RECEIVING - STORAGE
Pneumatic battery profile
Upon receipt, please inspect visually the exterior of the charger for any PzM profile (Water Less) - 65 cycles
physical damage. If necessary, proceed within 24 hours with the usual WL20 profile (Water Less 20) - 100 cycles
claims procedure with the transport company. This type of battery is fitted with an air injection circuit allowing
electrolyte circulation. The electrolyte circulation system reduces the
If the charger is to be stored before use, it should remain in the original charging time and the water consumption.
packaging, carefully closed. Store in a clean, dry area at a moderate
temperature (0 °C to +40 °C). If the equipment is stored at a temperature EC DECLARATION OF CONFORMITY
below 15°C, it must be gradually (24 hours) restored to operating
temperature before use, to prevent the risk of condensation that EnerSys hereby declares that the chargers in the
could cause electrical faults and short-circuits. Life IQ range covered by this declaration conform to:

SPARE PARTS Directive 2006/95/EC (Low Voltage Directive) :

EN60950-1
Please supply the unit’s serial number, indicated on the information plate
when ordering any spare parts. Directive 2004/108/EC (ElectroMagnetic Compatibility) :
EN61000-6-2, EN61000-6-4 :
INFORMATION PLATE Immunity and emissions limits for industrial electronics
(class A- Industrial Environments)
Located on either side of the charger.
Directive 2002/95/EC (RoHS)
GLOSSARY

Charger Features
The EnerSys chargers are managed by a microprocessor.
The microprocessor can calculate the battery capacity and automatically
sets the appropriate charging profile. This allows the charger to work
over a wide range of battery capacities. The control of the charging
factor is absolute on all battery types. The Life IQTM chargers adapt to
battery capacity and depth of discharge.

Charge factor
Charge factor is the quantity of Ampere Hours returned to the battery
during the charge cycle versus the amount removed during the last
discharge.

Refresh Charge
A refresh charge maintains the battery at the optimum level as long as it
is connected to the charger.

Desulphation charge
A desulphation charge is done prior to normal charging, and this
charge restores the specific gravity of over-discharged or under-utilised
batteries.

Equalisation charge
Done after the normal charge, a balancing charge that ‘equalises’ the cell
voltages and specific gravity of all cells in the battery.

Wi-IQ®
This device, permanently installed on the battery, wirelessly transmits
battery parameters to the charger in order to optimise the charge and to
manage the charge and discharge data.

Communicated parameters are:

Temperature, battery capacity, warnings (water level, voltage balance),
voltage, charging status …

The Wi-IQ also transmits data of the battery temperature during the
charging process and will possibly stop the charge if the temperature is
too high.

Charging profile
Defines the profile of the current applied to the battery during charging
in relation to available time. Diverse charging profiles can be selected.
The charger adapts to the battery based on capacity and state of charge
and age in order to maximize overall battery life. The control of the
overcharge factor, whatever the battery depth of discharge, provides a
reduction in water consumption (except on VRLA batteries) and energy
consumption .

Ionic profile
Also called “Ionic Mixing” this profile consists of applying short current
pulses to the battery, thus provoking gassing in the active material to
diffuse the sulphuric acid from the plates. This introduction of Ionic

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 DESCRIPTION COLOUR FUNCTION

Dark blue Waiting status until battery connected

INTRODUCTION
Light blue Battery on charge
The Life IQTM range of chargers is designed to recharge 24V, 36 V, 48 V
or 80 V batteries, depending on the version supplied, from a single- Light blue Orange Alternating, on charge indicating a defect
phase or 3-phase main supply. The microprocessor-controlled unit pump or overdischarge or thermal fault
automatically recognises the battery (voltage, capacity, charge level, etc.)
and very effectively analyses its condition for optimum handling. Several Green Battery charged
charging profiles are available (vented lead/acid batteries, VRLA batteries
(Hawker XFCTM), gel batteries or Water Less® batteries) depending on the Red Charger faults DF1, DF2, DF3, TH
configuration selected by the user. The capability for desulphation,
equalisation and refresh charging is also included. Green Orange Alternating, battery charged with defect
pump or overdischarge
FEATURES

