NexSys® TPPL Battery User's Manual

Introduction

The information in this document is essential for the safe handling and correct use of NexSys® TPPL batteries to supply power to electric industrial vehicles. The manual provides general system specifications, related safety measures, guidelines for commissioning, and recommended maintenance. This document should be kept and remain available for users who work with and are responsible for the battery. All users are responsible for ensuring that all applications of the system are suitable and safe, based on the circumstances expected or encountered during use.

This manual contains important safety instructions. Ensure you have read and understood the sections on battery safety and operation before putting the battery and the equipment in which it is installed into service. It is the owner's responsibility to ensure that the documentation and all related activities are followed, and that all legal requirements applicable to themselves and the applications in the respective countries are met. This user manual is not intended as a substitute for training regarding the handling and operation of the industrial vehicle or the NexSys® TPPL battery that may be required by local laws, entities, and/or industry standards. Prior to contact with the battery system, proper instructions and training for all users must be guaranteed. Refer to the explanation of terms and abbreviations at the end of this document.

For service, contact your representative or call: 1-800-ENERSYS (USA) 1-800-363-7797

Visit: www.enersys.com | www.experiencenexsys.com

For other regions, visit: https://www.enersys.com/en/sales-services/

Your safety and the safety of others is very important. ⚠️ WARNING: Failure to follow instructions may result in death or serious injury.

Nominal Values

NexSys® TPPL batteries are intended for traction applications. These valve-regulated lead-acid batteries utilize our EnerSys® TPPL technology (Thin Plate Pure Lead).

Nominal Values

Unlike conventional (open) lead cells and batteries with free-flowing electrolyte, NexSys® TPPL batteries have immobilized electrolyte. Instead of the normal cell cap, a valve is used to regulate internal gas pressure. This prevents the ingress of oxygen and allows over-produced charging gases to escape. When using VRLA batteries, the same safety requirements as for open lead batteries must be followed. This helps protect against hazards from explosive electrolytic gas and corrosive electrolyte.

Cell or battery valves must never be removed. These batteries do not need to be refilled, and no attempt should be made to add water.

All data, descriptions, or specifications in this document are subject to change without prior notice. Before using the product(s), the user is advised and cautioned to determine and assess the suitability of the product(s) for the specific use in question. Furthermore, the user is advised not to rely on the information in this document, as it may pertain to general use or an unspecified application. It is the user's ultimate responsibility to ensure that the product is suitable and that the information applies to the user's specific application. The product(s) herein are used under conditions beyond the manufacturer's control, thereby waiving all warranties, express or implied, regarding the suitability or usability of such product(s) for a particular use or in a specific application. The user expressly accepts all risks and liability, whether contractual, tortious, or otherwise, in connection with the use of the information in this document or the product itself.

Safety Measures

• Observe operating instructions and keep the user manual near the battery.
• Only qualified personnel may work on batteries!
• Wear safety glasses and protective clothing when working on batteries.
• Follow all local regulations and safety codes. Comply with IEC 62485-3 and EN 50110-1 if no regulations or codes exist.
• No smoking!
• Do not expose batteries to open fire, glowing embers, or sparks, as this could cause batteries to explode.
• Avoid sparks from cables or electrical equipment and electrostatic discharges.
• Electrolyte that comes into contact with eyes or skin must be washed immediately with plenty of clean water. After abundant rinsing, consult a doctor immediately!
• Clothing contaminated with electrolyte must be washed in water.
• Explosion and fire hazard.
• Avoid short circuits: Do not use non-insulated tools and do not place or drop metal objects on the battery. Remove rings, wristwatches, and clothing with metal parts that can come into contact with the battery terminals.
• Electrolyte is highly corrosive.
• During normal use of this battery, contact with electrolyte is not possible. If the cell containers are damaged, immobilized electrolyte (absorbed in the separator) is corrosive, just like liquid electrolyte.
• Batteries are heavy. Ensure safe installation! Use only suitable lifting and handling equipment.
• Lifting hooks must not damage cells, connectors, or cables.
• Do not place batteries unprotected in direct sunlight. Discharged batteries can freeze. Therefore, always store them in a frost-free environment.
• Dangerous electrical voltage!
• Avoid short circuits: High short-circuit currents are possible with NexSys® TPPL batteries.
• Caution – metal parts of the battery are always live: do not place tools or other objects on the battery!
• Note the hazards that can be caused by batteries.

