EnerSys 12NXS38, 12NXS62, 12NXS36, 12NXS50, 12NXS85 Technical Manual
...
Small traction motive power
NexSys
Designed to change the way you work
Technical Manual
®
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recombination Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Blocs & Range Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Blocs Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
State of Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Storage – NexSys blocs installed in equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Discharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Discharge Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Opportunity Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cycle Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
• Pay attention to the operating instructions and
keep them close to the bloc.
• Work on blocs must only be carried out by
skilled personnel!
• Use protective glasses and wear safety clothing
when working on blocs.
• Adhere to the current accident prevention rules in the
country where the blocs is used or DIN EN 50272-3,
DIN EN 50110-1.
• Keep children away from batteries!
• No smoking!
• Do not expose blocs to naked flames, glowing
embers or sparks, as it may cause the battery to
explode.
• Avoid sparks from cables or electrical apparatus as well
as electrostatic discharges.
• Acid splashes 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
immobilised electrolyte (absorbed in the separator) is
corrosive like liquid electrolyte.
• Batteries and monoblocs are heavy. Ensure secure
installation! Use only suitable handling equipment.
• Lifting hooks must not damage the blocs, 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 batteries are capable of
high short circuit currents.
• Caution — metal parts of the batteries are always live:
do not place tools or other objects on the battery!
• Pay attention to the hazards that can be caused by
batteries.
INTRODUCTION
Since their introduction in the early 1990s, thin plate pure lead (TPPL) blocs have been
established as a premium high performance bloc suitable for a wide range of demanding
applications. Today, the TPPL technology can be found in applications as diverse as
emergency power, avionics, medical, military and consumer equipment.
NexSys® blocs use the principles of advanced thin plate pure lead technology, to achieve
exceptionally high performance, energy density and cycling capability. These characteristics
make the NexSys range ideal for use in motive power applications such as Floor-care, Pallet
Trucks, AGV's, Personnel Carriers and Utility Vehicles.
This manual describes the NexSys bloc range, physical characteristics and the basic
information on storage operation and maintenance.
SAFETY PRECAUTIONS
Motive Power blocs for small traction Valve Regulated Lead Acid (VRLA) NexSys series:
TPPL technology.
NexSys blocs are designed using proven gas recombination technology, which removes the
need for regular water addition. The use of gas recombination technology for lead acid blocs
has completely changed the concept for motive power. This new technology gives the user
greater freedom to use valve regulated lead acid blocs in a much wide range of
applications.
The minimal level of gas emissions from this type of bloc allows the bloc to be used in
applications where previous restrictions might have been enforced. The NexSys range is
considered to be maintenance free, therefore there is no need for any routine water refilling
to be carried out on the bloc.
Warning: Do not use any type of oil, organic solvent, alcohol, detergent, strong acid, strong
alkali or petroleum based solvent or ammonia solution to clean the monoblocs. Such
materials may cause permanent damage to the monobloc casing.
3
NexSys Technical Manual
о
2
H
2
Electrolyte
Separator
Conventional
cell
Oxygenand
hydrogenescape
tothe
atmosphere
Oxygenevolved
frompositive
platetransfers
tonegativeand
recombines to
formwater.
RECOMBINATION TECHNOLOGY
How gas recombination works:
When a charge current flows through a fully charged conventional lead acid cell, electrolysis
of water occurs to produce hydrogen from the negative electrode and oxygen from the
positive electrode. This means that water is lost from the cell and regular topping up is
needed.
However, evolution of oxygen gas and hydrogen gas does not occur simultaneously,
because the efficiency of recharge of the positive electrode is not as good as the negative
electrode. This means that oxygen is evolved from the positive plate before hydrogen is
evolved from the negative plate.
At the same time that oxygen is evolved from the positive electrode, a substantial amount of
highly active spongy lead exists on the negative electrode before it commences hydrogen
evolution.
Therefore, provided oxygen can be transported to the negative electrode, conditions are
ideal for a rapid reaction between lead and oxygen:
i.e. This oxygen is electrochemically reduced on the negative electrode according to the
following scheme,→
2e- + 2H+ + 1/2 O H O
2 2
and the final product is water…….
The current flowing through the negative electrode drives this reaction instead of hydrogen
generation which would occur in a flooded cell.
This process is called gas recombination. If this process was 100% efficient no water would
be lost from the cell. By careful design of the constituents within the cell, gas recombination
up to 99% is achieved.
Principle of the oxygen Reduction Cycle
RECOMBINATION EFFICIENCY
Recombination efficiency is determined under specific conditions by measuring the volume
of hydrogen emitted from the bloc and converting this into its ampere hour equivalent. This
equivalent value is then subtracted from the total ampere hours taken by the bloc during the
test period, and the remainder is the blocs recombination efficiency and is usually expressed
as a percentage.
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NexSys Technical Manual
BLOC SUMMARY
RANGE SUMMARY
Table 1 – NexSys specifications
As recombination is never 100%, some hydrogen gas is emitted from NexSys® blocs
through the self-regulating valve; the Igas value for this technology of bloc is 1.5A/100 Ah
C5/C6.
5
Option A: SAE post Option B: M6 male front
terminal adapter
Terminal layout 1
Terminal layout 2
Terminal layout 3
Flexible connectors must be used for all monobloc connections.
EnerSys® approved fasteners must be used.
NexSys Technical Manual
12NXS26
12NXS36
12NXS38
12NXS50
12NXS61
12NXS62
12NXS85
12NXS90
12NXS120
12NXS137
12NXS157
12NXS166
12NXS186
12NXS86
12
12
12
12
12
12
12
12
12
12
12
12
12
12
26
36
38
50
61
62
85
90
120
137
157
166
186
86
26
36
38
50
61
62
85
90
120
137
157
166
186
86
9.84
9.84
7.74
8.66
11.02
12.95
15.55
11.89
13.31
16.90
16.90
22.09
22.09
12.99
250
250
197
220
280
329
395
302
338
429
429
561
561
330
3.82
3.82
6.50
4.72
3.82
6.53
4.13
6.89
6.81
6.79
6.79
4.92
4.92
6.79
97
97
165
120
97
166
105
175
173
172
172
125
125
172
5.79
7.76
6.69
9.92
10.39
6.85
10.39
8.78
10.71
9.36
10.75
11.14
12.78
8.43
147
197
170
252
264
174
264
223
272
238
273
283
317
214
5.67
7.64
6.37
9.76
9.76
6.53
9.76
8.94
10.75
9.36
10.80
10.35
11.69
8.62
144
194
162
248
248
166
248
227
273
238
274
263
297
219
21.10
29.00
38.40
41.00
42.00
53.10
60.00
69.45
94.80
105.00
117.00
113.30
131.10
77.40
9.60
13.20
17.40
18.60
19.10
24.10
27.20
31.50
43.00
47.60
53.10
51.20
59.40
35.10
M6 Female
M6 Female
M6 Female
M6 Female
M8 Female
M6 Female
M8 Female
M6 Female
M6 Female
M6 Female
M6 Female
M8 Female
M8 Female
3/8 - 16"
Female
1
1
1
1
2
1
2
3
3
2
2
2
2
1
A
A
A
A
—
A
—
A
A
B
B
B
B
A
Length Width
Height Terminal Height
in mm in mm in mm in mm
lbs
Kg
NexSys®
Bloc
Voltage
(v)
Nominal
Capacity C
5
[Ah] 1.70vpc
@ 30°C/86°F
Nominal
Capacity C
6
[Ah] 1.75vpc
@ 25°C/77°F
Dimensions Weight
Standard
Terminals
Terminal
Adapters
Terminal
Layout
Table1
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