NEXSYS 12NXS137 TPPL Batteries Blocs Owner’s Manual
- September 12, 2024
- NexSys
Table of Contents
12NXS137 TPPL Batteries Blocs
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Specifications
- Nominal capacity C5/C6:
- Nominal voltage:
- Discharge current:
- Rated temperature:
Product Usage Instructions
Safety Precautions
Before using the battery, ensure you follow these safety
precautions:
-
Do not remove cell or bloc valves.
-
Avoid placing metal objects on top of the battery.
-
Check for damaged cell containers as the immobilized
electrolyte can be corrosive. -
Store the battery in a frost-free zone to prevent
freezing. -
Avoid using oil, organic solvents, alcohol, or other chemicals
to clean the battery as it may cause damage and void the
warranty.
Commissioning
When commissioning the battery, follow these steps:
-
Ensure the battery compartment and battery are clean.
-
Check that battery end cables have good contact with terminals
and correct polarity. -
Use special coding systems for maintenance-free batteries to
prevent wrong charger connection. -
Avoid directly connecting electrical appliances to the battery;
use a DC-DC converter for low voltage loads.
Terminal Torque Specifications
Battery Model| Terminal Size| Terminal Torque (Nm)| Terminal Torque (Ibf in)|
Terminal Adapter
---|---|---|---|---
12NXS26, 12NXS36, 12NXS38, 12NXS50, 12NXS62, 12NXS90,
12NXS120| M6x1.0 Female| 6.8| 60| SAE
12NXS61, 12NXS85| M6x1.0 Female| 9.0| 80| N/A
12NXS86, 12NXS137, 12NXS157| M6x1.0 Female| 6.8| 60| SAE
12NXS166, 12NXS186| M8x1.25 Female| 9.0| 80| N/A
All 2-Volt Cells| M10x1.5 Female| 25.0| 222| SAE
Frequently Asked Questions (FAQ)
Q: What should I do if I notice damage to the cell
containers?
A: If you notice any damage to the cell containers, do not
attempt to use the battery and contact your service representative
for assistance.
Q: Can I use any cleaning materials on the battery?
A: Avoid using any type of oil, organic solvent, alcohol,
detergent, strong acids, strong alkalis, petroleum-based solvent,
or ammonia solution to clean the battery as this may cause
permanent damage and void the warranty.
Q: How should I store the battery to prevent freezing?
A: Always store the battery in a frost-free zone to prevent
freezing which can damage the battery.
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NEXSYS® TPPL BATTERIES
OWNER’S MANUAL
www.enersys.com
CONTENTS
Introduction ……………………………….. 3 Rating Data ………………………………… 4 Safety Precautions
……………………… 5 Commissioning…………………………… 6 Operation …………………………………… 7 Discharging
………………………………… 7 Charging …………………………………….. 8 Care of the Battery ……………………… 8
Storage ………………………………………. 9 Malfunctions ………………………………. 9 Disposal
……………………………………… 9 Terms and Abbreviations…………….. 10
2
INTRODUCTION
The information contained in this document is critical for safe handling and
proper use of NexSys® TPPL batteries for powering electrical industrial
equipment. It contains a global system specification as well as related safety
measures, codes of behavior, a guideline for commissioning and recommended
maintenance. This document must be retained and available for users working
with and responsible for the battery. All users are responsible for ensuring
that all applications of the system are appropriate and safe, based on
conditions anticipated or encountered during operation.
This owner’s manual contains important safety instructions. Read and
understand the sections on safety and operation of the battery before
operating the battery and the equipment into which it is installed.
It is the owner’s responsibility to ensure the use of the documentation and
any activities related thereto, and to follow all legal requirements
applicable to themselves and the applications in the respective countries.
This owner’s manual is not intended to substitute for any training on handling
and operating the industrial equipment or NexSys® TPPL battery that may be
required by local laws and/or industry standards. Proper instruction and
training of all users must be ensured prior to any contact with the battery
system.
Refer to the terms and abbreviations at the end of this document.
For service, contact your sales representative or call: 1-800-ENERSYS (USA)
1-800-363-7797 www.enersys.com
www.experiencenexsys.com For other regions, please visit
https://www.enersys.com/en/sales-services/
Your Safety and the Safety of Others is Very Important
w WARNING You can be killed or seriously injured if you don’t follow
instructions.
