SELECTION GUIDE FIFTH EDITION RESERVE POWER Publication No: EN-GPL-SG-003 - November 2008 GENESIS(R) Selection Guide EnerSys is the world's largest industrial battery manufacturer with (R) manufacturing and assembly plants located around the world, over 7,000 employees, and a worldwide sales and distribution network. A leader in both valve-regulated and flooded lead acid battery technologies, EnerSys is a major supplier to telecommunications, uninterrupted power supply (UPS), data processing, electronic, defence, aviation, and material handling markets across the globe. TABLE OF CONTENTS EnerSys operates several of the first lead acid battery plants in the Company background United States to receive the ISO 9001 certificates of registration, EnerSys(R) 2 covering the company's product design, manufacturing, assembly, Services and applications 3 and customer service functions. Features and benefits 4 ISO 9001 certification, covering 20 key elements, assures customers that EnerSys has fully documented and implemented manufacturing Technical information and quality systems that are consistently followed. Capacity as a function of temperature 5 State of charge 6 EnerSys' environmentally progressive Warrensburg, Missouri plant, home base of the GENESIS(R) product lines, covers 320,000 square feet Storage time as a function of temperature 6 on 33 acres and employs more than 400 people. EnerSys was the first Voltage regulations 6 battery company in the United States to receive ISO 14001 Charging recommendations 6 certification. ISO 14001 focuses on the environmental management system of the business and provides a systematic approach to resource conservation. GENESIS Batteries (R) GENESIS product family 7 EP performance specifications 8 EP mechanical specifications 8 (R) 70EP performance specifications 9 70EP mechanical specifications 9 GENESIS constant current (CC) and constant power (CP) discharge graphs 10 EnerSys supports its customers through global field sales offices and a select network of authorised Value Added Centres and international representatives and distributors. EnerSys offers technical support and customer service unparalleled in the industry. Additionally, the sales and support team is committed to meeting and exceeding the individual needs of each customer. Quick reference list Standard product listing 11 EnerSys' Warrensburg plant covers 320,000 square feet and is situated on 33 acres 2 www.enersys-emea.com Publication No: EN-GPL-SG-003 - November 2008 Value-Added Services In addition to our manufacturing capability, EnerSys(R) is proud to provide its customers with the following services: customised manufacturing design battery recycling on-line Internet technical information charging support product testing on-site technical seminars battery samples application engineering technical documentation Applications Batteries from EnerSys' "pure lead-tin" family are used in a wide variety of standby and portable/cyclic applications including those in: telecommunications electronics uninterruptible power supplies defence installations computer back-up electric vehicles medical equipment solar power lawn and garden equipment www.enersys-emea.com Publication No: EN-GPL-SG-003 - November 2008 3 Features and Benefits Sealed pure-lead cells were invented by a predecessor company of EnerSys(R) in 1973. The purity of the materials used is key to supporting the GENESIS(R) battery's performance benefits. A longer service life, meaning fewer replacements and the cost associated with it, combined with higher reliability and fewer system failures, result in a lower long-term cost of ownership to the end user or equipment owner. What are the advantages of EnerSys technology? 1. Power density - Per unit weight, the power provided by pure lead-tin products offers the greatest high-rate power density for your energy dollar. GENESIS' greater volumetric power allows engineers to consider more energy-supporting features or design smaller, lighter packages. At high-rate and pulse discharges, EnerSys' GENESIS products offer the best performance value when compared with competitive product in applications at less than 100 minutes of discharge. 