2.0 Operation
The acceptable ambient operating temperature range for the discharge of NexSys®
PURE batteries is between -20°F (-29°C) and 113°F (45°C). The acceptable ambient
charging temperature range is between 32°F (0°C) and 113°F (45°C).
The nominal rated capacity is at a battery temperature of 77°F (25°C). 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 41°F (5°C). The lifetime of the battery depends on the operating conditions. Optimal
battery life is obtained when the battery is operated, charged and stored in an ambient
temperature between 41°F (5°C) and 86°F (30°C); and discharges are equal to or lower
than 60% of the nominal 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. Consult an EnerSys®representative for the
proper equipment selection for your application.
The battery obtains its full capacity after about three charging and discharging cycles.
2.1 Discharging
Discharges over 80% DOD of the rated capacity are categorized as deep discharges
and are not acceptable 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 80% DOD in cold climates,
and recharge immediately.
The battery may be fitted with a Protection from Over-Discharge™ (POD™) 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:
• 60% DOD at an average loaded voltage of 1.96 volts per cell, or
• 80% DOD at an average loaded voltage of 1.92 volts per cell.
when discharged at average loads with currents in the range of I4to I8. At average
currents outside of this range, please seek advice from an EnerSys representative for
energy cut-off settings.
2.2 Charging
NexSys PURE batteries MUST be charged using an EnerSys approved charger with the
appropriate approved NexSys PURE 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 PURE batteries allows opportunity charging as often
as needed without damaging the batteries. Charge rate must be maintained between
0.18C6and 0.70C6, depending on the battery and charger type. NexSys PURE batteries
have an extremely low gas emission. Nevertheless, provisions must be made for
venting of the charging gases. Battery container lids and vehicle compartments must
always provide adequate ventilation. To allow for some recombination inefficiency,
NexSys PURE batteries should be considered to have a gassing rate of 1.5A per 100 Ah.
Electrical connections (i.e. DC connectors) must only be made or broken in the open
circuit condition. Stop the charger before disconnecting the battery.
3. Maintenance
The electrolyte is immobilized. 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.
3.1 Daily
• Plug the battery into the proper charger at every opportunity.
• Check the condition of the plugs, cables and make sure that all insulation covers
are in place and are in good condition.
3.2 Weekly
• Allow up to six 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.
3.3 Quarterly
At the end of the charge, take end of charge voltage readings, measure and record:
• The voltage of the complete battery.
• The voltages of each cell or bloc.
If significant changes from earlier measurements or differences between the cells are
found, please contact an EnerSys representative. If the run time of the battery is not
sufficient, check the following:
• That the required work is compatible with the battery capacity.
• Battery has been plugged into the charger at every opportunity.
• The settings of the charger.
3.4 Annually
Remove internal dust from the charger. Inspect and test all electrical connections
(sockets, cables and contacts). 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 Ωper volt of nominal voltage.
For batteries up to 20V nominal voltage the minimum value is 1000 Ω.
4. Care of the Battery
The battery should always be kept clean and dry. Any liquid in the battery tray must be
extracted and disposed of in the prescribed manner. Damage to the insulation of the
tray should be repaired after cleaning to prevent corrosion.
5. 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 68°F (20°C),
but no lower than 41°F (5°C).
If the truck/vehicle 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,
on-board computer, etc.) must be switched off. If the truck 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 2V assembled product has a maximum inspection-free storage time of six months,
if stored at or below 68°F (20°C) (provided the battery is fully charged when put into
storage and that all electronic devices or other equipment that could cause the battery
to discharge are disconnected), after which a refresh charge should be administered.
However, it is advisable to conduct an inspection and Open Circuit Voltage (OCV) check
after three months and recharge if the OCV is less than 2.10 volts per cell.
The 12V product has a maximum inspection-free storage time of two years, if stored
at or below 68°F (20°C) 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 check after 12 months and recharge if the OCV is less than 2.10
Volts per cell. When stored in temperatures in excess of 86°F (30ºC), the battery should
be OCV checked every six months. The graph below shows the relationship between
temperature, storage time and OCV.
A new battery may be stored for up to five years without degradation of performance
provided that an OCV check is conducted every 12 months and refresh charges are
administered as needed.
6. Malfunctions
If malfunctions are found on the battery or the charger, please contact an EnerSys
representative. The measurements taken in Section 3.3 will identify problems and help
establish a base to correct them.
7. Disposal
NexSys PURE batteries must be recycled. End-of-life 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 acid battery recycler.
