EnerSys Nexsys 12NXS26 User manual

OWNER’S MANUAL
www.enersys.com
NEXSYS®
TPPL BATTERY

CONTENTS
Introduction ...................................... 3
Rating Data ....................................... 4
Safety Precautions ........................... 5
Commissioning................................. 6
Operation .......................................... 7
Discharging ....................................... 7
Charging............................................ 8
Care of the Battery ........................... 8
Storage.............................................. 9
Malfunctions ..................................... 9
Disposal............................................. 9
2

The information contained in this document is critical for
safe handling and proper use of NexSys®TPPL batteries
for powering electrical industrial trucks. 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. 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 the sections on safety and operation of the battery before operating
the battery and the equipment into which it is installed.
It is the owner’s responsibility to ensure the use of the documentation and any activities
related thereto, and to follow all legal requirements applicable to themselves and the
applications in the respective countries.
This owner’s manual is not intended to substitute for any training on handling and
operating the industrial truck or NexSys®TPPL battery that may be required by
local laws and/or industry standards. Proper instruction and training of all
users must be ensured prior to any contact with the battery system.
Refer to the abbreviations and terms at the end of this document.
For service, contact your sales representative or call:
1-800-ENERSYS (USA) 1-800-363-7797
www.enersys.com
www.experiencenexsys.com
Your Safety and the Safety of Others is Very Important
wWARNING You can be killed or seriously injured if
you don’t follow instructions.
INTRODUCTION
3

RATING DATA
Rating Data
NexSys®TPPL batteries are for small traction applications. The batteries are lead-acid and, valve-regulated
utilizing our TPPL (Thin Plate Pure Lead) technology with carbon additive in active material formulation.
1. Nominal capacity C5/C6: See type plate
2. Nominal voltage: See type plate
3. Discharge current: C5/5h or C6/6h
4. Rated temperature: 30°C
Unlike conventional (vented) lead cells and
batteries with free liquid electrolyte, NexSys®TPPL
batteries have immobilized electrolyte. Instead
of a vent plug, a valve is used to regulate the
internal gas pressure, which prevents the ingress of
oxygen and allows the escape of excess charging
gases should an overcharged condition occur.
When operating VRLA batteries, the same safety
requirements should be followed as for vented
batteries. This will help protect against hazards
from explosion of electrolytic gas and corrosive
electrolyte.
Cell or bloc valves should never be removed. These
batteries do not require watering and no attempt to
add water should be made.
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 suitable 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.
4

SAFETY PRECAUTIONS
Safety Precautions
• Pay attention to the operating instructions and keep them close to the battery.
• Work on batteries must only be carried out by skilled personnel!
• Use protective glasses and wear safety clothing when working on batteries.
• Adhere to the current accident prevention rules in the country where the
battery is used or IEC 62485-3, EN 50110-1.
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as these
may cause the battery to explode.
• Avoid sparks from cables or electrical apparatus as well as electrostatic
discharges.
• Acid splashes into the eyes or on the skin must be washed immediately
with an abundance of clean water. After abundant flushing, consult a doctor
immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire.
• Avoid short circuits: do not use non-insulated tools, do not place or drop
metal objects on top of the battery. Remove rings, wristwatches and articles
of clothing with metal parts that might come into contact with the battery
terminals.
• Electrolyte is highly corrosive.
• In the normal operation of this battery, contact with acid isn’t possible. If the
cell containers are damaged, the immobilized electrolyte (absorbed in the
separator) is corrosive like the liquid electrolyte.
• Batteries are heavy. Ensure secure installation! Use only suitable handling
equipment.
• Lifting hooks must not damage the cells, connectors or cables.
• Do not place batteries in direct sunlight without protection. Discharged
batteries can freeze. For that reason, always store in a frost-free zone.
• Dangerous electrical voltage!
• Avoid short circuits: NexSys®TPPL batteries are capable of high short circuit
currents.
• Caution – metal parts of the battery are always live: do not place tools or
other objects on the battery!
• Pay attention to the hazards that can be caused by batteries.
Ignoring the operating instructions, and repair with
non-original parts will render the warranty void. All
failures, malfunctions and fault codes of the battery,
the charger or any other accessories, must be
notified to EnerSys®service immediately.
wWARNING Do NOT use any type of oil, organic
solvent, alcohol, detergent, strong acids, strong
alkalis, petroleum-based solvent or ammonia
solution to clean the jars or covers. These materials
may cause permanent damage to the cell or battery
jar and cover and will void the warranty.
Failure to follow these operation and maintenance
instructions or using parts that are non-original will
void the NexSys®TPPL battery warranty.
5

