EnerSys NexSys CORE Series Troubleshooting guide

Operation and maintenance instructions for NexSys® CORE batteries ENGLISH
Rating Data
1. Nominal capacity C5: see type plate
2. Nominal voltage: see type plate
3. Discharge current: C5/5h
4. Rated temperature: 30°C
NexSys CORE batteries series are valve-regulated lead-acid batteries. Unlike conventional batteries with liquid electrolyte these
batteries have immobilised electrolyte. Instead of a vent plug, a valve is used to regulate the internal gas pressure, preventing
the ingress of oxygen from the air and allowing the escape of excess charging gasses should an overcharged condition occur.
When operating valve-regulated lead-acid batteries the same safety requirements as for vented batteries apply, to protect against
hazards from electric current, from explosion of electrolytic gas and - with some limitations - from the corrosive electrolyte.
Battery valves should never be removed. These batteries do not require topping up with distilled or demineralised water.
1. Commissioning
NexSys CORE batteries are supplied in a charged condition.
The battery should be inspected to ensure it is in perfect
physical condition.
Check:
1. The battery cleanliness. Before installing, the battery
compartment has to be cleaned.
2. The battery end cables have a good contact to terminals
and the polarity is correct. Otherwise the battery, vehicle or
charger could be damaged.
Use special coding systems for maintenance free batteries for
the charging plug- and- socket devices to prevent acciden-
tal connection to the wrong type of charger. Never directly
connect an electrical appliance (for example: warning beacon)
to a part of the battery. This could lead to an imbalance of the
cells during the recharge, i.e. a loss of capacity, the risk of
insufficient discharge time, damage to the cells and voids
the battery warranty. Charge the battery (see 2.2) before
commissioning.
2. Operation
EN 62485-3 “Traction batteries for industrial trucks” is the
standard which applies. The nominal operating temperature
is 30°C. The optimum lifetime of the battery depends on the
operating conditions (temperature and depth of discharge).
The ambient temperature range of use for the battery is
between 0°C and +40°C , any use outside of this range must
be approved by the EnerSys Technical department. Optimal
battery life is obtained with the battery at a temperature of
25-30°C. Higher temperatures shorten the life of the battery
(according to IEC1431 technical report), lower temperatures
reduce the available capacity. The upper ambient temperature
limit is 40°C and batteries should not be operated above 55°C
battery temperature. The capacity of the battery changes with
temperature and falls considerably under 0°C.
The optimum lifetime of the battery depends on the operating
conditions and lifetime will be optimised with 60% DOD or
lower. The maximum permissible discharge is 80% of C5
nominal capacity. The battery obtains its full capacity after
about 3 charging and discharging cycles.
 • 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
EN 62485-3, EN 50110-1.
 • Nosmoking!
 • Do not expose batteries to naked ames,
glowing embers or sparks, as it 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 ushing
consult a doctor immediately!
 • Clothing contaminated by acid should be
washed in water.
 • Riskofexplosionandre.
 • 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 a
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CORE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.
Traction motive power batteries, valve regulated lead acid (VRLA) battery NexSys®CORE series:
TPPL (Thin Plate Pure Lead) technology
SAFETY PRECAUTIONS
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.

