SEVENTH EDITION - Rose Batteries

1 Publication No: US-GPL-AM-003 - September 2006 Genesis PureleadXE and EPAPPLICATIONMANUALSEVENTH EDITION2 Genesis XE & EP Application ManualPublication No: US-GPL-AM-003 - September OF CONTENTSP reface to the SEVENTH Edition2 Chapter 1: Introducing the Genesis component Genesis benefits3 Chapter 2: Technical the right Genesis and constant-current discharge characteristics & (CV) (CC) (IUU) charge circuit voltage (OCV) and state of charge (SOC) to recover overdischarged batteries10 Chapter 3: General Test runaway standard overdischarge recovery temperature storage recovery float life test at different temperatures13 Chapter 4: Installation, Operation & the A: Genesis XE Discharge Characteristics15-24 Appendix B: Genesis EP Discharge Characteristics25-31 Preface to the SeventhEditionThis EDITION of the Genesis application manual has beennecessitated by several is to introduce the GenesisXE range of Batteries , packagedto offer the same superiorperformance characteristics ofthe Genesis EP battery in morephysically demandingapplications such as hightemperature and high vibrationenvironments.

2 Appendix A offers exhaustiveconstant current (CC) andconstant power (CP)performance data and graphs forthe full range of Genesis XEbatteries to several end B offers the sameinformation for the EP series. Chapter 4 is new to this offers guidelines on theinstallation, operation andmaintenance of Genesisbatteries, with the goal ofmaximizing performance andservice , new and updated testdata have been includedthroughout the text, whereveravailable and No: US-GPL-AM-003 - September 1:Introducing the Genesis BackgroundSince its introduction in the early 1990s, the Genesis thinplate pure lead-tin (TPPL) battery has established itself asa premium high performance battery suitable for a widerange of demanding applications. Today, TPPL technology can be found in applications as diverse asemergency power, avionics, medical, military andconsumer equipment.

3 The Genesis TPPL battery is offered in either the EP orXE version, and Table shows the differencesbetween the two versions. Transportation classificationEffective September 30, 1995, Genesis Batteries wereclassified as "nonspillable Batteries ", and are exceptedfrom the Department of Transportation s comprehensivepackaging requirements if the following conditions aresatisfied: (1)The battery is protected against short circuitsand is securely packaged and (2)The battery and outerpackaging must be plainly and durably marked"NONSPILLABLE" or "NONSPILLABLE BATTERY".Genesis shipments from the Warrensburg location,will be properly labeled in accordance with applicableregulations. Packaging changes performed at otherlocations may require additional labeling, since inaddition to the battery itself containing the requiredmarking, the outer packaging of the battery must alsocontain the required marking: "NONSPILLABLE" or"NONSPILLABLE BATTERY".

4 Genesis Batteries have been tested and determined to bein compliance with the vibration and pressure differentialtests contained in 49 CFR (d).Because Genesis Batteries are classified as"Nonspillable" and meet the conditions above, [from (d)] they do not have an assigned UN numbernor do they require additional DOT hazard UL component recognitionAll Genesis Batteries are recognized as UL Non-halogenated plasticsAs the world becomes more environmentally aware,EnerSys is striving to provide the most environmentallyfriendly products possible. With this in mind, we areproud to say that the plastics used in our Genesisproduct line are non-halogenated and therefore do notcontain any of the following materials:Polybrominated biphenyls (PBB)Polybrominated biphenyl ethers (PBBE)Polybrominated biphenyloxides (PBBO)Polybrominated diphenyl ethers (PBDPE)Polybrominated diphenyl oxides (PBDPO)Tetrabromobisphenol-A (TBBA)Deca-bromo biphenyl ethers (DBBPE s).

5 The battery meets the non-halogenated flame retardancyrequirements of UL 94V-0 by using plastics with non-halogenated flame retardants. Finally, the plastic materialused in the manufacturing of Genesis Batteries is in fullcompliance with the German Dioxin Ordinance of 1994. Key Genesis benefitsTable lists some of this battery s features andbenefits. The Genesis battery is well suited for anyapplication - high rate, low rate, float or deep volumetric and gravimetric power densitiesMore power in less space and weightThin-plate designSuperior high rate discharge capabilityLow internal resistanceFlatter voltage profile under high-rate discharge;excellent low temperature performance1 Negligible gassing under normal chargeSafe for use in human environments such as offices and hospitals. Must be installed in non-gastight enclosures100% maintenance-free terminalsTrue fit-and-forget batteryFlexible mounting orientationBattery may be installed in any position except invertedRugged constructionTolerant of high shock and vibration environments, especially the XE versionAdvanced manufacturing techniquesHigh reliability and consistencyVery high purity lead-tin gridLower corrosion rates and longer lifeNon-halogenated flame retardant case and coverMeets UL 94 V-0 requirement, with an LOI >28%Excellent high-rate recharge capabilityAllows >90% recharge in under an hourLow self-dischargeLongest shelf life among VRLA Batteries (2 years at 25 C or 77 F)Wide operating temperature-40 C (-40 F) to +80 C (176 F)2 Table.