The Life IQ chargers are: Functions of keys

The keys offer the following general functions:
fitted as standard with:
• A wide LCD display with a five colour backlight indicating the status Key Function
of the charger (Waiting, On charge, Fault, Battery charged)
• Wireless communication with the battery controller, Wi-IQ®. This Navigation in the menu.
communication allows optimisation of the charge and automatic Start/End of list (Press 2 seconds)
adjustment of the charger to the battery according to temperature,
capacity and technology (vented, VRLA …). Communication The central button is equipped with
occurs during the charge to analyse the battery temperature and a two-coloured LED Green/Red
compensate for any loss in the output cables. (Green: charger is waiting, Red charger
• A real time clock allows the management of charging at a precise operating)
time of day (for example, to use off-peak electricity tariffs), for
equalising periods (for example: the user can configure an GREEN/RED Stop or Start of charge
equalisation charge once or several times a week as required).
• Anti arcing system for safe disconnection during the charge. Selection of active menu or validation
• A USB interface enables the connection of a USB stick to of value stored
download all data stored in the charger.
Cancel the value stored
optionally fitted with: (Press 2 seconds)
• Ethernet interface for remote management of the charger.

EXTERNAL COMPONENTS Start an equalisation charge.

Access to a sub-menu.
Presented below:

Single phase model 3 phases model Access to the menus (press 3 seconds)
Close the window.

001 002

Ref. Function
1. Ventilation louvres.
2. Display and control panel
3. AC input cable.
4. Battery cable.
5. Wall mounting frame.
6. Case retaining screw.
7. Navigation button – Stop/Start button of the charger
8. USB
9. Option connector (Electro-valve, BSI, Ethernet…).

Figure 1: Principal components of the charger.

CONTROL PANEL

Incorporates the Display and the Control Panel. See Chapters “The
Menus” and ”Using the charger” to get more detailed information.

LCD Display
The display is fitted with 5 different colours indicating the status of the
charger:

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 THE MENUS Battery

The menus provide access to the following functions: Auto/Manu capacity

• Last 200 charging cycles (Memorisations menu). The charger can estimate the capacity of the connected battery (Auto)
• Viewing of faults, alarms, etc. (Status menu). or the user can determine the capacity (Manu) via the Capacity menu.
• Download of data stored in the charger via the USB storage
memory. Capacity
• Charger configuration (Configuration menu). Determines the battery capacity for an optimised charge (Manu)
• Setting of date, language and others (Parameters menu).
• Management of password (Password menu) Temperature
• Viewing basic information, type of charger (Information menu) Defines the battery temperature when the charge is started.
This parameter adjusts the regulation voltages on the charging profile
ACCESS TO THE MENUS (values between –15°C and 65°C).
• Without Wi-IQ®: defines the average operating battery temperature
Functions of the keys before the charge.
To access the menu, press the key for 3 seconds. • With Wi-IQ: the battery operating temperature will be automatically
defined. It is recommended to enter the observed average
MEMORISED DATA temperature, especially in cold areas. The battery temperature will
be analysed during the charge; if it increases too much, the charger
Displays historical data from the last 200 charging cycles. will stop to prevent any possible damage.
The MEMO 1 refers to the latest record.
High temperature
Defines the safety limit in high temperatures.
Display an history • Without Wi-IQ: not used.
• With Wi-IQ: If the battery temperature, during the charge, reaches
the programmed limit, the charger will stop the charge and wait
until the temperature decreases.

Charge

Profile
For selecting the right charging profile for the battery:
ionic, gel, pneumatic, PzM (Water Less®) WL20 (Water Less® 20),
Hawker XFCTM
With Wi-IQ: the selection of the profile will be automatic and
006 the charger will recharge the battery with the appropriate profile
whatever profile has been selected.

Proceed as follows: AutoStart

Default is ON, so the charge will start as soon the battery is connected
1. Select a record with or .
to the charger. If Autostart is OFF, the charge will start only if the central
2. View the first screen by pressing . button is pressed.
3. View the successive lines by pressing .
Delayed start
4. Return to previous screen by pressing . Defines:
• Either the charging start deadline
• Or the charging start hour.
STATUS This delay enables the charger to be used during off-peak when the
electricity is at lower tariffs. Note: the charger doesn’t manage the
This menu displays the charger’s internal counters (number of normal summer/winter time changes.
charges, faults by type, etc.)
Conditional charge
Information displayed The charger will only commence the charge if the battery has reached
Reset information of this screen is done via the Configuration menu. the limit of depth of discharge of more than x%. For example if the user
wants to charge the battery only if it is discharged more than 30%, the
Indication Information parameter 30 has to be entered in the conditional charge. The 0 value
disables the function.
Number of complete charges.
Floating voltage
Number of incomplete charges. Setting a floating voltage at the end of charge to compensate eventual
consumption by the truck (AGV type). The parameter voltage determines
EGAL Number of automatic equalisation the floating voltage at the end of the charge. The parameter Current
charges carried out by the charger. defines the average current consumed by the truck electronics (crucial
for currents at the end of charge).
TH Number of temperature faults*.
Maximum current
DF1, etc. Number of faults an types 1, 2, 3, 4, 5 This manually decreases the maximum output current of the charger.
or fault pump*.
Equalisation
(*): see § Fault codes These parameters are not valid for GEL and Hawker XFCTM batteries.

