Battery Installation, Operation and Maintenance

GEN 1
THIN PLATE PURE LEAD
(TPPL) TECHNOLOGY

www.enersys.com
 GEN 1

OPERATION AND MAINTENANCE INSTRUCTIONS FOR NEXSYS® PURE BATTERIES

NexSys® PURE batteries are for traction applications. The batteries are Valve Regulated Lead Acid (VRLA) utilizing our Thin Plate Pure Lead (TPPL) technology.

RATING DATA
Nominal capacity C6 : see table below
Nominal voltage : see table below
Rated temperature : 77°F (25°C)

Unlike conventional batteries with liquid electrolyte, NexSys PURE batteries have immobilized electrolyte. Instead of a vent plug, a valve is used to regulate the internal gas
pressure, which prevents the ingress of oxygen and allows the escape of excess charging gasses should an overcharged condition occur. When operating VRLA batteries,
the same safety requirements apply as for vented batteries. This will help protect against hazards from electric current to explosion of electrolytic gas and corrosive
electrolyte.

Battery valves should never be removed. These batteries do not require watering.

Any data, descriptions or specifications set forth herein are subject to change without notice. Before using the product(s), the user is advised and cautioned to make its own
determination and assessment of the suitability of the product(s) for the specific use in question and is further advised against relying on the information contained herein
as it may relate to any general use or indistinct application. It is the ultimate responsibility of the user to ensure that the product is suited and the information is applicable
to the user’s specific application. The product(s) featured herein will be used under conditions beyond the manufacturer’s control and therefore all warranties, either express
or implied, concerning the fitness or suitability of such product(s) for any particular use or in any specific application, are disclaimed. The user expressly assumes all risk and
liability, whether based in contract, tort or otherwise, in connection with the use of the information contained herein or the product itself.

SAFETY PRECAUTIONS 4.00

CONTAINS: Lead, Sulfuric Acid (Electrolyte), Lead Compounds.

Color Key (Ref Only)
Harmful if swallowed, inhaled, or in contact with skin. Acid causes severe skin burns and eye damage.
May damage fertility or the unborn child if ingested or inhaled. May cause harm to breastfed children. Use any
WARNING - Do NOT use CMYKtype of oil, organic solvent, alcohol,
May cause cancer if ingested or inhaled. Causes skin irritation, serious eye damage. Contact with
internal components may cause irritation or severe burns. Causes damage to central nervous system,
blood and kidneys through prolonged or repeated exposure if ingested or inhaled. Irritating to eyes, detergent, strong acids,
Whitestrong alkalis, petroleum-based solvent or
respiratory system, and skin. May form explosive air/gas mixture during charging. Extremely
flammable gas (hydrogen). Explosive, fire, blast or projection hazard. Obtain special instructions
before use. Do not handle until all safety precautions have been read and understood. Wash
ammonia solution toBlack
clean the jars or covers. These materials may
thoroughly after handling. Do not eat drink or smoke when using this product. Avoid contact during
pregnancy/while nursing. Wear protective gloves/protective clothing, eye protection/face protection.
cause permanent damage
PMS 179 to15 the battery jar and cover and will void
Use only outdoors or in a well-ventilated area. Avoid contact with internal acid. Do not breathe the warranty. Pantone 186 C
dust/fume/gas/mist/vapors/spray. Keep away from heat/sparks/open flames/hot surfaces.
No smoking IF SWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a poison
center/doctor if you feel unwell. IF ON CLOTHING OR SKIN (or hair): Remove/Take off immediately
all contaminated clothing and wash it before reuse. Rinse skin with water/shower. IF INHALED:
Pantone 102 C
4.20 Remove person to fresh air and keep comfortable for breathing. Immediately call a POISON CENTER
or doctor/physician. IF IN EYES: Rinse cautiously with water for several minutes. Remove contact Pantone 298 C
lenses, if present and easy to do. Continue rinsing. If exposed/concerned, or if you feel unwell seek
medical attention/advice. Store locked up, in a well-ventilated area, in accordance
with local and national regulation. Dispose of contents/container in accordance
with local and national regulation. Keep out of reach of children.
PROPOSITION 65 WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm. Batteries
also contain other chemicals known to the State of California to LABEL
cause cancer. Wash hands after handling.
WARNING: Risk of fire, explosion or burns. Do not
LABEL
disassemble, heat above 60°C or incinerate. LABEL
Ventilate spaces where used or charged.
High Voltage: Risk of shock. Do not touch
uninsulated terminals or connectors. 15 Battery must
be recycled