2. Cycle life - Compared to competitive lead products (offering up to 200 full cycles), pure lead-tin batteries provide 50% to 200% greater full cycle capability. GENESIS product will deliver up to 400 cycles (80% DOD, C/5). And, because GENESIS incorporates a high vent-pressure design, EnerSys' products experience no "dry out" failure mode from repeated recharges. 3. Float life - Conventional sealed-lead batteries vary greatly in specified standby life: from three to six years at 20C, C/20. GENESIS, however, offer a ten-year design life at 25C, C/5, to 80% of rated capacity. At 20C, GENESIS Single Cells offer a fifteen-year design life. 4. High stable voltage delivery - The high stable voltage delivery of a pure lead-tin battery results from its low internal resistance. The flat discharge voltage profile of our batteries, similar to nickel cadmium, combined with our products' low internal resistance, means our batteries are able to discharge and recharge their power more quickly and efficiently and offer greater application flexibility. The pure lead-tin construction also gives more watts-per-unit weight at high discharge rates. 5. Widest temperature range - Due to the product's strong construction and high vent pressures, these batteries will maintain their performance and physical parameters in extreme conditions. At high temperatures, the chemical reaction in a battery that causes aging is accelerated. Pure lead-tin technology resists that chemical reaction more effectively than alloyed lead, thus allowing a battery to have a longer service life. At high temperatures, when conventional 4 www.enersys-emea.com lead batteries experience internal moisture loss from venting and case side wall distention, the GENESIS, with its steel can (metal jacket) and high venting pressure, does not experience these life-robbing conditions. GENESIS has twice the delivered capacity of conventional sealed-lead batteries at temperatures below -20C, offering unparalleled low-temperature performance. GENESIS electrodes are thinner, allowing more electrodes per cell, and therefore greater electrode surface area than conventional sealed-lead, thick electrode batteries. As a result, our batteries can reach a high state of charge in fast-charging applications in one-fourth the time of conventional, sealed-lead, thickplate batteries. This is 50% to 100% overall better performance for your energy dollar. 6. Rugged construction - Due to their strong external packaging and internal pure lead-tin composition, EnerSys' products can withstand not only extreme temperatures but also harsh usage. The pure lead-tin advantage Vent pressure Fast-recharge capability High-temperature tolerance Low-temperature performance High-temperature performance None Low GENESIS(R) pure lead-tin technology Fair Moderate Excellent High Conventional technology GENESIS external case for the EP product is constructed from UL 94V-0 rated non-halogenated flame-retardant materials. GENESIS products are shock and vibration resistant, designed to offer higher tolerance levels to meet demanding applications, including those in commercial and outdoor applications. The company's focus on battery-case integrity and high vent pressure, coupled with pure lead-tin's low grid-corrosion rate, means GENESIS provide the longest service life possible. Publication No: EN-GPL-SG-003 - November 2008 Because GENESIS are classified as "Nonspillable" and meet the conditions from 173.159(d) they do not have an assigned UN number nor do they require additional DOT hazard labeling. 