instruction manual block & traction batteries · traction batteries and 0°c to 40°c for the...

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Instruction ManualBlock & Traction batteries

NexSys® series batteries : Valve regulated lead acid (VRLA) , Thin Plate Pure Lead (TPPL) technology

1. Nominal capacity C5 : See Battery plate / decal2. Nominal voltage : See Battery plate / decal3. Discharge current : C5/5h4. Rated temperature : 30°C

The NexSys® battery series are valve-regulated lead-acid with Thin Plate Pure Lead technology, available in both traction and block types. Unlike conventional batteries with liquid electrolyte NexSys 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 gases 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 de-mineralised water. EnerSys® approved fasteners and flexible connectors must be used for all connections.

Ignoring the operating instructions, repair with non-original parts and disconnection of the Wi-IQ® or LVA controller , where fitted, will render the warranty void. All failures, malfunctions or defaults of the battery, the charger or any other accessories, must be notified to our Service department immediately.

Rating Data

Pay attention to the operating instructions and keep them close to the battery.Work on batteries should be carried out by skilled personnel only

Use protective glasses, clothes and footwear when working on batteries.Pay attention to local accident prevention rules or DIN EN50272-3 / IEC 62485_3 DIN EN50110-1 & AS/NZ1 337

No smoking!Do not expose batteries to naked flame, glowing embers or sparks, as it may cause the battery to explodeAvoid sparks from cables or electrical apparatus and electrostatic discharges.

Acid splashes into the eyes or on the skin must be washed immediately with plenty of clean water. After flushing, consult a doctor immediatelyClothing contaminated by acid should be washed in water

Do not remove the vent capsElectrolyte is highly corrosiveIn normal operation of this battery, contact with acid is not possible. If the cell containers are damaged, the immobilised electrolyte (absorbed in the separator) is corrosive like liquid electrolyte

Risk of explosion and fireAlways use insulated tools. Metal parts of battery are always live. Do not place tools or other metal objects such as jewelry on top of the battery!

Dangerous electrical voltage!Avoid short circuitsNexSys batteries are capable of high short circuit currents

Batteries are heavy!Ensure a secure installation and use only suitable lifting equipmentLifting hooks must not damage battery, connectors or cablesDo not place batteries in direct sunlight without protectionDischarged batteries can freeze - always store in a frost free zone

Pay attention to the environmental hazards that can be caused by the wrong disposal of batteriesDispose of batteries correctly according to the relevant local rules

Safety Precautions

NexSys® batteries are supplied in a fully charged condition. The battery should be inspected to ensure it is in perfect physical condition prior to placing into service.The battery cables must have good contact to terminals, check that the polarity is correct otherwise battery, vehicle or charger could be damaged.Never directly connect an electrical appliance (for example a warning beacon) to a part of the battery. This could lead to an imbalance of the cells during recharge with loss of capacity, risk of insufficient charge time and damage to cells, effecting battery life and VOIDING THE WARRANTY.Charge the battery (see point 4.0) before use and in the case of NexSys blocks, only blocks with the same state of charge should be connected together.The specified torque loading for the bolts of the cables and connectors for both NexSys blocks and traction batteries are detailed below.

Block Battery

Terminal TorqueStandard Terminal

Terminal TorqueTerminal Adaptor

12NXS26

M6 Female 6.8 Nm SAE 6.8 Nm

12NXS36

12NXS38

12NXS90

12NXS120

12NXS61 M8 Female 9.0 Nm NA NA

12NXS85

12NXS86 3/8 - 16” Female 6.8 Nm SAE 6.8 Nm

12NXS137 M6 Female 9.0 Nm

M6 MaleFront

Terminal9.0 Nm

12NXS157

12NXS158 M8 Female 9.0 Nm

M6 MaleFront

Terminal9.0 Nm

12NXS177

Traction Battery Terminal Torque (all connector and cable)

All Cells 25Nm +/- 2

Use special coding systems (colour plug etc) for NexSys batteries on the charging plug and socket devices to prevent accidental connection to a wrong type of charger.

DIN EN50272-3 / IEC 62485_3 and AS2402.2.2-2005 AS2359.2-1985 Part 2.7 apply to the operation of sealed VRLA traction batteries and battery electric industrial trucks in general.The optimum life of the battery depends on the operating conditions (temperature and depth of discharge).The ambient temperature range of use is 5°C to 45°C for traction batteries and 0°C to 40°C for the blocks. Any use outside of this range must be approved by the EnerSys®

technical department.

Optimal battery life is obtained with a battery temperature of 15-35°C.Higher temperatures shorten the life of the battery (according to IEC1431), lower temperatures reduce the available capacity which falls considerably under 0°C.The battery obtains its full capacity after about 3 charging and discharging cycles.

