Home>Lift trucks>Truck power>Opportunity charging without lithium-ion

Opportunity charging without lithium-ion

24 October 2016

The new NexSys range of high-performance motive power batteries from EnerSys offers fast charging, opportunity charging, zero change and virtually zero maintenance capabilities that deliver significant operational benefits and lifetime cost savings compared with traditional flooded and gel battery alternatives. 

Based on the proven Thin Plate Pure Lead (TPPL) technology, NexSys batteries are available in Standard and Fast charging configurations to support a wider range of applications than previous models. They are suitable for an extensive range of vehicles including lift trucks, order pickers, pallet trucks, AGV/LGVs and cleaning machines.

The NexSys batteries are manufactured using TPPL technology, widely recognised as the most advanced lead based technology on the market and perfected by EnerSys to deliver the highest possible performance and reliability. They are the only valve-regulated lead-acid design to provide an equivalent or higher ampere-hour capacity than traditional flooded batteries. NexSys batteries also deliver more usable power (watt-hours).

The first-generation TPPL batteries – the Hawker XFC range – introduced in 2007, provided an excellent alternative in terms of cost, performance and flexibility to new and emerging alternatives such as Lithium-Ion without many of the limitations. Recent enhancements in battery and charger technology mean that the new-generation NexSys batteries have longer life cycle expectancy, are virtually maintenance free, and can be charged at a standard rate of six hours or fast charged in less than four hours (depending on charger rating). The batteries are designed for opportunity charging that allows them to be topped up for short periods, such as during routine breaks or while other tasks are being undertaken, to maintain what amounts to continuous vehicle availability. This transforms the way operators can deploy their electric powered vehicles because there is no longer any need to change batteries or park equipment during a lengthy charge cycle.

Advanced new charging profiles developed by EnerSys allow NexSys batteries to be used with smaller charger models from the EnerSys modular range to support a greater variety of application profiles and machine types. 

NexSys batteries are available in Standard and Fast configurations so that OEMs and equipment operators can specify the right combination of battery, charger and monitoring system for their precise application and business requirement.

The NexSys Standard package is ideal for low to normal duty applications requiring up to 10 hours work with a typical daily energy throughput of 100% and where an opportunity charge is possible. Available with NexSys chargers, NexSys Standard is the most flexible and adaptable energy pack on the market. It enables up to 1450 cycles from 60% depth of discharge (DOD), and can be discharged down to 80% DOD.

The NexSys Fast package is ideal for multi-shift operations which typically demand up to 16 hours of work. In these applications the daily energy throughout of around 160% previously required a conventional battery to be changed at 80% DOD or charged for lengthy periods in situ. NexSys Fast supports a totally new approach to provide complete flexibility with increased autonomy. Its specific charging profile allows a rapid recharge in less than four hours from 60% DOD and shorter opportunity charging as often as needed, without damaging the batteries (charging from 40% to 80% state of charge in one hour and to 98% in two hours). These specialised capabilities are standard features in the NexSys iQ chargers.

Both packages utilise the advanced capabilities of the EnerSys Wi-iQ monitoring device to monitor the state of charge and operating conditions as well as storing complete data of the battery’s service life and providing meaningful fleet management reports. When used with the NexSys iQ charger range, it supports temperature control, enabling operations in cold environments and precise also data management for use in AGV applications.

In all configurations the NexSys packages eliminate the need for spare batteries and expensive, space-consuming change-and-charge infrastructure. This not only removes cost from the battery system but reduces complexity and makes battery deployment simpler and easier. The Charger has an energy efficiency up to 94% and a very low charging factor of the TPPL technology enables to reach up to 30% energy saving compared to Standard batteries. When the removal of all topping-up costs are also factored in the savings can be significant. 

The batteries are available in a range of industry-standard sizes so that OEMs can incorporate them easily into their existing designs. The cell boxes are highly resistant to shock and vibration to enhance ruggedness and reliability. The batteries require no topping which makes them virtually maintenance-free.
EnerSys has announced that NexSys batteries will replace the existing XFC battery ranges. Advances in manufacturing processes coupled with the projected life expectancy and predicted reliability ensure that the new range is competitively priced against traditional and alternative designs.