7. Fastest recharge - EnerSys' pure lead-tin chemistry allows GENESIS(R) to offer the shortest recharge efficiency of any sealed-lead battery on the market. With pure lead-tin, you can achieve a 95% state of recharge in less than one hour - without loss of capacity or electrolyte using conventional constantvoltage charging techniques. All batteries that have been tested and determined to be in compliance with the DOT Hazardous Material Regulations, the International Civil Aeronautics Organisation (ICAO), and the International Air Transport Association (IATA) Packaging Instruction 806 and Special Provision A67, are therefore exempt from all other requirements of these regulations and classified as a "nonspillable battery". Flexible charging options are possible with GENESIS, as no current limit is required when using a constant voltage charger. 8. Orientation/placement/transport - Due to the products' mechanical design, GENESIS can be mounted and operated in any position, except inverted, an attractive feature for less accessible areas. 9. Shelf life - Pure lead-tin batteries have an extremely low self-discharge rate, thus providing extended storage capability while maintaining high state-ofcharge levels for dependable operation. GENESIS offer UL94 V-0 non-halogenated flameretardant packaging, thus allowing the mounting of systems in sensitive areas and human environments. GENESIS has a shelf life more than two times that of conventional lead batteries. To assure maximum reliability, EnerSys recommends that all stored cells/batteries be recharged (boost charged) once every 24 months or when the open circuit voltage drops to 12.00 volts per battery, whichever occurs earlier. Inventory should be checked more frequently if storage temperature regularly exceeds 25C. GENESIS products are classified as "nonspillable batteries", and are excepted from the Department of Transportation's comprehensive packaging requirements if the following conditions are satisfied: (1) The battery is protected against short circuits and is securely packaged and (2) The battery and outer packaging must be plainly and durably marked "NONSPILLABLE" or "NONSPILLABLE BATTERY". GENESIS shipments from EnerSys(R) Warrensburg location, will be properly labeled in accordance with applicable regulations. Packaging changes performed at other locations may require additional labeling, since in addition to the battery itself containing the required marking, the outer packaging of the battery must also contain the required marking: "NONSPILLABLE" or "NONSPILLABLE BATTERY". GENESIS batteries have been tested and determined to be in compliance with the vibration and pressure differential tests contained in 49 CFR 173.159(d). Capacity as a function of temperature for GENESIS(R) Batteries Discharge time, hours 10 1 0.1 0.01 -40 -30 -20 -10 0 10 20 30 40 50 Temperature, C 15 MIN RATE www.enersys-emea.com C RATE C/5 RATE Publication No: EN-GPL-SG-003 - November 2008 5 Charging recommendations: State of charge for GENESIS(R) batteries 13.0 Broadly speaking, a battery may be recharged using either a constant voltage (CV) charger or a constant current (CC) charger, or a modification of either or both of these. 12.8 12.6 OCV, V 12.4 12.2 12.0 11.8 11.6 11.4 10 20 30 40 50 60 70 80 90 100 State of Charge, % Storage time as a function of temperature for GENESIS(R) batteries (Fully charged battery) Storage Time in Days 3000 1000 100 The exact regime chosen generally depends upon the time and economic constraints imposed by the system. Constant current charging is widely used in cyclic applications where a recharge must be accomplished in a relatively short time period. Constant voltage charging, where a single voltage level is applied across the battery terminals, is the most suitable method to recharge GENESIS(R) products. Depending on the CV charger's current limit, it is possible to recharge these batteries from a 100% discharged condition to better than 95% state of charge in less than one hour, using only the cyclic charge voltage. Constant voltage charging Constant voltage (CV) charging should be within the following ranges: 10 20 30 40 50 60 70 Temperature in Degrees Celsius Float Chargers, 12 volts: 13.5 to 13.8 volts @ 25C Voltage regulation for GENESIS(R) batteries 2.6 Discharge Rate C/10 or 0.1C Cell Voltage (Volts) 2.4 2.2 2.0 1.8 40C 104F 1.6 Fast Chargers, 12 volts: 14.7 to 15.0 volts @ 25C -40C -40F -20C -4F 0C 32F 25C 77F To avoid thermal runaway in warmer temperatures, and to improve charge acceptance in colder temperatures, the charger voltage should be compensated by approximately 18 millivolts per battery per degree centigrade variance from 25C. This is a negative coefficient, with the voltage being lowered as the temperature increases, and vice versa. 