The cycle life of the NexSys block and traction battery will be maximized if the batteries are shallow discharged and recharged as often as practicable. Depths of Discharge (DOD) to 40% of rated C5 capacity are the optimum level, followed by a recharge.NexSys batteries are ideally suited to opportunity charging and can operate in a Partial State of Charge (PSOC) condition without any adverse effect on performance or service life. The cycle life of the battery is dependent on the Depth of Discharge (DOD). The higher the DOD, the shorter the cycle life. Always limit the discharge to a maximum of 80% DOD. Discharges over 80% are categorized as deep discharges and are not allowed as they will considerably reduce the life expectancy of the battery or cause permanant damage.The presence of a discharge limiter on the vehicle is imperative. The following voltage cut-off settings must be used. (When discharged with currents in the range of I1 to I5)60% DOD set at 1.96 Volts per cell.80% DOD set at 1.92 Volts per cell.For batteries fitted with an LVA, the customer must observe the visual and audible warning signals that the battery has reached the required discharge levels and must be recharged immediately.Safety when discharging -The valves on top of the battery must not be removed, sealed or covered. Electrical connections (e.g. plugs) must only be connected or disconnected in the open circuit condition. Discharged batteries MUST be recharged immediately and MUST not be left in a discharged condition. Discharged batteries can freeze.

NexSys batteries MUST be charged using an approved NexSys charger. Failure to do so will affect the performance and life of the battery and void any warranty. The specific charging profile developed for NexSys blocks (NXBLOC) will allow rapid recharge in 3 to 6 hours from 60% DOD at charge rates 0.2 to 0.7 C5 with opportunity charging as often as needed without damaging the batteries - see technical manual.The NexSys traction battery series are available for both Standard duty and Heavy duty applications. In Standard duty applications the charger has NXSTND profile at a charge rate of 0.20 C5, and should recharge the battery in less than 6 hours from 60% depth with opportunity charging allowed (up to 20% extra energy reintegrated in 1 hour). In Heavy Duty applications the charger has NXFAST profile at charge rates 0.25 to 0.40 which allows fast recharge in 3.5 to 4 hours at 60% DOD with opportunity charging allowed up to 80% extra energy reintegrated (40% in 1h).

1. Commissioning Battery

2. Operation

3. Discharging

4. Charging

Charge rateC5

80% DOD> Full

charge

60% DOD> Full

charge

40% SOC

> 80% SOC

40% SOC

> 98% SOC

Traction Battery

0.4 4.2 3.4 1.2 2.0

0.32 5.0 4.0 1.5 3.4

0.2 7.4 5.8 2.4 4.0

Block Battery

0.7 2.8 2.37 0.7 0.9

0.5 3.6 2.9 1.0 1.5

0.2 7.4 5.8 2.4 4.0

Table above shows estimated charge times based on % DOD. Times may vary.It is important that the battery receives a complete charge (returning battery to 100% of its rated capacity) at least once per week. NexSys® batteries have an extremely low gas emission, however provision must be made for the venting of charging gases should any error in charging occur.For safety purposes when calculating gas emission levels, use 1.5A / 100AhC5. Doors, battery container lids and the covers of battery compartment 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.Always switch the charger OFF before disconnecting the battery.

NexSys chargers include specific automatic features embedded in the profile to ensure that the battery remains fully charged and balanced.

The electrolyte is immobilised, therefore the density of the electrolyte cannot be measured. Never refill with water!Never remove the safety valves from the blocks or cells. The battery should always be kept clean and dry to prevent current leakage. Damage to the coating of the tray should be repaired after cleaning, to ensure a good insulation and to prevent tray corrosion. If any service is required or any damage has occurred to any component of the system, please contact our Service Department without delay.

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.

Visually inspect for signs of dirt and mechanical damage to all components of the battery, paying particular attention to the battery charging plugs and cables.Ensure that the battery receives a full charge each week.

At the end of the charge, carry out end of charge voltage readings, measure and record the voltage of the complete battery and the voltages of the individual blocks or cells.If significant changes from earlier measures or differences between the blocks or cells are found, please contact our Service Department.If the discharge time of the battery is not sufficient, • Check that the required work load and pattern is compatible with the battery capacity.• The capacity and settings of the charger are correct and sufficient charge time is being applied.• The vehicle discharge limiter settings are correct.

Remove dust from inside the charger.Test all electrical connections of battery and charger (sockets, cables, and contacts).Check the torque loading of all the bolts and screws on the batteries.Check the insulation resistance of the truck and battery in accordance with DIN EN 1175-1, DIN EN 1987 part 1.

Batteries are dispatched from the manufacturer in a fully charged condition. The state of charge will decrease with storage when allowed to stand due to chemical reaction or parasitic standing loads. 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 battery be stored in a fully charged condition in a cool dry place, ideally below 20°C, with no parasitic standing loads and unplugged from the truck.If the truck or battery is going to be decommissioned for a period of 1 month or longer, disconnect battery from truck and professionally disconnect all electronic devices (such as the Wi-IQ®, LVA™). Contact our Service Department for assistance.It is advisable to conduct regular inspections of the Open Circuit Voltage (o.c.v) and recharge if the o.c.v is less than 2.10 Volts per cell.The graph below shows the relationship between temperature storage time and o.c.v. when not installed in vehicle.

