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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!

1.10 UL Component Recognition

All CYCLON batteries are recognised as UL components.

2.1 Single Cell Construction

Both the positive and negative plates are made of pure lead-

tin 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.

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.

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.

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).

Chapter 2:

Physical Features

Chapter 3:

CYCLON

Battery Benefits

Publication No: EN-CYC-AM-007 - December 2008