USB Manu Current

This defines the equalisation or desulphation current for a manual start.
This menu provides access to the USB function. The charger can store
charging data in a USB memory. Time
Sets the equalisation time from 1 hr to 48 hrs
Record Memo
Enables the storage of charge Memorisations and the Status data. The Delayed start (delay)
file, in CSV format (useable with Memoreport PC or Excel), will be stored Sets the delay between the normal charge and the equalisation charge
in the USB stick under the name: from 0 hr to 23 hrs.
MDDDHHMM.CSV with
M : for Memorization Frequency
DDD : Day of the year Selects one or several periods for carrying out the equalisation charge.
HH : Hour of file creation The user can select one or several days per week.
MM : Minute of file creation
Refresh
Eject Default is ON, (only for the IONIC profile) the refresh charge after the
For safe removal of the USB stick without damaging the data file. main charge maintains the battery in good condition by adding some
pulse after the main charge. If the refresh is OFF, the refresh charge is
CONFIGURATION disabled, but the equalization charge is still operating as defined on the
previous menu.
This menu allows to configure the charger.

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 Cable USING THE CHARGER
Length
Selects the length of battery-charger DC cable from 1 m to 11 m. UNPACKING

Section The charger is delivered with the following:

Defines the battery-charger DC cable cross-section. Select one section • 2m AC mains cable.
over the list of values (10, 16, 25, 35, 50, 70, 95 or 120 mm²). • 3m DC battery cable.
• This technical manual.
Network (Option)
Sets the protocol and configuration for the connection of the charger to MECHANICAL INSTALLATION
a network, type Ethernet or series.
The charger must be mounted in a vertical position. For wall mounted
Option chargers, the bottom of the charger must be at least 0.60 m from the
floor and/or the charger below and the top of the unit at least 1.0 m from
Options test the ceiling. The minimum distance between two adjacent chargers must
Carries out a test of correct functionality of the options - managing the be 0.30 m.
pump, electro-valve and remote display green/red during 30 seconds.
See paragraph Recommendations and avoid areas where the chargers
Electrovalve time may be splashed with water, or saline environments.
Defines the opening time (between 15 and 300 seconds – ionic
profile – pneumatic, PzM (Water Less®) WL20 (Water Less® 20) of The charger is held by 4 x M6 or M10 screws suitable for the type of sup-
the electro-valve for the automatic water refilling of the batteries. port. The drilling pattern is depending on the charger model. See illustra-
tion below.
Reset Memo/status
To reset the memorizations and status recorded by the charger. Standard charger model 2 - Fixing L x H: 120 x 470 mm

PARAMETERS

Date/Time
Sets date and time of the charger. The charger doesn’t manage
summer/winter time changes.

Language
Selects the language displayed in the menus.

Region
Selects the format for date, metric/imperial units for temperature and
length.

Contrast
Modifies the display contrast level.

Change Password
Changes the password.

PASSWORD

Manages a password to limit access to charger menu..

Charger model 2 with optional pump - Fixing L x H: 304 x 355 mm
INFORMATION

Gives information on the software version, memory and time clock.

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 Standard charger model D - Fixing L x H: 470 x 350 mm Standard charger model E with optional pump -
Fixing L x H: 470 x 350 mm

Standard charger model D with optional pump - ELECTRICAL CONNECTIONS

Fixing L x H: 470 x 350 mm

Single phase and 3-phase input

Connection to the mains supply will be 230V AC single phase or 400V AC
3-phase and must be connected using a suitable plug and adequately
sized circuit breaker (not included). Current requirements in Amps are
indicated on the charger information plate.

Battery output
It is essential to ensure correct polarity. However, reversed polarity will
result in blowing the output fuse, inability to charge and the fault code
DF2 to be displayed. See Fault Codes.
Connection to the battery should be done using the cables supplied:
• RED cable: battery POSITIVE.
• BLACK cable: battery NEGATIVE.