6 Key features and benefits of the Genesis battery1 See Table and Figure in Section of Chapter 22 The XE version of the Genesis battery may be used at 80 C (176 F) when fitted with a metal jacket Chapter 1:Introducing the Genesis Battery lifeThe life expectancy of a Genesis battery depends on thespecific application. It is expressed in terms of eithercycles or years. While life in years is self-explanatory,a cycle refers to a sequence in which a charged battery isdischarged and then charged back up. One completesequence constitutes one cycle. In general, if the batteryis to be discharged frequently, cycle life rather thancalendar life is more relevant. On the other hand, if thebattery is to be used primarily as power backup, calendarlife of the battery should be situations where one is not quite sure whether theapplication is cyclic or standby (float), the followingcriteria may be used to determine the applicationcategory: If the averagetime on charge between two successivedischarges is thirty (30) days, the application may beconsidered to be of a standby (float) nature.

7 The minimumtime between two successivedischarges must not be less than fourteen (14) either of these two criteria is not satisfied, theapplication should be considered 2:Technical IntroductionThis section is at the heart of this manual. Because ofthe wide variety of data and information included inthis chapter, it is divided into smaller, self-containedsections, allowing the reader to locate specificinformation in the quickest possible Choosing the right Genesis versionAs mentioned before, the Genesis pure lead-tin batteryis available in EP and XE versions. The EP battery isadequate under most operating conditions. Special application situations such as high ambienttemperature or high shock and vibration require theXE version. Table summarizes the differences between thetwo versions and is designed to help you choose theright version for your application.

8 In this table, thedifferences are highlighted in red boldfaced. FeatureGenesis EPGenesis XETechnologyPure lead-tin absorbed glass mat (AGM)Float life @ volts per cell (Vpc) charge10 years @ 25 C (77 F)N/ACycle life 400 to 80% depth of discharge (DOD)Shock & vibration toleranceGoodBetterOperating temperature range -40 C to +45 C (-40 F to 113 F) -40 C to +45 C (-40 F to 113 F) -40 C to +60 C (-40 F to 140 F) -40 C to +80 C (-40 F to 176 F)with metal jacket (denoted EPX)with metal jacket (denoted XEX)Shelf life @ 25 C (77 F) 2 years from 100% charged down to 12V per blockCapacity @ 10-hr. rate100% (reference) 95%Weight100% (reference) 105%DimensionsSame footprintQuick charge6C to 8C charge acceptance at room temperatureOverdischarge abuse toleranceExceeds DIN standard for overdischarge recoveryHigh-rate discharge 100% (reference) 95%Flame retardant ratingV-0 rated case and coverCase & cover colorBlackOrangeShippingAir shippable with no restrictionsTable : Choosing the right Genesis version4 Publication No: US-GPL-AM-003 - September 2:Technical Information While several factors affect the life of a battery, cycle lifedepends primarily on the depth of discharge (DOD).

9 At aDOD of 80%, the Genesis battery will deliver about 400cycles; at 100% DOD, that number decreases to about320 cycle life estimates assume shows the relationship betweenDOD and cycle : Cycle life and depth of discharge (DOD)In contrast to cycle life, ambient temperaturedramatically affects float life. For roughly every 8 C risein ambient temperature above 25 C (77 F), the float lifeof a VRLA battery is cut in half. In other words, a 10-yearbattery at 25 C (77 F) is only a 5-year battery at 33 C(91 F). Additionally, float life is cut in half for every100mV per cell over the recommended float relationship between ambient temperature andexpected float life is given by the Arrhenius equation defines the relationship between theambient temperature and the rate of internal positive-grid corrosion of the battery, which is the normal processof battery aging.

10 A key point to note is that the temperature in question isthe battery ambient temperature. If the system is in a25 C (77 F) environment and the battery is installed nextto a power transformer where the temperature averages32 C (90 F), then all battery calculations must be basedon 32 C (90 F).The Arrhenius equation is the theoretical foundation forthe relationship used in practice to derive theacceleration factor for a given temperature. The equationis shown below, in which AF is the acceleration factorand Tis the battery ambient temperature in an example, consider a battery in a float applicationat an ambient temperature of 37 C ( F). Replacing Twith 37 in the equation above the acceleration factor (AF)in this case would be 2( )or A 10-year battery inthis situation should be expected to last only years (10 = ).