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 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.

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