2.1 Discharging
The valves on the top of the battery must not be sealed or
covered. Electrical connections (e.g. plugs) must only be
made or broken in the open circuit condition. Discharges over
80% of the rated capacity are categorised as deep discharges
and are not acceptable as they reduce considerably the life
expectancy of the battery. Discharged batteries MUST be
recharged immediately and MUST not be left in a discharged
condition.
Note: The following statement only applies to partially
discharged batteries.
Discharged batteries can freeze. Limit the discharge to a
maximum of 80% DOD. The cycle life of the battery will
depend on the DOD, the higher the DOD, the shorter the
cycle life. The presence of a discharge limiter on the vehicle
is imperative.
The following energy cut-off settings must be used:
• 60%DOD1.96V
• 80%DOD1.92V
when discharged with currents in the range of I1to I5.
The battery is tted with a Low Voltage Alarm (LVA) and
the customer must observe the visual and audible warning
signals that the battery has reached its maximum discharge
level and must be charged immediately.
AtlowercurrentspleaseseekadvicefromEnerSys®Service.
2.2 Charging
NexSys®CORE batteries must be charged using NexSys or
Lifespeed iQ™ Modular chargers. These chargers MUST
be used on these batteries. Non respecting the matching
charges will invalidate any warranty. NexSys CORE batteries
are suitable for both standard duty applications as well as
heavy duty ones. In standard duty applications the charger
(0.2-0.25 charging rate) will recharge the battery from
80% depth of discharge in 6 hours and short opportunity
charges are allowed (up to 20% extra energy reintegrated
in 1 hour). The specific charging profile developed for
recharging NexSys CORE batteries allows a fast recharge
(0.26-0.4 C5) in less than 4 hours 60% DOD and opportunity
charging as often as needed without damaging the bat-
teries. Opportunity charge can be performed up to 80%
extra energy reintegrated (reintegration rate 40% in 1 hour).
Charging
Rate
from 80% DOD
-> Full charge
from 60% DOD
-> Full charge
from 40% SOC
-> 80%
from 40% SOC
-> 98% SOC
0.4 C54.6 4.1 1 2
0.32 C55 4.3 1.25 3.4
0.2 C56.25 5.25 2 4
NexSys CORE batteries have an extremely low gas emission
under normal circumstances. For safety purposes when
calculating gas emission levels, use 1.5A / 100Ah C5.
Nevertheless, provision must be made for venting of the
charging gases. Doors, battery container lids and the covers
of battery compartments must be opened or removed. With
the charger switched off, connect the battery to the charger,
ensuring that the polarity is correct (positive to positive, negative
to negative). Now switch the charger on. NexSys CORE batteries
must receive their full charge at least once a week.
2.3 Equalising charge
NeySysand LifespeediQ chargerswill automaticallyprovide
an equalising charge, following normal full charge (conditions
embedded into the profile).
3. Maintenance
The electrolyte is immobilised. The density of the electrolyte
can not be measured. Never remove the safety valves from
the cell. In case of accidental damage to the valve, contact
EnerSys service for replacement.
3.1 Daily
• Rechargethebatteryaftereverydischarge.
• Check the condition of the plugs, cables and that all
insulation covers are in place and in good condition.
3.2 Weekly
• Visualinspectionforsignsofdirtandmechanicaldamage
to all component parts of the battery, pay particular
attention to the battery charging plugs and cables.
3.3 Quarterly
At the end of the charge, carry out end of charge voltage,
readings, measure and record:
• Thevoltageofthecompletebattery
• Thevoltagesofeachcell
If significant changes from earlier measurements or
differences between the cells are found, please contact
EnerSys service. If the discharge time of the battery is not
sufficient, check:
• That the required work is compatible with the battery
capacity
• Thesettingsofthecharger
• Thesettingsofthedischargelimiteronthevehicle.
3.4 Annually
Remove internal dust from the battery.
Electrical connections: test all connections (sockets, cables,
and contacts). In accordance with EN 1175-1 at least once per
year, the insulation resistance of the truck and the battery
must be checked by an electrical specialist. The tests on
the insulation resistance of the battery must be conducted
in accordance with EN 1987-1. The insulation resistance
of the battery thus determined must not be below a value
of 50 Ω. per Volt of nominal voltage, in compliance with
EN 62485-3. For batteries up to 20 V nominal voltage the
minimum value is 1000Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent
tracking currents. Cleaning must be done in accordance
with the ZVEI code of practice “The Cleaning of Vehicle
Traction batteries”. 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 ensure that the insulation value complies with
EN 62485-3 and to prevent tray corrosion.
Call EnerSys service if it is necessary to remove cells.
Never use (apply ) mineral grease on the battery, the sealing
material of the terminal is incompatible and it can be per-
manently damaged. If it‘s necessary, use (apply) the silicone
greasewithTPFE.
5. Storage
Batteries are dispatched from the manufacturer in a fully
charged condition. The state of charge will decrease with
storage.Allbatterieslosetheirstoredenergywhenallowed
to stand 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 inuenced by
temperature.
If the truck/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, on-board
computer etc) must be switched off. If the truck or battery
is going to be decommissioned for a period of 1 month or
longer, all electronic devices (such as Wi-iQ®, LVA) must be
professionally disconnected by EnerSys service – please
contact us for assistance.
High temperatures greatly reduce storage life.
Standard storage time for a battery not installed into a truck
is1monthwithoutneedtorecharge.Maximumstoragetime
is 6 months at 20°C provided the battery is fully charged
when put into storage and provided that all electronic devices
(LVA,Wi-iQ)orotherequipmentthatcouldcausethebattery
to discharge are disconnected. However, it is advisable to
conduct an inspection and open circuit voltage check after
3 months and implement a refresh charge if necessary.
6. Malfunctions
If malfunctions are found on the battery or the charger,
EnerSys service should be called in without delay. The
measurements taken in point 3.3 will facilitate fault finding
andtheirelimination.Aservicecontractwithuswillmakeit
easier to detect and correct faults in good time.

The two electronic devices will also provide indications
according to the table below.
1. Low Voltage Alarm
Description Comment Stop
Condition
1LED
Slow
ashing
green
Normal operation
1LED Flashing
red
SOC < 40%, the battery
needs to be recharge soon
Battery on
charge
V>2.08V/c
1LED
Flashing
green
(0.2s ON -
5s OFF)
Normal operation,
battery on discharge
1LED
Fast
ashing
green
Normal operation,
battery on charge
2 Buzzer
Beeping
3 times
every
5 minutes
SOC < 40%, the battery
needs to be recharge soon
Battery on
charge
V>2.08V/c
2 Buzzer
Beeping 1
time every
5 seconds
SOC < 20%, the battery
needs to be recharged
immediately
Battery on
charge
V>2.08V/c
2. Wi-iQ®
Description Comment
Tricolour
LED
Green blinking hardware OK
Blue rapid blinking wireless identification
Red blinking temperaturewarning>55°C
Blue LED Rapid blinking wireless identification
Slow blinking voltage balance warning
7. Disposal
NexSys®CORE batteries are recyclable. Scrap batteries must
be packaged and transported in accordance with prevailing
transportation rules and regulations. Scrap batteries must be
disposed of in compliance with local and national laws by a
licensed or certified lead acid battery recycler.
8. Certificate
TricolourLED
BlueLED
1
2

Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries that are not returned for the recycling process must be disposed of as hazardous waste!
www.enersys.com EN-BT-NXC-IU-001-03.2020
ENERSYSSARLRueAlexanderFlemingZIEst–CS40962F-62033ArrasCedex-Francedeclaresunderoursoleresponsibility
that the product:
Product Name:Wi-iQ
Part Number:AA-xxxxxx
to which this declaration relates, is in conformity with the following normative European and International standards:
Health & Safety (Directive 2014/53/EU)
• IEC/EN 61010-1:2010
EMC (Directive 2014/53/EU)
• ETSIEN301489-1,V2.1.1:2016; ETSIEN301489-17,V3.1.1:2016; EN62479:2010;EN 61000-6-2 : 2005
Radio Spectrum (Directive 2014/53/EU)
• EN300328V2.1.1(2016-11)
Date : 06.02.2018, Arras
Name : Bruno Konevetz
Title : Charger Quality Manager EMEA
Signature :
Declaration of Conformity