6. Maintenance

6.1 Daily Maintenance

6.2 Weekly Maintenance

6.3 Quarterly Maintenance

6.4 Annual Maintenance

7. Storage

5. Equalise Charging

If malfunctions are found on the battery or the charger, our Service Department should be called without delay. The measurements taken in point 6.3 will facilitate fault finding and their elimination.A service contract with us makes it easier to detect and correct faults in good time.

NexSys® batteries are lead acid and are therefore very recyclable. Scrap batteries must be packaged and transported in accordance with local transportation regulations and disposed of in compliance with local and national laws by a licensed recycler.

NexSys batteries could be fitted with both the Wi-IQ® and LVA™ battery monitoring devices.The Wi-IQ device provides visual warnings to the operator on the current status of the battery. Refer to table below. The Wi-IQ also measures current and Ah throughput. The information is stored in memory and can be transferred to a computer via the Wi-IQ Reporting Suite software.The Low Voltage Alarm (LVA) device alerts the user that the battery requires recharge. By analyzing the battery voltage during operation and storage the LVA emits a visible and audible signal to alert the user of the impending and immediate need to recharge the battery.

8. Malfunction

9. Disposal

10. On Board Electronic systems

LVA™ (Low Voltage Alarm) - Default settingsCustom SOC warning setting available

Description Comment Stop

LEDSlow

flashing green

Normal Operation

LEDFast

flashing green

Normal OperationBattery on

charge

LED

Flashing green

0.2s ON5s OFF

Normal OperationBattery on discharge

LED Flashing Red

SOC less than 40%Needs to be recharged

Recharge batteryV >2.08

vpc

Buzzer

Beep3 timesevery

5 minutes



vpc

Buzzer

Beep 1 timeevery

5 seconds



vpc

Wi-IQ®

Description Comment

Tri ColourLED

Flashing green Hardware OK

Fast flashing blue Wireless ID

Flashing red

TempWarning

Over 55°C

BlueLED

Fastflashing Wireless ID

Slow flashing

VoltageBalancewarning

Tricolour LEDBlue LED

BuzzerLED

NexSys® BlockDate: Open Circuit Voltage Date: Open Circuit VoltageBlock 1 Block 1Block 2 Block 2Block 3 Block 3Block 4 Block 4

Date: Open Circuit Voltage Date: Open Circuit VoltageBlock 1 Block 1Block 2 Block 2Block 3 Block 3Block 4 Block 4





NexSys® Traction BatteryS/N: Date:

Cell Open Circuit Voltage Cell Open Circuit

Voltage Cell Open Circuit Voltage Cell Open Circuit

Voltage1 13 25 372 14 26 383 15 27 394 16 28 405 17 296 18 307 19 318 20 329 21 3310 22 3411 23 3512 24 36

S/N: Date:

Cell Open Circuit Voltage Cell Open Circuit

Voltage Cell Open Circuit Voltage Cell Open Circuit

Voltage1 13 25 372 14 26 383 15 27 394 16 28 405 17 296 18 307 19 318 20 329 21 3310 22 3411 23 3512 24 36

Back to the manufacturer!Batteries with this sign must be recycled.Batteries not returned for the recycling process must be disposed of as hazardous waste!

When using motive power batteries and chargers, the operator must comply with the current standards laws, rules, and regulations in force in the country of use !

Publication: MPANXS10.2016 © 2016 EnerSys. All rights reserved. All trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted.Subject to revisions without prior notice. E&OE

SingaporeNo. 85 Tuas Ave 1Singapore, 639518+65 6558 7333

Japan5F Mitaka Mitsubishi BuildingShimorenjyaku 3-26-12Mitaka, 181 0013Tokyo+81 0422 70 3831

Australia / New Zealand46 Egerton StreetSilverwater, NSW, 2128Australia+61 2 9739 9999

MalaysiaNo. 10 Jalan Anggerik Mokara 31/47Kota Kemuning, Seksyen 3140460 Shah AlamSelangor Darul Ehsan, Malaysia+60 3 5125 1111

IndiaPlot No. 1057M, 1st FloorRoad #45, Jubilee HillsHyderabad, 500033+91 40 670 46701

ChinaRoom 902, Sheng Gao Int. BuildingNo. 137 Xian Xia RoadShanghai, PRC, 200131+86 21 6273 6300

Asia Regional Headquarters#11-03Gateway East Building152 Beach RoadSingapore, 189721

instruction manual block & traction batteries · traction batteries and 0°c to 40°c for the...

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