Operation and maintenance instructions for NexSys
®
CORE batteries
ENGLISH
Rating Data
1. Nominal capacity C
5
:
see type plate
2. Nominal voltage:
see type plate
3. Discharge current:
C
5
/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 C
5
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 flames,
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 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 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.
