The new cells based on thin plate pure lead (TPPL) battery technology are available in heights from 370 to 675 millimeters and cover C5 capacities from 130 to 980 ampere-hours. "This expansion of the portfolio builds on the already proven benefits of Nexsys technology," explains Martin Walsh, Product Manager EMEA for TPPL technology at Enersys. The expansion of the range should also open up a broader market, as the new range covers more types of industrial trucks.

The performance of the Nexsys traction batteries is based on TPPL technology, which makes it possible to reduce operating costs over the entire service life compared to other wet cell and gel batteries. Thanks to higher energy density and the possibility of intermediate charging, the Nexsys batteries can be recharged in a short time, for example during a break or shift change, which leads to almost uninterrupted vehicle availability, according to the manufacturer. This in turn increases the productivity of operators and vehicles, as the vehicles no longer have to be parked offline for charging or battery changes. The batteries can simply be charged in the vehicle, which simplifies multi-shift operation.

Maintenance time and effort are almost completely eliminated, as the batteries are closed and do not need to be topped up with water. The risk of injury to users and damage to the floor of the system is minimized, as battery acid cannot be spilled during the refilling process and the time and effort required for the refilling process is eliminated. This reduces water costs and the low charge factor of the batteries also reduces energy costs.

Thanks to minimal outgassing, the vehicles can be loaded close to their place of use. There is no longer any need for space for the loading compartments with the required air conditioning systems or travel routes to these compartments. There is also no need to keep a comprehensive set of spare batteries or lifting equipment on hand.

The Nexsys two-volt TPPL cells are made from pure lead plates, which are much thinner than lead-calcium/antimony grids. This allows more electrodes to be placed in the same space, increasing battery capacity and power density. TPPL is the only valve-regulated lead-acid battery technology that offers an equivalent or even higher capacity in ampere-hours than conventional wet cell batteries. The pure lead grain structure makes the grid much more resistant to corrosion. Positive and negative battery plates have a low impedance, resulting in a higher current flow during both discharging and charging. The electrolyte is embedded in a high-quality microporous glass mat separator, which offers high absorption capacity and stability and therefore a high number of cycles. As a result, the cell housings are shock and vibration resistant.

Standard and quick charge configuration

Nexsys batteries are offered in a standard and fast charge configuration, allowing manufacturers and equipment operators to specify exactly the right combination of battery, charger and monitoring system for their application and business needs. The standard configuration is best suited for applications with light to normal operating conditions with up to ten operating hours and a typical daily energy throughput of 100 percent, where intermediate charging is possible. The fast-charge configuration is designed for multi-shift operation, typically requiring up to 16 hours of operation. The special charging profile of these batteries enables fast charging in less than four hours from a depth of discharge of 60 percent and frequent intermediate charging as required without damaging the battery. as