SDS

COMMISSIONING
Check:
1.
The battery cleanliness. Before installing, the battery
compartment also has to be cleaned.
2.
All cables and crimped connectors are in good condition to support high
electrical currents.
3.
The battery and cables have a good contact to terminals and the
polarity is correct. Otherwise the battery, vehicle or charger could be
severely damaged.
4.
Ensure that all insulation covers are fitted correctly.
5.
It is extremely important to ensure the integrity of battery
connections. Multi-point crimping must be used.
NOTE: Flexible cable or
braid
connectors
must
be
used
for
all
bloc
connections. Appropriate
fastener kits and
approved
parts
must
be
used. These can be supplied in EnerSys

approved accessory kits.
Integral to the fasteners system is an appropriate locking washer.
Spring-flat washers must not be used.
Connectors must be adequately fastened (see Table 3) with the locking
washer in place to maintain contact integrity when exposed to
operational shock/vibrations.
Use a special coding system for NexSys TPPL blocs for the charging plug-and-
socket devices to prevent accidental connection to the wrong type of charger.
Never directly connect an electrical appliance (ie: 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 before commissioning. Only blocs with the same state of
charge should be connected together.
The specified torque loading for the bolts/screws of the end cables and
connectors are detailed in the Table 3.
OPERATION
EN 50272-3 "Safety requirements for secondary batteries and battery
installations. Part 3 traction batteries” is applicable to this product range. The
nominal operating temperature is 77°F (25°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
50°F (10°C) and 113°F (45°C). Temperatures outside of this range must be
approved by the EnerSys Technical Department. Optimal battery life is
obtained at a temperature of 77°F (25°C). Higher temperatures shorten the life
of the battery (according to IEC1431 technical report); lower temperatures
reduce the available capacity. It is mandatory that the depth of discharge does
not exceed 80% of the nominal C
6
capacity.
Figures 5 and 6 show the relationship between depth of discharge and cycle
life.
OPERATING TEMPERATURE
DISCHARGING
The valves on the top of the battery must not be sealed or covered. Electrical
connections (i.e. lugs) 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 considerably reduce
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.
Partially discharged and fully discharged batteries can freeze. Limit the
discharge to 80% DOD. The presence of a Protection from Over
Discharge (POD) device is mandatory and cut-off voltage must be set
at the value detailed in Table 4,
when discharging with
currents
in
the range of I1 to I5. At lower currents, please seek advice from the
EnerSys Application Engineering Authority.
80% DOD
Cut-off voltage setting [Vpc]
60% DOD 1.96 V
1.92 V
The NexSys
®
blocs are supplied in a charged state. The battery should be
inspected to ensure it is free from defects.
Table 3 – Torque settings
The battery obtains its full capacity after about three charging and
discharging cycles.
Table 4 - Cut-off voltage limits
NexSys
®
batteries and EnerSys approved chargers are designed for use
within an ambient temperature range of 50°F (10°C) to 113°F (45°C). For
use outside this range, you should consult with EnerSys Technical
Department. Applications outside the recommended temperature range will
be considered, but it will be mandatory to use an EnerSys charger with
communication capability and the battery must be equipped with Wi-iQ
®
monitoring device to manage the charge profile in accordance with the
battery temperature. The upper temperature limit is 113°F (45°C) and
batteries should not be operated above this temperature.
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