Standard charger model E - Fixing L x H: 470 x 350 mm

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 FACTORY SETUP Ref. Without Wi-IQ® With Wi-IQ

The charger is delivered with a factory setup as follows: 1. Charger status (CHARGE, AVAIL, DEFAULT, EQUAL..), possible
pump fault or DF4.
Profile: As ordered
2. Alternating display of battery voltage, voltage per cell, Ah
Output DC cable length: 3m
restored, charging time, remaining charging time, percentage
Configuration: As ordered of battery charge.
Automatic equalisation: No
Delayed start enabled: No 3. Set up operating battery T°C, Battery temperature and
and battery capacity if manual capacity given by the Wi-IQ
mode set. (*).
• If no modifications are required, go directly to the section:
Charging the battery. 4. Charging current
• If changes are required, go to the Configuration section.
5. Programmed charging profile. Detected charging profile (*).
CHARGING THE BATTERY
6. Various information can be displayed: equalisation symbol
It is now assumed that the charger has been set up as per the required at the end of charge, USB connection symbol, Wi-IQ link
Configuration section. Charging can only begin with a battery of the symbol, possibly battery default DF4.
appropriate type, capacity and voltage connected to the charger.
7. Empty line. Alternating, detected serial
Off-charge display number, as information is
With the charger in waiting mode, the display shows information received and alarms if
concerning the charger (top and bottom lines): present. See § Fault codes.
1. Charger type (Battery voltage + current).
2. Last selected charging profile.
3. Software version.
4. Waiting indication.
5. Date and time of the charge.
6. Set up battery operating temperature.

Alternating battery temperature/capacity if the ‘manu’ capacity mode

is selected.

012

WAIT (*) as information is received.

As soon as the countdown time has elapsed, the display shows the
information relative to the charge.

To induce the start of the charge if the delayed charge has been pro-
010 grammed:

1. Connect the battery

Delayed start 2. Press the central button to stop the charger.

If the charger was programmed for a delayed start (Configuration
menu/Delayed start), charging will begin following that delay. or at 3. Press and hold the central button for 3 seconds. Release.
the specified time. The display shows the time remaining before the
programmed charging starts. Defaults DF1, DF2, DF3 and TH inhibit the charge. Refer to section Fault
codes.
Starting a desulphation cycle before charging
Desulphation of a vented battery is started manually, in this case the End of charge without equalisation
charger will consider the configuration in the menu Equalisation with the 1. The backlight of the screen becomes green at the end of a correct
current and time set up in the charger menu. To start the desulphation charge.
charge, please proceed as follows. And the indication AVAIL is displayed. Possible alternating display
between DF5 default and pump default and DF4 (ref.1). The displays
1. Connect the battery shows alternately: (ref. 2):
• charging time achieved.
2. Press the central button to stop the charger. • number of Ah restored.

3. Press and hold the button . Refer to sections Memorisations or Status for detailed information
relevant to the end of charge.
4. Press the central button to start the charger.
If the battery remains connected, and in order to maintain it in a
Release . fully charged condition, refresh charges followed by equalisation
charges will be automatically initiated according to the battery
The standard charging cycle will have to be started manually after the technology.
desulphation cycle is completed.
2. If an equalisation charge has been programmed (vented battery), it
Initiating the equalisation charge after a standard will start automatically. Alternatively, an equalisation charge can be
charge triggered manually; go to section End of charge with equalisation.
An equalisation charge can be programmed at the end of charge when
3. Press the central button or disconnect the battery that is now ready
the user presses the button during the standard charge or when the for use.
battery is available. The equalisation symbol appears on the top, left side
of the display. The equalisation current is defined by the charger. End of charge with equalisation
Equalisation only applies to vented batteries. Start can be manual or
Starting the charge automatic.
1. If Autostart = On (default ON), the charge starts automatically when
the battery is connected to the charger. To stop the charge, press Manual start
the central button . 1. At the end of charge (green lighted display on), press the key .
If Autostart = OFF the charge will start only if the central button is
pressed. To stop the charge, press the central button . The start of the equalisation charge is indicated by the message
EQUAL. During the equalisation charge, the charger displays the
The displays shows information relative to the connected battery current (ref 4) and alternating, the battery voltage, voltage per cell,
and counts down the time remaining until the effective charge remaining time (ref 2).
begins.
2. The battery will be available as soon as the screen becomes green.