1.4 1.2 0 1 2 3 4 5 6 7 8 9 10 11 12 Time (Hours) 6 www.enersys-emea.com Publication No: EN-GPL-SG-003 - November 2008 There is no need to limit the inrush current to the battery during the initial phase of constant voltage charging. The low internal resistance of GENESIS(R) batteries allows for large inrush current without damage. Since not all of the charge returned is accepted to replenish the electro-chemical potential, a good rule of thumb to use is that the charge returned should be 105% to 110% of the capacity delivered on the previous discharge. Most current waveforms are not pure DC nor are they pure sine waves. Therefore, consult the EnerSys(R) Application Support Department for assistance when evaluating the charger current waveforms for your specific application. GENESIS(R) product family (All capacities at 10hr. rate 25C to 1.67Vpc) GENESIS(R) EP: Products Internal Nominal res. of fully short circuit charged cell current for m @ 25C charged battery DIMENSIONS Length in. mm Width in. mm Height in. mm Weight lb. kg Brass Terminal (metric) Capacity Part Number G13EP 13Ah 0770-2007 8.5 1,400A 6.910 175.51 3.282 83.36 5.113 129.87 10.8 4.9 M6 w/ss hardware G13EPX 13Ah 0770-2003 8.5 1,400A 6.998 177.75 3.368 85.55 5.165 131.19 12.0 5.4 M6 w/ss hardware G16EP 16Ah 0769-2007 7.5 1,600A 7.150 181.61 3.005 76.33 6.605 167.77 13.5 6.1 M6 w/ss hardware G16EPX 16Ah 0769-2003 7.5 1,600A 7.267 184.58 3.107 78.92 6.666 169.32 14.7 6.7 M6 w/ss hardware G26EP 26Ah 0765-2001 5.0 2,400A 6.565 166.75 6.920 175.77 4.957 125.91 22.3 10.1 M6 w/ss hardware G26EPX 26Ah 0765-2003 5.0 2,400A 6.636 168.55 7.049 179.04 5.040 128.02 23.8 10.8 M6 w/ss hardware G42EP 42Ah 0766-2001 4.5 2,600A 7.775 197.49 6.525 165.74 6.715 170.56 32.9 14.9 M6 w/ss hardware G42EPX 42Ah 0766-2003 4.5 2,600A 7.866 199.80 6.659 169.14 6.803 172.80 35.1 15.9 M6 w/ss hardware G70EP 70Ah 0771-2001 3.5 3,500A 13.020 330.71 6.620 168.15 6.930 176.02 53.5 24.3 M6 w/ss hardware G70EPX 70Ah 0771-2003 3.5 3,500A 13.020 330.71 6.620 168.15 6.930 176.02 56.0 25.4 M6 w/ss hardware X denotes metal jacket design for extreme duty www.enersys-emea.com Publication No: EN-GPL-SG-003 - November 2008 7 GENESIS(R) EP performance specifications Constant current discharge/amps to 1.67Vpc @ 25C DURATION Products 5 min 10 min 15 min 30 min 60 min 90 min 5 hr 8 hr 10 hr 20 hr 70.8 43.6 32.2 18.6 10.4 7.3 2.5 1.6 1.3 .7 G16EP (16Ah) 90.0 54.8 40.1 23.0 12.7 8.9 3.0 2.0 1.6 .8 G26EP (26Ah) 143.4 90.7 67.4 39.0 21.7 15.1 5.0 3.2 2.6 1.4 G42EP (42Ah) 212.0 138.4 104.1 60.8 33.8 23.5 7.9 5.1 4.2 2.3 G13EP (13Ah) Constant current discharge/watts per cell to 1.67Vpc @ 25C DURATION Products 5 min 10 min 15 min 30 min 60 min 90 min 5 hr 8 hr 10 hr 20 hr G13EP (13Ah) 758.4 481.8 361.2 231.6 121.2 85.8 29.4 19.2 15.6 8.4 G16EP (16Ah) 975.6 609.6 453.6 264.6 190.2 105.0 36.0 23.4 19.2 10.2 G26EP (26Ah) 1532 995 751 444 251 175.8 59 38 31 16 G42EP (42Ah) 2291 1540 1173 698 394 276 94 62 51 28 Charging/Temperature/Life: CHARGING PER CELL Products Cyclic TEMPERATURE RANGE Float G13EP, G16EP CV 14.7-15.0 CV 13.5-13.8 G26EP & G42EP CC* CC* G13EPX, G16EPX CV 14.7-15.0 CV 13.5-13.8 G26EPX & G42EPX CC* CC* Storage & discharge -40C to +45C LIFE EXPECTANCY Charge C/5 Cycle life 100% DOD -40C to +45C 400 Float life at 25C (20C) 10 years (15 years) -40C to +60C -40C to +60C 400 10 years (15 years) Maximum recommended storage time before recharge - 24 months @ 25C or 2.0Vpc, whichever is earlier Atmospheric pressure range - Vacuum to 2 atmospheres Terminal attachment torque for G13EP & G16EP - 50 in.