3
RATING DATA
NexSys® TPPL batteries are for traction applications. The batteries are lead- acid and valve-regulated utilizing EnerSys® TPPL (Thin Plate Pure Lead) technology.
Rating Data
1. Nominal capacity C5/C6: 2. Nominal voltage: 3. Discharge current: 4. Rated
temperature:
See type plate (C5 for EMEA/C6 for North America) See type plate C5/5h or C6/6h (C5 for EMEA/C6 for North America) 30 °C (86 °F) for C5 or 25 °C (77 °F) for C6
Unlike conventional (vented) lead cells and batteries with free liquid
electrolyte, NexSys® TPPL batteries have immobilized electrolyte. Instead of a
vent plug, a valve is used to regulate the internal gas pressure, which
prevents the ingress of oxygen and allows the escape of excess charging gases
should an overcharged condition occur. When operating VRLA batteries, the same
safety requirements should be followed as for vented batteries. This will help
protect against hazards from explosion of electrolytic gas and corrosive
electrolyte.
Cell or bloc valves should never be removed. These batteries do not require
watering and no attempt to add water should be made.
Any data, descriptions or specifications set forth herein are subject to
change without notice. Before
using the product(s), the user is advised and cautioned to make their own determination and assessment of the suitability of the product(s) for the specific use in question, and is further advised against relying on the information contained herein as it may relate to any general use or indistinct application. It is the ultimate responsibility of the user to ensure that the product is suitable and the information is applicable to the user’s specific application. The product(s) featured herein will be used under conditions beyond the manufacturer’s control and therefore all warranties, either expressed or implied, concerning the fitness or suitability of such product(s) for any particular use or in any specific application, are disclaimed. The user expressly assumes all risk and liability, whether based in contract, tort or otherwise, in connection with the use of the information contained herein or the product itself.
4
SAFETY PRECAUTIONS
Safety Precautions
· 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. ·
Follow all local regulations and safety codes. Where no regulations or codes
exist, follow IEC 62485-3 and EN 50110-1.
· No smoking! · Do not expose batteries to naked flames, glowing embers or
sparks, as these
may cause the battery to explode. · Avoid sparks from cables or electrical
apparatus as well as electrostatic
discharges.
· Acid splashed 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,
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® TPPL 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.
Ignoring the operating instructions, and repairing 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.
w WARNING Do NOT use any type of oil, organic solvent, alcohol, detergent,
strong acids, strong alkalis, petroleum-based solvent or ammonia solution to
clean the jars or covers. These materials may cause permanent damage to the
cell or battery jar and cover, including safety risks involving electrolyte,
and will void the warranty.
Failure to follow these operation and maintenance instructions or using parts
that are non-original will void the NexSys® TPPL battery warranty.
5
COMMISSIONING
Commissioning
NexSys® TPPL cells and batteries are supplied in a charged condition. The
battery should be inspected to ensure it is in proper physical condition.
Check: 1.The battery compartment and the battery should be in a clean
condition. 2.The battery end cables have good contact with the terminals and
the polarity is correct.
Use special coding systems for maintenance-free batteries for the charging
plug and socket devices to prevent accidental connection to the wrong type of
charger.
Never directly connect an electrical appliance (e.g. warning beacon) to a part
of the battery. This could lead to an imbalance of the cells. This will damage
all cells in the battery and void the battery warranty. A DC-DC converter must
be used to supply any low voltage loads.
NexSys® TPPL battery units that are assembled into strings must use flexible
cable connections with adequate length to ensure there is no stress on the
terminal due to battery movement. EnerSys®approved fasteners must be used. The
valves on the top of the battery must not be sealed or covered. NexSys® TPPL
batteries may be installed in any direction except inverted. Only batteries
with the same state of discharge should be connected together.
Charge the battery (see “Charging” on page 8) before the first discharge.
Sufficient controls should be enacted (colored connectors, Wi-iQ® device,
etc.) to ensure the battery is only charged using an EnerSys®-approved charger
with the appropriate approved NexSys® TPPL battery charging profile.
