EnerSys Nexsys 12NXS26 Troubleshooting guide

15
1. Commissioning
NexSys blocs are supplied in a charged condition. The bloc
should be inspected to ensure it is in perfect physical condition.
Check:
1. The bloc compartment and the bloc should be in a clean
condition.
2. The bloc end cables should have a good contact with the
terminals and the polarity is correct.
Use special coding systems for maintenance free blocs for
the charging plug and- socket devices to prevent accidental
connection to the wrong type of charger. Never directly
connect an electrical appliance (for example: warning beacon)
to a part of the bloc. This could lead to an imbalance of the
blocs during the recharge, i.e. a loss of capacity, the risk of
insufficient discharge time, damage to the blocs and voids the
NexSys bloc warranty.
Charge the bloc (see 2.2) before the first discharge. Only blocs
with same state of charge should be connected together.
Operation and maintenance instructions for NexSys®blocs ENGLISH
NexSys®blocs are for small traction applications.
The blocs are lead-acid, valve-regulated utilizing our TPPL (Thin Plate Pure Lead) technology.
Rating Data
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 blocs with liquid electrolyte, NexSys blocs 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 gasses
should an overcharged condition occur. When operating lead-acid, valve-regulated blocs, the same safety requirements apply
as for vented blocs. This will help protect against hazards from electric current from explosion of electrolytic gas and corrosive
electrolyte.
Bloc valves should never be removed. These blocs do not require watering with distilled or demineralized water.
Flexible connectors must be used for all bloc connections. EnerSys®approved fasteners must be used.
SAFETY PRECAUTIONS
WARNING - 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 bloc 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 bloc
warranty.
DANGER
CONTAINS: Lead, Sulfuric Acid (Electrolyte), Lead Compounds.
Harmful if swallowed, inhaled, or in contact with skin. Acid causes severe skin burns and eye damage. May damage fertility
or the unborn child if ingested or inhaled. May cause harm to breastfed children. May cause cancer if ingested or inhaled.
Causes skin irritation, serious eye damage. Contact with internal components may cause irritation or severe burns. Causes
damage to central nervous system, blood and kidneys through prolonged or repeated exposure if ingested or inhaled.
Irritating to eyes, respiratory system, and skin. May form explosive air/gas mixture during charging. Extremely flammable
gas (hydrogen). Explosive, fire, blast or projection hazard. Obtain special instructions before use. Do not handle until all
safety precautions have been read and understood. Wash thoroughly after handling. Do not eat drink or smoke when using
this product. Avoid contact during pregnancy/while nursing. Wear protective gloves/protective clothing, eye protection/face
protection.
Use only outdoors or in a well-ventilated area. Avoid contact with internal acid. Do not breathe
dust/fume/gas/mist/vapors/spray. Keep away from heat/sparks/open flames/hot surfaces.
No smoking IF SWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting.
Call a poison center/doctor if you feel unwell. IF ON CLOTHING OR SKIN (or hair):
Remove/Take off immediately all contaminated clothing and wash it before reuse.
Rinse skin with water/shower. IF INHALED: Remove person to fresh air and keep
comfortable for breathing. Immediately call a POISON CENTER or doctor/physician.
IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses,
if present and easy to do. Continue rinsing. If exposed/concerned, or if you feel
unwell seek medical attention/advice. Store locked up, in a well-ventilated
area, in accordance with local and national regulation. Dispose of
contents/container in accordance with local and national regulation.
Keep out of reach of children.
WARNING: Risk of fire, explosion or burns. Do not
disassemble, heat above 60ºC or incinerate. Ventilate
spaces where used or charged.
High Voltage: Risk of shock. Do not touch
uninsulated terminals or connectors.