REWIND
VIEW 2
Failure to follow these Operation and Maintenance Instructions R
or.13
using parts that are non-original will void the NexSys PURE battery warranty.
TYP
PRINT DIE LINE, DIMENSIONS, NOTES OR REV BLOCK.
1. Commissioning The specified torque loading for the bolts/screws of the terminals and terminal adaptors
R AND LABEL MUST BE UL RECOGNIZED. for NexSys PURE blocs are detailed in the table below:
NexSys PURE batteries are supplied in a charged condition. The battery should be
AL DEFINED PER MS3000-5.
inspected to ensure it is in good physical condition. NexSys® PURE Standard Terminal Terminal Terminal
RK TO BE CENTERED WITHIN ±0.015". Battery Type Terminal Torque [in/lbs] Adapter Torque [in/lbs]
Check:
IONAL TOLERANCES: X.XXX = ± 0.030
• The battery compartment and the battery are in a clean condition. 12NXS26
IZE: 3" ID; MAX OD: 7.9"
• The battery cable ends have good contact with the terminals
ARTWORK: 2200-0333
12NXS36
OLL MUST BE MARKED PER is
and the polarity VENDOR'S
correct. UL FILE, WITH A 12NXS38
M OF P/N, VENDOR NAME, LOT # & UL MARK PRINTED IN 12NXS50 M6 Female 60 SAE 60
Never directly connect an electrical appliance (i.e. warning beacon)REV
to a partDATE
of the ECO DRW CHK
12NXS62 APP
EACH ROLLbattery.
MUST ThisBE MARKED WITH QUANTITY PER ROLL.
could lead to an imbalance of the cells. This will damage all cells in the 12NXS90
G BETWEEN LABELS
battery IS TO
and void the BE REMOVED;
battery warranty. GAP BETWEEN
A DC-DC 01 to8/29/16
converter must be used supply any 9001733 12NXS120
MWR DR SS
SHALL BE low voltage
0.125 loads.
- 0.313” 02 10/19/18 9001973 LES DR SS
12NXS61
E WITH ONLY ZEBRA 5095 M8 Female 80 M6 Male 60
NexSys PURE 12V(F2220-0333) RIBBON. into strings must use flexible cable
blocs that are assembled 12NXS85
connections with adequate length to ensure there is no stress on the terminal due to
battery movement. EnerSys® approved fasteners must be used. The valves on the top 12NXS86 3/8 - 16” Female 60 SAE 60
of the battery must not be sealed or covered. NexSys PURE batteries may be installed
in any direction except inverted. Only batteries with the same state of discharge should 12NXS137
M6 Female 80 M6 Male 80
be connected together. 12NXS157
12NXS166
Charge the battery (see Section 2.2) before the first discharge. Sufficient controls M8 Female 80 M6 Male 80
12NXS186
should be enacted (colored connectors, Wi-iQ® device, etc) to ensure the battery is only
charged using an EnerSys approved charger with the appropriate approved NexSys Terminals for NexSys PURE 2V cells are torqued at the factory and do not require any
PURE profile. checking or re-torquing in the field.
 2.0 Operation 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
The acceptable ambient operating temperature range for the discharge of NexSys® sufficient, check the following:
PURE batteries is between -20°F (-29°C) and 113°F (45°C). The acceptable ambient • That the required work is compatible with the battery capacity.
charging temperature range is between 32°F (0°C) and 113°F (45°C). • Battery has been plugged into the charger at every opportunity.
• The settings of the charger.
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 3.4 Annually
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 Remove internal dust from the charger. Inspect and test all electrical connections
battery life is obtained when the battery is operated, charged and stored in an ambient (sockets, cables and contacts). Check the torque loading of the bolts/screws on bloc
temperature between 41°F (5°C) and 86°F (30°C); and discharges are equal to or lower type products. Test the insulation resistance of the battery. Insulation resistance of the
than 60% of the nominal C6 capacity. Operation of the battery outside of the optimum battery thus determined must not be below a value of 50 Ω per volt of nominal voltage.
temperature range may require the use of a Wi-iQ® device and NexSys+ charger for For batteries up to 20V nominal voltage the minimum value is 1000 Ω.
proper temperature-adjusted charging. Consult an EnerSys® representative for the
proper equipment selection for your application. 4. Care of the Battery

The battery obtains its full capacity after about three charging and discharging cycles. 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
2.1 Discharging tray should be repaired after cleaning to prevent corrosion.