The specified torque loading for the bolts/screws of the end cables and connectors are detailed in the table below:
NexSys® TPPL Battery Type Standard Terminal
12NXS26 12NXS36 12NXS38 12NXS50 12NXS62 12NXS90 12NXS120
M6x1.0 Female
12NXS61 12NXS85
M6x1.0 Female
12NXS86
3/816″ Female
12NXS137 12NXS157
M6x1.0 Female
12NXS166 12NXS186
M8x1.25 Female
All 2-Volt Cells
M10x1.5 Female
Terminal Torque
Nm
Ibf in
Terminal Adapter
6.8
60
SAE
9.0
80
N/A
6.8
60
SAE
9.0
80
M6 Front Terminal
25.0
222
N/A
6
OPERATION
Operation
The nominal rated capacity is at a battery temperature of 30 °C (86 °F) for C5
or 25 °C (77 °F) for C6. The optimum lifetime of the battery depends on the
operating conditions (temperature and depth of discharge). Higher temperatures
shorten the life of the battery; lower temperatures reduce the available
capacity. The capacity of the battery falls considerably under an internal
temperature of 5 °C (41 °F). Optimal battery life is obtained when the battery
is operated, charged and stored at an ambient temperature between 5 °C (41 °F)
and 30 °C (86 °F); and discharges are equal to or lower than 60 % of the
nominal C5/C6 capacity. Operation of the battery outside of the optimum
temperature range may require the use of a Wi-iQ® device and
NexSys®+ charger for proper temperature-adjusted charging. The acceptable
ambient operating temperature range for the discharge of NexSys® TPPL
batteries are discharged between -29 °C and 45 °C (-20 °F and 113 °F). Ambient
charging temperature between 0 °C and 40 °C (32 °F and 104 °F). Consult an
EnerSys® representative for the proper equipment selection for your
application.
The battery obtains its full capacity after about 3 charging and discharging
cycles. The valves on the top of the battery must not be sealed or covered
during storage or operation. Electrical connections (i.e. plugs) must only be
connected or disconnected while the battery is not under load (not charging or
discharging).
Discharging
Discharges over 60 % DOD of the rated capacity are categorized as deep
discharges and are not recommended as they reduce the life of the battery.
Discharged batteries MUST be recharged immediately and MUST NOT be left in a
discharged condition. The cycle life of the battery will depend on the DOD;
the higher the average DOD, the shorter the cycle life.
Partially discharged and fully discharged batteries can freeze, which
irreversibly damages the battery. Limit the discharge to a maximum of 60 % DOD
in cold climates, and recharge immediately.
The battery may be equipped with a Protection from Over-DischargeTM (PODTM)
device to provide
visual and audible warning signals. An observed warning signal indicates the
battery has reached its maximum discharge level and must be charged
immediately.
The following load cut-off settings must be used : · 50 % DOD at an average
loaded voltage of
1.98 volts per cell, or · 60 % DOD at an average loaded voltage of
1.96 volts per cell, or · 80 % DOD at an average loaded voltage of
1.91 volts per cell when discharged at average loads with currents in the
range of C4 to C8. At average currents outside of this range, please seek
advice from an EnerSys representative for energy cut-off settings.
7
CHARGING AND CARE
Charging
NexSys® TPPL batteries MUST be charged using an EnerSys-approved charger with
the appropriate approved NexSys® TPPL battery charging profile. Failure to do
so will affect the performance and life of the battery and invalidate any
warranty. The specific charging profile developed for recharging NexSys® TPPL
batteries allows opportunity charging as often as needed without damaging the
batteries. Charge rate must be maintained between 0.18C and 0.40C for 2-volt
cells and 0.18C and 0.70C for 12-volt blocs, depending on the battery and
charger type. NexSys® TPPL batteries have extremely low gas emission rates.
Nevertheless, provisions must
be made for venting of the charging gases. Battery container lids and
equipment compartments must always provide adequate ventilation. To allow for
some recombination inefficiency, NexSys® TPPL batteries should be considered
to have a gassing rate of 1.5A per 100 Ah.
Equalizing Charge: EnerSys-approved chargers include specific features to
ensure that the battery remains properly charged and equalized. Equalization
charge shall be performed a minimum of once per week.
