EnerSys CYCLON APPLICATION MANUAL
APPLICATION MANUAL
1973 TO 2008
Publication No: EN-CYC-AM-007 - December 2008
Wherever the world
needs stored energy,
EnerSys
Powered by more than 100 years
of expertise, EnerSys
world’s largest industrial battery
manufacturer, operating 21
facilities worldwide. Along with
manufacturing and distributing a
wide range of reserve power and
motive power batteries, chargers,
power equipment, and battery
accessories, EnerSys provides
unmatched aftermarket and
customer support to its customers
in over 100 countries worldwide.
®
is there.
®
is the
A rugged, reliable
alternative to
conventional lead
alloy batteries.
At first glance, a conventional lead battery may
seem like a better reserve-power deal than the
rechargeable, sealed-lead CYCLON
But a closer look reveals the real bottom line:
for long-term cost of ownership, there’s simply
no comparison. By housing a sealed, pure-lead,
thin-plate design within an extremely rugged steel
casing, CYCLON batteries outperform lead alloy
batteries in a number of ways:
• Per unit weight, CYCLON® batteries deliver
the greatest high-rate power density for
your energy dollar.
• CYCLON® batteries can be recharged to 95%
capacity in under an hour, and boast a design
life of ten years for single cell products and up
to eight years for monobloc products.
• CYCLON
in extreme applications and temperatures (up
to twice the capacity at -20°C) - and are safe
enough for installations in offices or hospitals.
®
batteries perform remarkably well
®
battery.
Add it all up and the real value of CYCLON batteries
becomes clear. Their power and extended service
life means more efficient operation with fewer
replacements, while their reliability means fewer
system failures. From general purpose to extremely
demanding applications CYCLON batteries simply
offer better performance and lower long-term cost
of ownership.
2
Rugged construction and reliable performance
in extreme temperatures make Cyclon
®
batteries ideal for a range of applications:
• Telecommunications
• Defence installations
• Aerospace
• Global positioning
systems
• Uninterrupted
Power Supply (UPS)
Equipment
• Emergency lighting
• Medical equipment
• Computer back-up
• Electric vehicles
• Solar power
equipment
• General electronics
• Lawn and garden
equipment
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3
Powerful design:
A CYCLON® Single Cell
Resealable safety valve
A 50-PSI vent lets gases escape, then
automatically reseals, so there’s no risk
of excessive gas accumulation within the
battery, or “dry out” failure from repeated
recharges.
Pure lead plates
Made from 99.99% pure lead, CYCLON
battery plates are extremely thin, so they
offer more surface area than conventional
batteries - and far more power.
®
AGM plate separator
High-purity acid is absorbed right into
the Absorbed Glass Mat (AGM) plate
separators, so the CYCLON battery provides
leak-proof operation in any position.
Steel can enclosure
The CYCLON battery’s metal outer jacket
offers extreme shock, vibration, temperature,
and flammability protection.
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Publication No: EN-CYC-AM-007 - December 2008
Table of Contents
Chapter 1: Introducing CYCLON® Batteries ..................................................................................................................... 6
1.1 Introduction ........................................................................................................................................................ 6
1.2 Sealed Design .................................................................................................................................................... 6
1.3 Low Temperature Performance ......................................................................................................................... 6
1.4 High Rate Charge & Discharge Capabilities ...................................................................................................... 6
1.5 Long Life in Float Applications .......................................................................................................................... 6
1.6 Structural Resistance ......................................................................................................................................... 6
1.7 Packing Flexibility .............................................................................................................................................. 6
1.8 High Power Density ........................................................................................................................................... 6
1.9 Transportation Classification ............................................................................................................................. 6
1.10 UL Component Recognition .............................................................................................................................. 7
Chapter 2: Physical Features ............................................................................................................................................. 7
2.1 Single Cell Construction .................................................................................................................................... 7
2.2 Monobloc Construction ..................................................................................................................................... 7
Chapter 3: CYCLON
3.1 Introduction ........................................................................................................................................................ 7
3.2 High Discharge Current ..................................................................................................................................... 7
3.3 Low Temperature Operation .............................................................................................................................. 8
3.4 Position Flexibility .............................................................................................................................................. 8
3.5 Recombinant VRLA Design ............................................................................................................................... 8
3.6 Shock & Vibration Characteristics ..................................................................................................................... 9
3.7 Float Life Characteristics ................................................................................................................................... 9
3.8 Cycle Life Characteristics .................................................................................................................................. 9
3.9 Fast Charging Characteristics ........................................................................................................................... 9
3.10 Storage Characteristics ..................................................................................................................................... 9
Chapter 4: Discharging CYCLON
4.1 Introduction ........................................................................................................................................................ 9
4.2 Discharge Voltage Profile ................................................................................................................................... 9
4.3 Discharge Level ............................................................................................................................................... 10