If operating instructions are ignored and repairs are carried out with non-original parts, the warranty is void. All defects, malfunctions, and error codes of the battery, charger, or other accessories must be reported immediately to the EnerSys® service department.

WARNING: DO NOT use any type of oil, organic solvent, alcohol, cleaning agent, strong acids, strong alkalis, petroleum-based solvent, or ammonia solution to clean the battery cases or covers. These materials can cause permanent damage to the cell or battery holder and cover, including safety risks related to electrolyte, and will void the warranty.

Failure to observe these operating and maintenance instructions or the use of non-original parts will void the warranty of this NexSys® TPPL battery.

Commissioning

NexSys® TPPL cells and batteries are delivered charged. Inspect the battery to ensure it is in good physical condition.

Check the following:

1. The battery compartment and the battery must be clean.
2. The battery end cables must make good contact with the terminals, and the polarity must be correct.

For maintenance-free batteries, use special coding systems for the male and female connectors to prevent accidental connection to the wrong type of charger.

Never connect an electrical device (e.g., warning light) to a part of the battery. This can lead to cell imbalance. This will damage all cells in the battery and void the battery's warranty. Use a DC-DC converter for lower voltage loads.

The flexible cable connections of NexSys® TPPL battery units mounted in strings must be long enough so that the battery's movement does not strain the terminal connection. Use only EnerSys® approved fasteners.

The valves on top of the battery must not be sealed or covered. NexSys® TPPL batteries can be installed in any orientation except upside down. Only batteries with the same discharge state may be connected together.

Charge the battery (see 'Charging' on page 8) before discharging it for the first time. Sufficient control measures must be taken (colored connectors, Wi-iQ® device, etc.) to ensure that the battery is only charged with an EnerSys® approved charger with the correct approved NexSys® TPPL charging profile.

The table below specifies the tightening torques for the terminal and connector bolts/screws:

Usage

Usage

Nominal capacity is at a battery temperature of 30 °C (86 °F) for C5 or 25 °C (77 °F) for C6. The maximum lifespan of the battery depends on the operating conditions (temperature and depth of discharge). Higher temperatures shorten the battery's lifespan, while lower temperatures reduce available capacity. Battery capacity drops significantly below an internal temperature of 5 °C (41 °F). The optimal battery lifespan is achieved when the battery is used, charged, and stored at an ambient temperature between 5 °C (41 °F) and 30 °C (86 °F); and discharges are equal to or less than 60% of the nominal C5/C6 capacity. If the battery is used outside the optimal temperature range, it may be necessary to use a Wi-iQ® device and a NexSys®+ charger for correct charging at the appropriate temperature. The acceptable ambient temperature range for discharging NexSys® TPPL batteries is between -29 °C and 45 °C (-20 °F and 113 °F). Ambient charging temperature is between 0 °C and 40 °C (32 °F and 104 °F). Consult an EnerSys® representative for proper equipment selection for your application.

Full battery capacity is achieved after 3 charge and discharge cycles. The valves on top of the battery must not be sealed or covered during storage or operation. Electrical connections (e.g., connectors) should only be connected or disconnected when the battery is not under load (not being charged or discharged).

Discharge

Discharges exceeding 60% of the nominal capacity are considered full discharges and are not desirable, as they shorten battery lifespan. Discharged batteries MUST be recharged immediately and MUST NOT be left in a discharged state. Battery lifespan depends on the depth of discharge. The higher the average depth of discharge, the shorter the lifespan.

Partially and fully discharged batteries can freeze, which will irreparably damage the battery. Limit discharge to a maximum of 60% DOD in cold climates and recharge immediately.

The battery may be equipped with a "Protection from Over-Discharge™ (POD™)" device that provides visual and audible warning signals. An observed warning signal indicates that the battery has reached its maximum discharge and must be recharged immediately.

Set the discharge limit values as follows:

• 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

for average discharge currents in the range between C4 and C8. For average currents outside this range, contact an EnerSys representative for advice on discharge limiting settings.

