User manual

Chapter 1:
Introducing the Genesis Battery
1.1 Introduction
The purpose of this guide is to describe the characteristics
of the sealed-lead family of rechargeable CYCLON
®
cells and
batteries from EnerSys
®
in its many different applications.
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.
1.3 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.
1.6 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.
1.9 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 Non-
Hazardous 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.”
Chapter 1:
Introducing CYCLON
®
Batteries
6
Publication No: EN-CYC-AM-007 - December 2008
www.enersys-emea.com