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 Automatic start TEMP* Critical battery Wait until the battery
If the equalisation charge has been programmed temperature. temperature cools down, check
(Configuration/Equalisation menu), the equalisation charge is initiated the battery state (water, profile)
automatically.
Verify the set up of temperature
If the battery remains connected, and in order to maintain it in a fully in the menu Configuration-
charged condition, refresh charges followed by an equalisation charge Battery-High temperature.
will be automatically initiated according to the battery technology. Control the temperature sensor
Similar indications to those displayed in manual start (see above) of the Wi-IQ.
are displayed.
DEF EEP* Memory/Charger menu. Change the main board
DISPLAY OF HISTORICAL DATA PER CHARGE DEF MENU*

For viewing and resetting stored information, please refer to section DEF CFG* Error in configuration or Check the input fuses and the
Memorisations. 1 phase missing 3 phases, if OK, enter the pass-
word, go into the configuration
CHARGER HISTORICAL DATA menu, select charge menu,
select charger list and select
For viewing and resetting the charger history, please refer to section the right configuration on the
Status. list.

MESSAGES AND FAULT CODES

IQ SCAN Look for present Wi-IQ®

IQ LINK Set the link

Fault Cause Solution Wi-IQ-Charger

DF1* Charger problem. DF1 appears when the charger Low electrolyte level Battery water topping up or
is not able to supply its output ensure that the Wi-IQ is
current. Follow the breakdown properly adjusted and
procedure for the charger with installed (see Wi-IQ mounting
control of the IGBT, diode, instructions)
mains voltage …
Default of balance voltage Check each battery cell during
DF2* Output default. Check the correct connection detected by the Wi-IQ discharge.
of the battery (reversed polarity
cables) and the output fuse. Check the Wi-IQ is correctly
set-up (see Wi-IQ instructions
DF3* Wrong battery. Too high or too low battery of mounting).
voltage. Battery voltage must
be between 1.6V and 2.4V per Battery temperature Verify the battery electrolyte
cell. Use correct charger for T too high. level or the correct set up of
the battery. the charger.

DF4 Battery discharged more Charge continues. Check the temperature sensor
than 80% of its capacity. of the Wi-IQ.

DF5 Battery requires DF5 appears when the charging Preventive maintenance Consult a qualified factory
inspection. profile has been achieved with indicator. representative to conduct
a fault condition, that can be a preventive maintenance
current increase in regulation operation.
phase demonstrating a battery
heating or badly programmed (*): blocking fault preventing charging from continuing.
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..).

DF PUMP Fault in the air circuit Check the proper operation of

of the electrolyte the pump via the menu
circulation system. Option-Option test.

Check the air circuit (pump,

tubes).

If this fault occurs, the charger

will adapt the battery charging
profile for a safe, optimised
charge.

TH* Thermal problem in Verify the correct operation of

charger resulting in the fans, check for too high
charge interruption. ambient temperature, or
whether there is poor natural
ventilation to the charger.

STOP* Critical battery electrolyte Top up battery electrolyte level

level in accordance with ‘battery
operating instructions’.

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 Wherever you do business, EnerSys® can support
you with motive power energy. The Hawker® branded
battery range, matched chargers and systems provide
trouble free performance under the most demanding
service conditions. Our strategically located manufacturing
plants are efficient and responsive with a culture of
continuous improvement and added value for our
business partners.

EnerSys has an enviable position in technology leadership

and with significant investment in research and development
we intend to stay at the leading edge in product innovation.
The recently developed energy solutions: Water Less® 20
and Hawker XFCTM batteries, Lifetech and Lifespeed IQTM
HF chargers, have defined new benefits for our customers:
faster recharge, more machine availability, lower operating
and investment costs, reduced carbon footprint. Our team of
development engineers is driven by the desire to build the
best energy solutions and works closely with our customers
and suppliers to identify development opportunities. Our
bias for rapid innovation means we get new products to
market fast.

EnerSys's integrated sales and service network is

dedicated to providing our customers with the best
solutions and after-sales support for their business.
Whether you require 1 battery or a complete fleet of
batteries, chargers, a battery handling system and a
state of the art fleet management system, you can count
on us. EnerSys is the world's largest industrial battery
manufacturer and we are dedicated to being the best.

11.2011 - Subject to revisions without prior notice

European Headquarters: Local contact:

EnerSys EMEA Enersys Ltd
EH Europe GmbH Oak Court
Löwenstrasse 32 Clifton Business Park
8001 Zürich Wynne Avenue
Switzerland Swinton
Phone: +41 44 215 74 10 Manchester M27 8FF
Fax: +41 44 215 74 11 Phone: 0161 794 4611
Fax: 0161 727 3809
Please refer to the website address for details of your nearest EnerSys office:
www.enersys-emea.com

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