4.4 Overdischarge Recovery .................................................................................................................................. 10
Chapter 5: CYCLON
5.1 Introduction ...................................................................................................................................................... 11
5.2 State of Charge ................................................................................................................................................ 11
5.3 Storage ............................................................................................................................................................ 11
Chapter 6: Charging CYCLON
6.1 Introduction ...................................................................................................................................................... 11
6.2 General ............................................................................................................................................................. 11
6.3 Series-parallel CYCLON
6.4 Constant Voltage (CV) Charging ...................................................................................................................... 12
6.5 Fast Charging or Cyclic Charging .................................................................................................................... 12
6.6 Float Charging ................................................................................................................................................. 13
6.7 Temperature Compensation ............................................................................................................................ 13
6.8 Constant Current (CC) Charging ...................................................................................................................... 14
6.9 Taper Current Charging.................................................................................................................................... 15
Chapter 7: CYCLON
7.1 Introduction ...................................................................................................................................................... 15
7.2 Cycle Life ......................................................................................................................................................... 15
7.3 Float Life .......................................................................................................................................................... 16
®
Battery Benefits ............................................................................................................................. 7
®
Batteries .................................................................................................................... 9
®
Battery Storage ............................................................................................................................ 11
®
Batteries ....................................................................................................................... 11
®
Battery Systems ..................................................................................................... 12
®
Battery Service Life ..................................................................................................................... 15
Chapter 8: Safety Issues .................................................................................................................................................. 16
8.1 Introduction ...................................................................................................................................................... 16
8.2 Gassing ............................................................................................................................................................ 16
8.3 Shorting............................................................................................................................................................ 17
Appendix A ............................................................................................................................................................................ 17
Appendix B .............................................................................................................................................................. Back Cover
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Publication No: EN-CYC-AM-007 - December 2008
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Chapter 1:
Chapter 1:
Introducing the Genesis Battery
Introducing CYCLON® Batteries
1.1 Introduction
The purpose of this guide is to describe the characteristics
of the sealed-lead family of rechargeable CYCLON
batteries from EnerSys
®
in its many different applications.
®
cells and
The unique cylindrical design overcomes many limitations
of competitive lead-acid systems without sacrificing cost
effectiveness, reliability, ruggedness and long life which have
always been assets of the lead-acid battery. Some of the
features are described below.
1.2 Sealed Design
Individual cells and monobloc batteries are sealed to prevent
electrolyte leakage. Since the cell operates during its normal
life without loss of water, even during continuous overcharge,
no water or electrolyte checks are required. Because of the
sealed design, the cell, monobloc or battery assembly can be
oriented in any position for ease of installation. In addition, the
combination of a sealed design and a mechanically operated
resealable Bunsen valve allows the cell to be operated even in
a vacuum.
1.6 Structural Resistance
The rugged outer metal case of the single cell design
increases its resistance to shock, crushing or damage due
to dropping, while allowing a very high vent pressure of 50
pounds per square inch (psi) or about 3.4 atmospheres (atm).
The cylindrical shape of the monobloc case also allows the
highest plastic case vent pressure of 8 psi (0.54 atm), as well
as providing resistance to case distortion due to heat.
1.7 Packing Flexibility
All CYCLON battery single cells can be used in parallel for
additional capacity. The individual cell construction allows
the battery to be laid out inside a battery cavity in an almost
infinite variety of patterns, maximising space utilisation. Heat
sealed combinations of the monoblocs add to the flexibility of
mounting configurations as well as contributing to savings in
space requirements.
1.8 High Power Density
CYCLON batteries have very high power density, particularly
at high rates of discharge. Please refer to Appendix A for
several graphs and charts that detail these capabilities.
1.3 Low Temperature Performance
The exceptional low temperature performance of CYCLON
batteries have been made possible by the use of plates that
provide a high surface area, coupled with a separator system
that minimises diffusion and resistance effects. This results
in good utilisation of active material and excellent voltage
regulation over a wide temperature range.
1.4 High Rate Charge & Discharge Capabilities
The thin plate construction of CYCLON batteries contribute
to high utilisation of the active plate materials and very
low internal impedance. This means that the cells can be
discharged at high rates, allowing the use of smaller batteries
for short duration, high rate discharges. Another advantage of
the very low internal resistance is the fast recharge capability.
