EnerSys Battery Technologies User Guide

EnerSys Battery Technologies

Product Information

Specifications

• Battery Technologies: Advanced Battery Solutions
• Features: Less watering, intuitive design, low upkeep, high reliability, low risk, enhanced battery innovations
• Charging Flexibility: Various topping-up intervals based on charger type
• Ideal Applications: e-Commerce, Construction, Manufacturing
• Available Options: Aquamatic water refill system, Electrolyte Circulation (EC) system

Product Usage Instructions

Charging Flexibility and Topping Up Intervals

Based on your charger type, you can achieve different topping-up intervals for optimal performance.

• Standard 50 Hz Charger: Topping up every 4 weeks
• High-Frequency Modular Charger: Topping up every 8 weeks
• High-Frequency Modular Charger & Electrolyte Circulation
• (EC): Topping up every 13 weeks (4 times per year) or even 20 weeks*

Ideal Applications

Consider the recommended applications for optimal performance.

• Low to normal-duty applications: 5 days per week
• Heavy-duty applications: Up to 7 days per week

Available Options

• Utilize the Aquamatic water refill system for easy topping up from a central point. For enhanced performance, consider the Electrolyte Circulation (EC) system.

Actionable Intelligence & Connectivity

• Monitor your battery’s performance with battery monitoring tools and optimize its operation for the lowest Total Cost of Ownership (TCO).

Support and Recycling

• Contact EnerSys for battery support services including design, installation, certification, testing, maintenance, and repair.
• Additionally, participate in their comprehensive recycling program for lead-acid batteries.

FAQ

Where can I find more information about battery monitoring and application analysis?

You can visit the EnerSys website at www.enersys.com or contact their respective headquarters in the US, Europe, or Asia for detailed information on battery monitoring and application analysis.

ADVANCED BATTERY SOLUTIONS

EnerSys® is focused on rapid innovation and our whole team is driven by the desire to build the best energy solutions, working closely with our customers and suppliers to identify development opportunities.

LESS WATERING MORE BENEFITS

WATER LESS® BATTERIES

• Water Less® batteries combine the power and reliability of tubular vented technology with the convenience of extended watering intervals. Less frequent topping-up means reduced labor costs.
• These batteries are suitable for multi-shift operations. Water Less® batteries provide a high level of power and reliability for all industrial truck applications; thanks to the extended capacity range.
• Water Less® batteries are at the leading edge of battery technology and bring added efficiency to your business. A low electrolyte level indicator fitted on the battery informs the user when water topping up is needed.

WATER LESS® 20 BATTERIES

• Water Less® 20 batteries are capable of operating for up to 100 cycles (approx. 20 weeks in normal duty applications) before topping-up is required.
• Standard batteries with 50 Hz chargers would normally need topping up weekly so moving to 20 weeks could reduce your labor costs by as much as 90%.
• Water Less® 20 traction batteries provide the level of power and reliability needed for low to heavy-duty industrial truck applications.

INTUITIVE DESIGN

• All Water Less® batteries (PzM) use proven PzS technology. The positive electrodes are diecast tubular plates (PzS) and provide increased efficiency.
• Constructional specifications like a larger electrolyte capacity, a reduced prism height, and new flip-top plugs ensure added value for our customers.
• ****Extremely low maintenance. Reduced labor costs for water topping.
• Integrated plug-and-play power systems with compatible components from one trusted supplier.
• System power and performance with ownership costs verified before purchase and a warranty you can count on.

ENHANCED BATTERY INNOVATIONS

ADVANTAGES

• Extremely low maintenance, robust, and dependable
• Extended watering intervals (4, 8 or 13 weeks)*
• Up to 75% reduced labor costs with less topping up required**
• Suitable fitment for all truck types (sizes in DIN and BS ranges)
• Warranty: Specific country conditions and customer agreements apply
• Depending on the selected charging technology
• When paired with our high-frequency chargers

EVEN MORE APPLICATIONS

• Water Less® batteries are suitable for use in the following material handling applications.
• Counterbalance trucks
• Reach trucks
• Pallet trucks
• Order pickers
• AGV/LGV

MORE CHARGING FLEXIBILITY

• The charging technology must be tailored to the characteristics of the battery and the application.
• This is a crucial factor for the economic operation of the batteries.
• Water Less® batteries are suitable for 50Hz and our high-frequency charging range.

IMPAQ™ and NexSys®+ Chargers adapt automatically to:

• Capacity of the battery
• Voltage of the battery
• Depth of discharge of the battery
• The Water Less® 20 charging profile also has a 33% lower end-of-charge current (compared to standard regimes) which reduces ventilation requirements and gives opportunities for de-centralised charging of Water Less® 20 batteries.