The specified torque loading for the bolts/screws of the end
cables and connectors are detailed in the table below:
NexSys®
Bloc Type
Standard
Terminal
Terminal
Torque
Terminal
Adapter
Terminal
Torque
Nm
Nm Ibf
in
Nm Ibf
in
12NXS26
12NXS36
12NXS38
12NXS90
12NXS120
M6
Female
6.8 60 SAE 6.8 60
12NXS61
12NXS85
M6
Female
9.0 80 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
9.0 80 M6 Front
Terminal
9.0 80
2. Operation
The nominal operating temperature is 30°C at C5/C6rate.
The optimum lifetime of the bloc depends on the operating
conditions (temperature and depth of discharge). The ambient
temperature range of use for the bloc is between +5°C and
+45°C, any use outside of this range must be approved by
an EnerSys®representative. Optimal bloc life is obtained
with the bloc at a temperature of 25°C – 30°C. Higher
temperatures shorten the life of the bloc, lower temperatures
reduce the available capacity. The upper temperature limit
is +45°C and blocs should not be operated above this
temperature. The capacity of the blocs changes with
temperature and falls considerably under +10°C. The optimum
lifetime of the bloc depends on the operating conditions
(moderate temperature and discharges equal to or lower
than 60% of the nominal capacity C5/C6). The bloc obtains its
full capacity after about 3 charging and discharging cycles.
2.1 Discharging
The valves on the top of the bloc must not be sealed or
covered.
Electrical connections (i.e. plugs) must only be made or
broken in the open circuit condition. Discharges over 80% of
the rated capacity are categorized as deep discharges and are
not acceptable as they reduce the life of the bloc. Discharged
blocs MUST be recharged immediately and MUST not be left
in a discharged condition.
Note: The following statement only applies to partially
discharged blocs.
Discharged blocs can freeze. Limit the discharge to a
maximum of 80% DOD. The cycle life of the bloc will depend
on the DOD, the higher the DOD, the shorter the cycle life.
The following energy cut-off settings must be used :
• 60% DOD set at 1.96 Volts per cell; or
• 80% DOD set at 1.92 Volts per cell; or
when discharged with currents in the range of I1to I6.
At lower currents please seek advice from an EnerSys®
representative.
2.2 Charging
NexSys®blocs MUST be charged using an EnerSys approved
specified charger. Failure to do so will affect the performance
and life of the bloc and invalidate any warranty. The specific
charging profile, with High Charging Rates, developed for
recharging the NexSys blocs allows a rapid recharge in
3 hours from 60% DOD and opportunity charging as often as
needed without damaging the blocs.
The NexSys blocs have an extremely low gas emission.
Nevertheless, provisions must be made for venting of the
charging gases. Doors, bloc container, lids and the covers of
battery compartments must be opened or removed. With the
charger switched off, connect the bloc to the charger, ensuring
that the polarity is correct. (Positive to positive, negative to
negative). Now switch the charger ON.
2.3 Equalizing Charge
The EnerSys approved charger includes specific features to
ensure that the bloc remains charged and equalized.
3. Maintenance
The electrolyte is immobilized. The density of the electrolyte
cannot be measured. Never remove the safety valves from the
bloc. In case of accidental damage to the valve, contact your
EnerSys representative for replacement.
3.1 Daily
• Recharge the bloc after every discharge.
• Check the condition of the plugs, cables and make sure
that all insulation covers are in place and are in good
condition.
3.2 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 bloc, paying particular attention
to the battery charging plugs and cables.
3.3 Quarterly
At the end of the charge, take end of charge voltage readings,
measure and record:
• The voltage of the complete bloc
• The voltages of each bloc
If significant changes from earlier measurements or differences
between the blocs are found, please contact an EnerSys
representative.
If the run time of the bloc is not sufficient, check the
following:
• That the required work is compatible with the bloc capacity
• The settings of the charger
3.4 Annually
Internal dust removal from the charger.
Electrical connections: test all connections (sockets, cables,
and contacts).
Blocs having terminals with insert: check the torque
loading of the bolts/screws. Test the insulation resistance
of the bloc. Insulation resistance of the bloc thus determined
must not be below a value of 50 Ω. per Volt of nominal
voltage. For blocs up to 20 V nominal voltage the minimum
value is 1000 Ω.
4. Care of the bloc
The bloc should always be kept clean and dry. Any liquid in the
bloc 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.

5. Storage
Blocs are shipped from the manufacturer fully charged. The
state of charge will decrease with storage. All blocs lose
their stored energy when allowed to be in open-circuit, due
to parasitic chemical reactions. The rate of selfdischarge
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 bloc should be stored in a cool dry place,
ideally below 20°C. The bloc has a maximum inspection-free
storage life of 2 years, if stored at or below 20°C, after
which a refresh charge should be administered. However, it is
advisable to conduct an inspection and open circuit voltage
check after 12 months and recharge if the OCV is less than
2.10 Volts per cell. The bloc may be stored for up to 5 years
without degradation of performance provided that an open
circuit voltage (OCV) check is conducted every 12 months.
When stored in temperatures in excess of 30°C, the battery
should be OCV checked every 6 months. The graph below
shows the relationship of battery state of charge as a function
of open circuit voltage.
2.19
2.18
2.17
2.16
2.15
2.14
2.13
2.12
2.11
2.10
2.09
2.08
2.07
2.06
105
100
95
91
86
82
77
72
68
63
58
54
49
45
0 5 10 15 20 25 30 35 40
Months
STATE OF CHARGE AS A FUNCTION OF OPEN CIRCUIT VOLTAGE
OPEN CIRCUIT VOLTAGE
STATE OF CHARGE [%]
2.05 40
2.04 35
30°C 25°C 20°C40°C
6. Malfunctions
If malfunctions are found on the bloc or the charger, please
contact an EnerSys representative. The measurements taken
in paragraph 3.3 will identify problems and help establish a
base to correct them.
7. Disposal
NexSys blocs are recyclable. Scrap blocs must be packaged
and transported in accordance with prevailing transportation
rules and regulations. Scrap blocs must be disposed of in
compliance with local and national laws by a licensed or
certified lead acid OK recycler.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
Pb
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9602-6718 rev 07 / 11-09-17 © 2017 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its
affiliates unless otherwise noted. Subject to revisions without prior notice. E.&O.E.
10.2017