Depending on the depth of discharge and charge current
available, the CYCLON battery cell can be fully charged in a
few hours.
1.5 Long Life in Float Applications
The high purity of the lead-tin grid (the purity of the lead
is in excess of 99.99%) used in CYCLON battery cells
results in long life on float charge. Depending on the ambient
temperature and the specific product (single cell
or monobloc) selected, one can get up to ten (10) years
float life at 25°C and 15 years float life at 20°C.
1.9 Transportation Classification
The Department of Transportation (DOT) has classified all
CYCLON batteries as “nonspillable wet electric storage
batteries.” Having been tested and found in compliance
with section 173.159 (d) of the 49 CFR, subchapter 173.159,
CYCLON batteries are exempt and unregulated regarding
shipping requirements of DOT 173.159. As a result, CYCLON
batteries do not have an assigned UN number, nor do they
require additional DOT hazard-communication labeling or
placarding. CYCLON
®
batteries may be shipped by air or
ground transportation without restriction.
CYCLON batteries and their outside shipping container
must be labeled “nonspillable” or “nonspillable battery.”
This labeling requirement is to clarify and distinguish to
shippers and transporters that all batteries have been tested
and determined to be in compliance with DOT HMR 49 NonHazardous Materials, and International Civil Aeronautics
Organisation (ICAO) and International Air Transport (IATA)
Packaging Instruction 806 and Special Provision A67 Vibration
and Pressure Differential Tests, and are therefore unregulated
and classified as “nonspillable wet electric storage
battery.”
®
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Publication No: EN-CYC-AM-007 - December 2008
All CYCLON® cells and batteries are packaged, marked,
labeled, and documented according to the appropriate
transportation regulations when shipped from an EnerSys
facility. A shipper that fails to follow these same requirements
may be subject to substantial civil and/or criminal penalties
and may cause a safety hazard.
All CYCLON battery packages must be capable of
passing International Safe Transit Association (ISTA)
Procedure 1A testing.
Packages weighing no more than 20 lbs. must be
packaged in a minimum 200 lb. burst strength or 32
ECT certified carton.
Packages weighing over than 20 lbs. must be packaged in
a minimum 275 lb. burst strength or 44 ECT certified carton.
No individual package can exceed a total gross weight
of 70 lbs.
It is the responsibility of the shipper to ensure each employee
who directly affects hazardous material/dangerous goods
transportation safety is appropriately trained in accordance
with the selected mode of transportation.
The terminals of CYCLON battery cells can cause shorts
if they are not insulated during shipping. Protective caps
or other durable inert material must be used to insulate
each terminal of each cell unless cells are shipping in the
original packaging from EnerSys in full box quantities.
Protective caps are available for all cell sizes by
contacting EnerSys Customer Service at 1-800-964-2837.
International customers should call 1-660-429-6437.
Assembled batteries must have short circuit protection during
shipping. Exposed terminals, connectors, or lead wires must
be insulated with a durable inert material to prevent exposure
during shipping.
FAILURE TO COMPLY WITH THESE REQUIREMENTS CAN
CAUSE A FIRE DURING SHIPPING AND HANDLING!
®
The external spade terminals on CYCLON battery
single cells are inserted through the polypropylene inner top
and are effectively sealed by expansion into the lead busbars.
The element is then stuffed into the jar liner and the inner top
and liner are bonded together. At this state of construction,
the cell is sealed except for the open vent hole.
A unique vacuum fill process then adds sulphuric acid and
the Bunsen relief valve is placed over the vent hole. In the
manufacture of a single cell, the sealed element is then
inserted into the metal can, an outer plastic top added and
crimping completes the assembly. The metal case is for
mechanical strength and is the principal factor contributing to
the high pressure rating of the resealable vent. The cell is now
charged for the first time (electrochemically formed).
2.2 Monobloc Construction
The monobloc construction differs from single cell
construction as it is essentially a battery consisting of multiple
cells, each cell element inserted in a single plastic container.
Spade terminals are inserted into the molded openings
connecting internally to the plate tab lead busbars. Intercell
plate tabs are connected by through-the-wall welds. Acid is
added using the vacuum fill process, the cover is heat sealed
in place and a Bunsen relief valve installed.
The battery is now formation charged.
Chapter 3:
CYCLON® Battery Benefits
3.1 Introduction
This chapter is devoted to describing specific performance
characteristics of CYCLON batteries that make them
a superior battery choice, particularly for demanding
applications such as temperature extremes typically
encountered in outdoor environments.