TOPPING UP INTERVALS

THE TOPPING-UP INTERVALS CAN BE ACHIEVED AS FOLLOWS

• +/- 1 week in the most common applications at 20°C
  • Based on 80% DoD C5, 1 cycle per day, 5 days per week

MORE OPERATING TIME — LONGER TOPPING UP INTERVALS

IDEAL APPLICATIONS

• Operations running 1-2 shifts per day, up to 5-6 days per week – Low to normal-duty applications
• Multi-shift operation with battery changes, 3 shifts per day, up to 7 days per week – Heavy-duty applications
• Operations looking to reduce maintenance and water topping intervals
• Ideal Industries: Automotive, Logistics, Retail & e-Commerce, Construction, Manufacturing

AVAILABLE OPTIONS

EASY TOPPING UP

• The Aquamatic water refill system makes it possible to top up all the cells from one central point through an easy, integrated system.

ACHIEVE OPTIMUM PERFORMANCE

• The Electrolyte Circulation (EC) system consists of a pipe system that is fitted in the cells.
• Electrolyte circulation provides optimum performance, reduces recharge time, helps keep the battery cooler, and maximizes battery service life in more arduous operations.

ACTIONABLE INTELLIGENCE & CONNECTIVITY

• A further option for Water Less® batteries is the Wi-iQ® battery monitoring device range, which precisely manages the state of charge and operating conditions of the battery as well as storing complete data of the battery’s service life and provides fleet management reporting.
  • The Wi-iQ® battery monitoring device communicates with NexSys®+ Chargers, enabling battery temperature control, making it possible to work in colder environments.
• Available free for Android™ and iOS® operating systems, the E Connect™ mobile app allows users to see and share a range of real-time battery and charger operating data on smartphones or tablet devices.

BATTERY MONITORING

EnerSys® offers solutions that make managing your battery fleet straightforward and affordable. BSI40™, EZ Select™, and LifeNetwork™ are the spearheads of battery fleet management, enabling charging room management and communication with state of charge monitoring. Customizable to your needs, these solutions will make your energy and facility management easy and efficient.

APPLICATION ANALYSIS

OPTIMIZE YOUR POWER SOLUTION WITH THE LOWEST TCO

• Before EnSite™ modeling software, finding the most efficient power solution for your material handling equipment meant relying on hand calculations and guesswork.
• But with EnSite™ modeling software, we use your application data to determine which battery and charger combination will be optimal for your operation’s needs and goals.
• We work with you to collect a range of data about your application. Then we use your data in our EnSite™ modeling software to find a solution that meets your requirements for the lowest TCO for your operation.
• Tailors solutions to meet application demands
• Compares battery and charger combinations
• Predicts overall application performance
• Estimates greenhouse gas reductions
• Calculates TCO reductions and overall ROI

ABOUT ENERSYS

OUR SOLUTIONS PUT TOTAL POWER IN MOTION FOR YOUR BUSINESS

• Enersys® is the global leader in stored energy solutions for industrial applications and designs, manufactures, and distributes energy systems solutions and motive power batteries, specialty batteries, battery chargers, power equipment, battery accessories and outdoor equipment enclosure solutions to customers worldwide.
• Enersys® Motive Power solutions form a complete, turnkey power system to make your operations more productive and profitable.
• Motive Power batteries and chargers are utilized in electric forklift trucks and other industrial electric-powered vehicles requiring stored energy solutions.
• Enersys® also provides aftermarket and customer support services to its customers in over 100 countries through its sales and manufacturing locations around the world.
• Wherever you are in Europe, EnerSys® is within reach and ready to support your fleet with 40+ Service locations.
• 24/7 coverage from 150+ authorized service technicians
• Tailored service contracts to your requirements
• Proactive cloud-based monitoring and real-time service scheduling
• Comprehensive maintenance reporting and monitoring plans
• Our battery support services range from system design, installation, and certification to testing, maintenance, and repair.
• Our comprehensive recycling support program accepts lead acid batteries of all sizes, from all manufacturers.
• Our advanced tools and technologies deliver actionable intelligence to optimize battery maintenance and operation.
• EnerSys World Headquarters
• 2366 Bernville Road
• Reading,
• PA 19605, USA
• EnerSys EMEA
• EH EuropeGmbH
• Baarerstrasse 18
• 6300 Zug, Switzerland
• EnerSys Asia
• 152 Beach Road
• Gateway East Building #11-08
• Singapore 189721
• www.enersys.com
• © 2024 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates except Android and iOS which are not the property of EnerSys. Subject to revisions without prior notice. E.&O.E.
• EMEA-EN-PG-HAW-WL-0424

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