Care of the Battery
NexSys® TPPL batteries are maintenance-free and it is not possible to add
water nor measure SG of the battery. The electrolyte is immobilized and the
density of the electrolyte cannot be measured. Never remove the safety valves
from the battery. In case of accidental damage to the valve, contact your
EnerSys representative for replacement.
The battery should always be kept clean and dry. Any liquid in the battery
tray must be extracted and disposed of in an appropriate manner. Damage to the
insulation of the tray should be repaired after cleaning to prevent corrosion
and ensure insulation.
Daily: · Recharge the battery after every discharge. · Check the condition of
the plugs and cables, and
make sure that all insulation covers are in place and are in good condition.
Weekly: · Allow up to 6 hours for a full charge at least once
per week. · Visually inspect for signs of dirt and mechanical
damage to all component parts of the battery, paying particular attention to
the battery charging plugs and cables.
Quarterly: At the end of the charge, take end-of-charge voltage readings, then
measure and record: · The voltage of the complete battery. · The voltages of
individual cells or blocs.
If significant changes from earlier measurements or differences between the
cells or blocs are found, please contact an EnerSys representative.
If the run time of the battery is not sufficient, check the following: · The
required work is compatible with the battery
capacity. · The battery has been plugged in at all
opportunities. · The settings of the charger.
Annually: Check the torque loading of the bolts/ screws on bloc-type products.
Test the insulation resistance of the battery. Insulation resistance of the
battery thus determined must not be below a value of 50 per volt of nominal
voltage. For batteries up to 20V nominal voltage the minimum value is 1000 .
8
STORAGE
Storage
Batteries are shipped from the manufacturer fully charged. The state of charge
will decrease with storage. All batteries lose their stored energy when
allowed to be in 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 influenced by temperature. High temperatures greatly
reduce storage life. It is recommended that the fully charged battery should
be stored in a cool dry place, ideally below 20 °C (68 °F), but no lower than
5 °C (41 °F).
If the equipment 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, onboard computer, etc.) must be switched off. If the equipment or
battery is going to be decommissioned for a period of one month or longer, all
electronic devices (such as Wi-iQ® device, POD device) must be professionally
disconnected by an EnerSys service representative.
The NexSys® TPPL product has a maximum inspection-free storage time of 18
months, if stored at or below 20 °C (68 °F) with no electronic devices
connected. After this time a refresh charge
should be administered. However, it is advisable to conduct an inspection and
Open Circuit Voltage (OCV) check after 12 months and recharge if the OCV is
less than 2.10 volts per cell. When stored at temperatures in excess of 30 °C
(86 °F), the battery should be OCV-checked every six months. The graph above
shows the relationship between temperature, storage time and OCV.
A new battery may be stored for up to two years without degradation of
performance provided that an OCV check is conducted every 12 months and
refresh charges are administered as needed.
Malfunctions
If malfunctions are found on the battery or the charger, please contact an
EnerSys representative. The measurements taken in the “Quarterly” section of
Care of the Battery will identify problems and help establish a base to
correct them.
Disposal
NexSys® TPPL batteries must be recycled. End-oflife batteries must be packaged
and transported in accordance with prevailing transportation rules and
regulations. End-of-life batteries must be disposed of in compliance with
local and national laws by a licensed or certified lead battery recycler.
9
TERMS AND ABBREVIATIONS
Terms and Abbreviations
Term/Abbreviation C4 C5 C6 C8 DC DOD OCV POD PPE SAE SDS SG SoC TPPL VRLA
Explanation/Description Battery capacity at the 4 hour discharge rate Battery capacity at the 5 hour discharge rate at 30 °C (86 °F) Battery capacity at the 6 hour discharge rate at 25 °C (77 °F) Battery capacity at the 8 hour discharge rate Direct Current Depth of Discharge Open Circuit Voltage Protection from Overdischarge Device Personal Protective Equipment Society of Automotive Engineers Safety Data Sheet Specific Gravity State of Charge Thin Plate Pure Lead Valve Regulated Lead Acid
10
NOTES
11
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Trademarks and logos are the property of EnerSys and its affiliates except UL
and CE, which are not the property of EnerSys. Subject to revisions without
prior notice. E.&O.E.
GLOB-EN-OM-NEX-TPPL 0424