NexSys®batteries are supplied in a fully charged
condition. The battery should be inspected to ensure it is
in perfect physical condition prior to placing into service.
The battery cables must have good contact to terminals,
check that the polarity is correct otherwise battery, vehicle
or charger could be damaged.
Never directly connect an electrical appliance (for
example a warning beacon) to a part of the battery. This
could lead to an imbalance of the cells during recharge
with loss of capacity, risk of insufcient charge time and
damage to cells, effecting battery life and VOIDING THE
WARRANTY.
Charge the battery (see point 4.0) before use and in the
case of NexSys blocks, only blocks with the same state
of charge should be connected together.
The specied torque loading for the bolts of the cables
and connectors for both NexSys blocks and traction
batteries are detailed below.
Block
Battery
Terminal Torque
Standard Terminal
Terminal Torque
Terminal Adaptor
12NXS26
M6
Female 6.8 Nm SAE 6.8 Nm
12NXS36
12NXS38
12NXS90
12NXS120
12NXS61 M8
Female 9.0 Nm NA NA
12NXS85
12NXS86 3/8 - 16”
Female 6.8 Nm SAE 6.8 Nm
12NXS137 M6
Female 9.0 Nm
M6 Male
Front
Terminal
9.0 Nm
12NXS157
12NXS158 M8
Female 9.0 Nm
M6 Male
Front
Terminal
9.0 Nm
12NXS177
Traction
Battery Terminal Torque (all connector and cable)
All Cells 25Nm +/- 2
Use special coding systems (colour plug etc) for NexSys
batteries on the charging plug and socket devices to
prevent accidental connection to a wrong type of charger.
DIN EN50272-3 / IEC 62485_3 and AS2402.2.2-2005
AS2359.2-1985 Part 2.7 apply to the operation of sealed
VRLA traction batteries and battery electric industrial
trucks in general.
The optimum life of the battery depends on the operating
conditions (temperature and depth of discharge).
The ambient temperature range of use is 5°C to 45°C for
traction batteries and 0°C to 40°C for the blocks. Any use
outside of this range must be approved by the EnerSys®
technical department.
Optimal battery life is obtained with a battery temperature
of 15-35°C.
Higher temperatures shorten the life of the battery
(according to IEC1431), lower temperatures reduce the
available capacity which falls considerably under 0°C.
The battery obtains its full capacity after about 3 charging
and discharging cycles.
The cycle life of the NexSys block and traction battery will
be maximized if the batteries are shallow discharged and
recharged as often as practicable. Depths of Discharge
(DOD) to 40% of rated C5 capacity are the optimum level,
followed by a recharge.
NexSys batteries are ideally suited to opportunity charging
and can operate in a Partial State of Charge (PSOC)
condition without any adverse effect on performance or
service life. The cycle life of the battery is dependent on
the Depth of Discharge (DOD). The higher the DOD, the
shorter the cycle life. Always limit the discharge to
a maximum of 80% DOD. Discharges over 80% are
categorized as deep discharges and are not allowed
as they will considerably reduce the life expectancy
of the battery or cause permanant damage.
The presence of a discharge limiter on the vehicle is
imperative. The following voltage cut-off settings must
be used.
(When discharged with currents in the range of I1 to I5)
60% DOD set at 1.96 Volts per cell.
80% DOD set at 1.92 Volts per cell.
For batteries tted with an LVA, the customer must
observe the visual and audible warning signals that the
battery has reached the required discharge levels and
must be recharged immediately.
Safety when discharging -
The valves on top of the battery must not be removed,
sealed or covered. Electrical connections (e.g. plugs)
must only be connected or disconnected in the open
circuit condition. Discharged batteries MUST be
recharged immediately and MUST not be left in a
discharged condition. Discharged batteries can freeze.
NexSys batteries MUST be charged using an approved
NexSys charger. Failure to do so will affect the
performance and life of the battery and void any warranty.
The specic charging prole developed for NexSys
blocks (NXBLOC) will allow rapid recharge in 3 to
6 hours from 60% DOD at charge rates 0.2 to 0.7 C5
with opportunity charging as often as needed without
damaging the batteries - see technical manual.
The NexSys traction battery series are available for both
Standard duty and Heavy duty applications.
In Standard duty applications the charger has NXSTND
prole at a charge rate of 0.20 C5, and should recharge
the battery in less than 6 hours from 60% depth with
opportunity charging allowed (up to 20% extra energy
reintegrated in 1 hour).
In Heavy Duty applications the charger has NXFAST
prole at charge rates 0.25 to 0.40 which allows fast
recharge in 3.5 to 4 hours at 60% DOD with opportunity
charging allowed up to 80% extra energy reintegrated
(40% in 1h).
1. Commissioning Battery
2. Operation
3. Discharging
4. Charging