COMMISSIONING
Commissioning
NexSys®TPPL cells and batteries are supplied in a
charged condition. The battery should be inspected
to ensure it is in proper physical condition.
Check:
1.The battery compartment and the battery
should be in a clean condition.
2.The battery end cables have good contact with
the terminals and the polarity is correct.
Use special coding systems for maintenance-free
batteries for the charging plug and socket devices
to prevent accidental connection to the wrong type
of charger.
Never directly connect an electrical appliance
(i.e. warning beacon) to a part of the battery. This
could lead to an imbalance of the cells. This will
damage all cells in the battery and void the battery
warranty. A DC-DC converter must be used to
supply any low voltage loads.
NexSys®TPPL battery units that are assembled into
strings must use flexible cable connections with
adequate length to ensure there is no stress on
the terminal due to battery movement. EnerSys®-
approved fasteners must be used. The valves
on the top of the battery must not be sealed or
covered. NexSys®TPPL batteries may be installed
in any direction except inverted. Only batteries with
the same state of discharge should be connected
together.
Charge the battery (see “Charging” on page 8)
before the first discharge. Sufficient controls should
be enacted (colored connectors, Wi-iQ®device, etc)
to ensure the battery is only charged using an
EnerSys®-approved charger with the appropriate
approved NexSys®TPPL battery charging profile.
NexSys®TPPL
Battery Type Standard Terminal
Terminal Torque
Terminal Adapter
Terminal Torque Nm
Nm Ibf in Nm Ibf in
12NXS26
12NXS36
12NXS38
12NXS50
12NXS62
12NXS90
12NXS120
M6 Female 6.8 60 SAE 6.8 60
12NXS61
12NXS85 M6 Female 9.0 80 N/A N/A N/A
12NXS86 3/8–16" Female 6.8 60 SAE 6.8 60
12NXS137
12NXS157 M6 Female
9.0 80 M6 Front Terminal 9.0 80
12NXS166
12NXS186 M8 Female
All 2-Volt
Cells M10x1.5 Female 25.0 222 None N/A N/A
The specified torque loading for the bolts/screws of the end cables and connectors are
detailed in the table below:
6

OPERATION
Operation
The nominal rated capacity is at a battery
temperature of 30°C (86°F) for C5 or 25°C (77°F) for
C6. The optimum lifetime of the battery depends
on the operating conditions (temperature and
depth of discharge). Higher temperatures shorten
the life of the battery; lower temperatures reduce
the available capacity. The capacity of the battery
falls considerably under an internal temperature
of 5°C (41°F). Optimal battery life is obtained when
the battery is operated, charged and stored in
an ambient temperature between 5°C (41°F) and
30°C (86°F); and discharges are equal to or lower
than 60% of the nominal C6 capacity. Operation of
the battery outside of the optimum temperature
range may require the use of a Wi-iQ®device
and NexSys®+ charger for proper temperature-
adjusted charging. The acceptable ambient
operating temperature range for the discharge of
NexSys®TPPL batteries is between -29°C (-20°F)
and 45°C (113°F). The acceptable ambient charging
temperature range is between 0°C (32°F) and 45°C
(113°F). Consult an EnerSys®representative for the
proper equipment selection for your application.
The battery obtains its full capacity after about 3
charging and discharging cycles. The valves on the
top of the battery must not be sealed or covered
during storage or operation. Electrical connections
(i.e. plugs) must only be made or broken while
the battery is in the open circuit condition (not
charging or discharging).
Discharging
Discharges over 60% DOD of the rated capacity
are categorized as deep discharges and are
not acceptable as they reduce the life of the
battery. Discharged batteries MUST be recharged
immediately and MUST not be left in a discharged
condition. The cycle life of the battery will depend
on the DOD; the higher the average DOD, the
shorter the cycle life.
Partially discharged and fully discharged batteries
can freeze, which irreversibly damages the battery.
Limit the discharge to a maximum of 60% DOD in
cold climates, and recharge immediately.
The battery may be fitted with a Protection from
Over-Discharge™ (POD™) device to provide
visual and audible warning signals. An observed
warning signal indicates the battery has reached
its maximum discharge level and must be charged
immediately.
The following load cut-off settings must be used :
• 50% DOD at an average loaded voltage of 1.98
volts per cell, or
• 60% DOD at an average loaded voltage of 1.96
volts per cell
when discharged at average loads with currents in
the range of I4 to I8. At average currents outside
of this range, please seek advice from an EnerSys
representative for energy cut-off settings.
7