1.10 UL Component Recognition
All CYCLON batteries are recognised as UL components.
Chapter 2:
Physical Features
2.1 Single Cell Construction
Both the positive and negative plates are made of pure leadtin and are extremely thin. The plates are pasted with lead
oxides, separated by an absorbing glass mat separator and
spirally wound to form the basic element. Lead busbars are
then welded to the exposed positive and negative plate tabs.
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3.2 High Discharge Current
CYCLON battery cells can be discharged at very high
currents while maintaining a reasonably flat voltage profile.
This characteristic is achieved because of the high plate
surface area and closeness of the plates to each other due to
the use of thin plates in a spirally wound construction.
Typical maximum current capabilities of single cells and
monoblocs are shown in Table 3-1 below. In all cases, the
duration of discharge is one (1) minute to 1.50 volts per cell at
an ambient temperature of 25°C (77°F).
Publication No: EN-CYC-AM-007 - December 2008
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Higher currents than those shown in the table may be
maintained for durations shorter than one minute. The
ability of the cell or monobloc to maintain higher currents
is dependent on the magnitude of the current, its duration,
the frequency of its application and, most importantly, on
the ability of the terminal connection to act as a heat sink
and dissipate the heat generated. For high rate applications
we strongly recommend testing under actual or simulated
application conditions.
Table 3-1
CYCLON
®
Battery Type Max. amps to 1.50 VPC
D single cell (2.5Ah) 65
Tall D single cell (4.5Ah) 65
D monobloc (2.5Ah) 50
X single cell (5.0Ah) 65
E single cell (8.0Ah) 65
X monobloc (5.0Ah) 50
E monobloc (8.0Ah) 50
J single cell (12.0Ah) 100
BC single cell (25.0Ah) 250
3.3 Low Temperature Operation
Exceptional low temperature characteristics are maintained
through the use of a separator system that minimises
resistance and diffusion effects. This feature, combined with a
large plate surface area, results in efficient utilisation of active
materials and excellent voltage regulation.
Because the cell operates as a "starved" electrolyte system,
there is only enough electrolyte to maintain the rated capacity
of the cell. The capacity available at low temperatures is a
function of both temperature and discharge current.
Figure 3-1 shows another reason why CYCLON
®
battery cells
have good discharge performance at low temperatures.
Figure 3-1: Internal Resistance Vs. Temperature
500
400
lanimon % ,ecnatsiser .tnI
300
200
As the temperature drops, the increase in internal resistance
is relatively gradual down to a little under 0°C (32°F). This
also explains why CYCLON battery cells have excellent low
temperature performance.
3.4 Position Flexibility
With the starved electrolyte system, the sulphuric acid
is absorbed within the cell plates and the glass mat separator.
The cell is virtually dry with no free electrolyte, allowing it
to be charged, discharged or stored in any position without
electrolyte leakage.
3.5 Recombinant VRLA Design
One of the most important features of the CYCLON battery
design is its recombinant valve regulated lead-acid (VRLA)
design. This mode of operation is possible because the cell is
able to use the oxygen cycle during overcharge. The oxygen,
evolved at the positive electrode when the cell is overcharged,
is recombined at the negative electrode. A self-resealing valve
is provided as a safety vent in case of misapplication or other
abuse of the cell that would cause the internal cell pressure to
increase.
In CYCLON batteries, water loss is greatly reduced due to two
design features. First, because water tends to decompose
around impurities in the lead, the rate of such decomposition
is reduced due to the high purity of the lead used in CYCLON
batteries. Second, the use of high pressure seals contains the
gases within the cell, promoting more efficient recombination.
In a conventional lead-acid cell, the charge current
electrolyses the water to produce hydrogen from the negative
electrode and oxygen from the positive electrode. Thus water
is lost from the cell, and it must be replenished by means of
frequent topping up with water.
The evolution of the two gases does not occur at the same
time due to the fact that the recharge efficiency of the positive
electrode is less than that of the negative electrode. This
means that oxygen is evolved from the positive plate before
the negative plate can generate hydrogen.
As oxygen is evolved from the positive plate, a significant
quantity of highly active spongy lead exists on the negative
electrode before the negative plate can generate hydrogen.
If the oxygen that is generated by the positive plate can be
transported to the negative plate, the spongy lead will react
rapidly with the oxygen to form lead oxide as shown by the
following reaction:
2Pb + O
2 ➔ 2PbO (Eqn. 1)
100
0
-4 -30 -20 -10 0 10 20 30 40
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Temperature, ºC
Publication No: EN-CYC-AM-007 - December 2008
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