Discharges over 80% DOD of the rated capacity are categorized as deep discharges 5. Storage
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 Batteries are shipped from the manufacturer fully charged. The state of charge will
cycle life of the battery will depend on the DOD; the higher the average DOD, the decrease with storage. All batteries lose their stored energy when allowed to be in
shorter the cycle life. 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
Partially discharged and fully discharged batteries can freeze, which irreversibly temperature. High temperatures greatly reduce storage life. It is recommended that
damages the battery. Limit the discharge to a maximum of 80% DOD in cold climates, the fully charged battery should be stored in a cool dry place, ideally below 68°F (20°C),
and recharge immediately. but no lower than 41°F (5°C).

The battery may be fitted with a Protection from Over-Discharge™ (POD™) device to If the truck/vehicle is going to be unused for periods in excess of 48 hours, the
provide visual and audible warning signals. An observed warning signal indicates the ignition key must be removed and any auxiliary equipment (such as lights, beacons,
battery has reached its maximum discharge level and must be charged immediately. on-board computer, etc.) must be switched off. If the truck or battery is going to be
The following load cut-off settings must be used: decommissioned for a period of one month or longer, all electronic devices (such as
• 60% DOD at an average loaded voltage of 1.96 volts per cell, or Wi-iQ device, POD device) must be professionally disconnected by an EnerSys service
• 80% DOD at an average loaded voltage of 1.92 volts per cell. representative.

when discharged at average loads with currents in the range of I4 to I8. At average The 2V assembled product has a maximum inspection-free storage time of six months,
currents outside of this range, please seek advice from an EnerSys representative for if stored at or below 68°F (20°C) (provided the battery is fully charged when put into
energy cut-off settings. 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.
2.2 Charging 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.
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 The 12V product has a maximum inspection-free storage time of two years, if stored
and life of the battery and invalidate any warranty. The specific charging profile at or below 68°F (20°C) with no electronic devices connected. After this time a refresh
developed for recharging NexSys PURE batteries allows opportunity charging as often charge should be administered. However, it is advisable to conduct an inspection and
as needed without damaging the batteries. Charge rate must be maintained between open circuit voltage check after 12 months and recharge if the OCV is less than 2.10
0.18C6 and 0.70C6, depending on the battery and charger type. NexSys PURE batteries Volts per cell. When stored in temperatures in excess of 86°F (30ºC), the battery should
have an extremely low gas emission. Nevertheless, provisions must be made for be OCV checked every six months. The graph below shows the relationship between
venting of the charging gases. Battery container lids and vehicle compartments must temperature, storage time and OCV.
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
A new battery may be stored for up to five years without degradation of performance
• Plug the battery into the proper charger at every opportunity. provided that an OCV check is conducted every 12 months and refresh charges are
• Check the condition of the plugs, cables and make sure that all insulation covers administered as needed.
are in place and are in good condition.
6. Malfunctions
3.2 Weekly
If malfunctions are found on the battery or the charger, please contact an EnerSys
• Allow up to six hours for a full charge at least once per week. representative. The measurements taken in Section 3.3 will identify problems and help
• Visually inspect for signs of dirt and mechanical damage to all component parts of establish a base to correct them.
the battery, paying particular attention to the battery charging plugs and cables.
7. Disposal
3.3 Quarterly
NexSys PURE batteries must be recycled. End-of-life batteries must be packaged and
At the end of the charge, take end of charge voltage readings, measure and record: transported in accordance with prevailing transportation rules and regulations. End-
• The voltage of the complete battery. of-life batteries must be disposed of in compliance with local and national laws by a
• The voltages of each cell or bloc. licensed or certified lead acid battery recycler.
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© 2020 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates except UL,
which is not the property of EnerSys. Subject to revisions without prior notice. E.&O.E.
AM-NXSPURE-GEN1-IOM AA October 2020