CHARGING AND CARE
Care of the Battery
NexSys®TPPL batteries are maintenance-free and
it is not possible to add water nor measure SG
of the battery. The electrolyte is immobilized and
the density of the electrolyte cannot be measured.
Never remove the safety valves from the battery.
In case of accidental damage to the valve, contact
your EnerSys representative for replacement.
The battery should always be kept clean and dry.
Any liquid in the battery tray must be extracted
and disposed of in the prescribed manner. Damage
to the insulation of the tray should be repaired
after cleaning to prevent corrosion.
Daily:
• Recharge the battery after every discharge.
• Check the condition of the plugs and cables, and
make sure that all insulation covers are in place
and are in good condition.
Weekly:
• Allow up to 6 hours for a full charge at least once
per week.
• Visually inspect for signs of dirt and mechanical
damage to all component parts of the battery,
paying particular attention to the battery
charging plugs and cables.
Quarterly:
At the end of the charge, take end-of-charge
voltage readings, measure and record:
• The voltage of the complete battery.
• The voltages of individual cells or blocs.
If significant changes from earlier measurements
or differences between the batteries are found,
please contact an EnerSys representative.
If the run time of the battery is not sufficient, check
the following:
• That the required work is compatible with the
battery capacity.
• That the battery has been plugged in at all
opportunities.
• The settings of the charger.
Annually: Check the torque loading of the bolts/
screws on bloc-type products. Test the insulation
resistance of the battery. Insulation resistance of
the battery thus determined must not be below
a value of 50 Ωper volt of nominal voltage. For
batteries up to 20V nominal voltage the minimum
value is 1000 Ω.
Charging
NexSys®TPPL batteries MUST be charged using
an EnerSys-approved charger with the appropriate
approved NexSys®TPPL battery charging profile.
Failure to do so will affect the performance and
life of the battery and invalidate any warranty. The
specific charging profile developed for recharging
NexSys®TPPL batteries allows opportunity charging
as often as needed without damaging the batteries.
Charge rate must be maintained between 0.18C6
and 0.40C6 for 2-volt cells and 0.18C6 and 0.70C6 for
12-volt blocs, depending on the battery and charger
type. NexSys®TPPL batteries have extremely low
gas emission rates. Nevertheless, provisions must
be made for venting of the charging gases. Battery
container lids and vehicle compartments must
always provide adequate ventilation. To allow for
some recombination inefficiency, NexSys®TPPL
batteries should be considered to have a gassing
rate of 1A per 100 Ah.
Equalizing Charge: EnerSys-approved chargers
include specific features to ensure that the battery
remains properly charged and equalized.
8

STORAGE
Storage
Batteries are shipped from the manufacturer fully
charged. The state of charge will decrease with
storage. All batteries lose their stored energy
when allowed to be in open-circuit, due to parasitic
chemical reactions. The rate of self-discharge
is non-linear and decreases with decreasing
state of charge. It is also strongly influenced by
temperature. High temperatures greatly reduce
storage life. It is recommended that the fully
charged battery should be stored in a cool dry
place, ideally below 20°C (68°F), but no lower than
5°C (41°F).
If the vehicle is going to be unused for periods
in excess of 48 hours, the ignition key must be
removed and any auxiliary equipment (such as
lights, beacons, onboard computer, etc.) must be
switched off. If the truck or battery is going to be
decommissioned for a period of one month or
longer, all electronic devices (such as Wi-iQ device,
POD device) must be professionally disconnected
by an EnerSys service representative.
The NexSys®TPPL product has a maximum
inspection-free storage time of 18 months, if
stored at or below 20°C (68°F) with no electronic
devices connected. After this time a refresh charge
should be administered. However, it is advisable
to conduct an inspection and Open Circuit Voltage
(OCV) check after 12 months and recharge if the
OCV is less than 2.10 volts per cell. When stored
at temperatures in excess of 30°C (86°F), the
battery should be OCV checked every six months.
The graph below shows the relationship between
temperature, storage time and OCV.
A new battery may be stored for up to two years
without degradation of performance provided that
an OCV check is conducted every 12 months and
refresh charges are administered as needed.
Malfunctions
If malfunctions are found on the battery or the
charger, please contact an EnerSys representative.
The measurements taken in Quarterly Section of
Care of the Battery will identify problems and help
establish a base to correct them.
Disposal
NexSys®TPPL batteries must be recycled. End-of-
life batteries must be packaged and transported
in accordance with prevailing transportation rules
and regulations. End-of-life batteries must be
disposed of in compliance with local and national
laws by a licensed or certified lead battery recycler.
9

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