Charging and Maintenance

Charging

NexSys® TPPL batteries MUST be charged with an EnerSys approved charger with the correct approved NexSys® TPPL charging profile. Failure to do so will adversely affect battery performance and lifespan and void the warranty. The specific charging profile developed for charging NexSys® TPPL batteries allows for opportunity charging as needed without damaging the batteries. The charge factor should be maintained between 0.18C and 0.40C for 2-volt cells and between 0.18C and 0.70C for 12-volt blocks, depending on the battery type and charger. NexSys® TPPL batteries have extremely low gas emission values. Nevertheless, provisions must be made for charging gas escape. The equipment compartments and battery box covers must always allow sufficient ventilation. For NexSys® TPPL batteries, consider a gas formation rate of 1.5 A per 100 Ah due to a certain degree of inefficiency in recombination.

Equalization Charge: EnerSys approved chargers have special functions that ensure the battery is properly charged and balanced. An equalization charge should be performed at least once a week.

Battery Maintenance

NexSys® TPPL batteries are maintenance-free, and it is not possible to add water or measure the battery's SG. The electrolyte is immobilized, and the electrolyte density cannot be measured. Never remove the battery's safety vents. In case of accidental damage to a vent, contact your EnerSys representative to replace the vent.

The battery must always be kept clean and dry. Any liquid present in the battery box must be correctly removed and disposed of. To ensure insulation and prevent corrosion, any damage to the box's insulation must be repaired after cleaning.

Daily:

• Recharge the battery after each discharge.
• Check the condition of connectors and cables and ensure all insulating covers are in place and in good condition.

Weekly:

• Allow at least six hours per week for fully charging the battery.
• Visually inspect all battery components for signs of dirt and mechanical damage, paying particular attention to the battery's charging connectors and cables.

Quarterly:

At the end of the charging cycle, read the charging voltage and measure and record the following values:

• The voltage of the fully charged battery.
• The voltages of individual cells or blocks.

If significant deviations from previous measurements or differences between cells or blocks are found, contact an EnerSys representative.

If the battery's operating time is insufficient, check the following:

• Whether the work to be performed is compatible with the battery capacity.
• Whether the battery is charged on all occasions.
• The charger settings.

Annually:

Check the tightening torque of the bolts/screws on block-type products. Test the battery's insulation resistance. The measured insulation resistance of the battery must not have a value lower than 50 Ω per V of nominal voltage. For batteries with a nominal voltage up to 20 V, the minimum value is 1000 Ω.

Storage

Batteries are shipped from the factory in a fully charged state. During storage, the battery's charge will decrease. All batteries lose their charge when in an open circuit due to parasitic chemical reactions. The self-discharge rate is non-linear and decreases as the battery becomes more discharged. The state of charge is also strongly influenced by temperature. Higher temperatures significantly shorten lifespan. It is recommended to store the fully charged battery in a cool, dry place, ideally at a temperature below 20 °C (68 °F), but not below 5 °C (41 °F).

If the equipment is not used for more than 48 hours, the ignition key must be removed, and all auxiliary equipment (such as lights, beacons, onboard computer, etc.) must be switched off. If the equipment or battery is taken out of service for a period of one month or longer, all electronic devices (such as Wi-iQ®, POD) must be professionally disconnected by an EnerSys service representative.

The NexSys® TPPL product has a maximum inspection-free storage time of 18 months when stored at a temperature of 20 °C (68 °F) or lower and with no electronic devices connected. After this time, it must be recharged. However, it is advisable to perform an inspection and open-circuit voltage check (OCV) after 12 months and recharge the battery if the open-circuit voltage is below 2.10 V per cell. If the battery is stored at temperatures above 30 °C (86 °F), the battery's open-circuit voltage must be checked every 6 months. The graph above shows the relationship between temperature, storage time, and OCV.

A new battery can be stored for up to two years without performance degradation, provided that an OCV check is performed every 12 months and the battery is recharged as needed.

Faults

Contact an EnerSys representative if you find that the battery or charger is exhibiting faults. The measurements taken according to the 'Quarterly' section will reveal problems and form the basis for corrections.

Disposal

NexSys® TPPL batteries must be recycled. Discarded batteries must be packaged and transported in accordance with applicable transport rules and regulations. Discarded batteries must be disposed of as waste in accordance with local and national legislation by an authorized or certified lead-acid recycling company.

Terms and Abbreviations

Notes

No specific notes provided in the original document.