-lbs (5.6 nm) Terminal attachment torque for G26EP & G42EP - 60 in.-lbs (6.8 nm) *Users planning to use CC should consult the EnerSys Application Support Department GENESIS(R) EP mechanical specifications (A, B & C - Maximum) DIMENSIONS Products A in. B mm in. C mm in. D mm in. E mm in. mm Weight lb. kg G13EP 6.910 175.51 3.282 83.36 5.113 129.87 5.56 141.2 0.81 20.6 10.8 4.9 G13EPX 6.998 177.75 3.368 85.55 5.165 131.19 5.56 141.2 0.81 20.6 12.0 5.4 G16EP 7.150 181.61 3.005 76.33 6.605 167.77 5.74 145.8 0.67 16.9 13.5 6.1 G16EPX 7.267 184.58 3.107 78.92 6.666 169.32 5.74 145.8 0.67 16.9 14.7 6.7 G26EP 6.565 166.75 6.920 175.77 4.957 125.91 0.64 16.3 1.06 27.0 22.3 10.1 G26EPX 6.636 168.55 7.049 179.04 5.040 128.02 0.69 17.5 1.11 28.2 23.8 10.8 G42EP 7.775 197.49 6.525 165.74 6.715 170.56 0.74 18.8 0.87 22.0 32.9 14.9 G42EPX 7.866 199.80 6.659 169.14 6.803 172.80 0.79 20.1 0.91 23.2 35.1 15.9 UL Recognised Component. Meets UL 1989 Caution: Batteries contain toxic materials (Pb and H 2SO4) * Avoid short circuit * Do not charge in gas-tight container Sealed-lead rechargeable battery must be recycled or disposed of properly. Contact EnerSys Customer Service for details. 8 www.enersys-emea.com Publication No: EN-GPL-SG-003 - November 2008 GENESIS(R) 70EP performance specifications Constant current discharge/amps to 1.67Vpc @ 25C DURATION Products G70EP (70Ah) 5 min 10 min 15 min 30 min 60 min 90 min 5 hr 8 hr 10 hr 20 hr 342.4 228.5 173.4 102.5 57.4 40.6 13.4 8.7 7.1 3.9 Constant power discharge/watts per battery to 1.67Vpc @ 25C DURATION Products G70EP (70Ah) 5 min 10 min 15 min 30 min 60 min 90 min 5 hr 8 hr 10 hr 20 hr 3680 2519 1940 1173 670 486 161 105 86 47 Charging/Temperature/Life: CHARGING PER CELL Products Cyclic TEMPERATURE RANGE Float Storage & discharge LIFE EXPECTANCY Charge C/5 Cycle life 100% DOD Float life at 25C (20C) G70EP CV 14.7-15.0 CC* CV 13.5-13.8 CC* -40C to +45C -40C to +45C 400 10 years (15 years) G70EPX CV 14.7-15.0 CC* CV 13.5-13.8 CC* -40C to +60C -40C to +60C 400 10 years (15 years) Maximum recommended storage time before recharge - 24 months @ 25C or 2.0Vpc, whichever is earlier Atmospheric pressure range - Vacuum to 2 atmospheres Terminal attachment torque for G70EP - 60 in.-lbs (6.8 nm) *Users planning to use CC should consult the EnerSys Application Support Department GENESIS(R) 70EP mechanical specifications (A, B & C - Maximum) DIMENSIONS Products A in. B mm in. C mm in. D mm in. E mm in. mm Weight lb. kg G70EP 13.020 330.71 6.620 168.15 6.930 176.02 9.69 246.13 2.45 62.23 53.5 24.3 G70EPX 13.020 330.71 6.620 168.15 6.930 176.02 9.69 246.13 2.45 62.23 56.0 25.4 G13EP - G16EPX G26EP - 42EPX G70EP & G70EPX A B E B B D E D E A M6 X 1.0 SCREW A D M6 X 1.0 SCREW M6 X 1.0 SCREW C C C All shown without metal jacket UL Recognised Component. Meets UL 1989 Caution: Batteries contain toxic materials (Pb and H 2SO4) * Avoid short circuit * Do not charge in gas-tight container Sealed-lead rechargeable battery must be recycled or disposed of properly. Contact EnerSys Customer Service for details. www.enersys-emea.com Publication No: EN-GPL-SG-003 - November 2008 9 700 700 100 100 10 10 1 1 0.5 0.01 Amps per battery Amps per battery GENESIS(R) constant current (CC) discharge 0.5 0.1 1 10 50 Discharge time in hrs. to 1.67 VPC at 25C 13Ah 16Ah 26Ah 42Ah 70Ah 7000 7000 1000 1000 100 100 10 10 5 5 0.01 0.1 1 10 Watts per battery Watts per battery GENESIS(R) constant power (CP) discharge 50 Discharge time in hrs. to 1.67 VPC at 25C 13Ah 10 www.enersys-emea.com 16Ah 26Ah 42Ah 70Ah Publication No: EN-GPL-SG-003 - November 2008 ENERSYS(R) STANDARD PRODUCT LIST GENESIS(R) EP Batteries PART NUMBER DESCRIPTION 0770-2007 G13EP (13Ah) 12V 13Ah Page 8 Page 8 0770-2003 G13EPX (13Ah) 12V 13Ah Page 8 Page 8 0769-2007 G16EP (16Ah) 12V 16Ah Page 8 Page 8 0769-2003 G16EPX (16Ah) 12V 16Ah Page 8 Page 8 0765-2001 G26EP (26Ah) 12V 26Ah Page 8 Page 8 0765-2003 G26EPX (26Ah) 12V 26Ah Page 8 Page 8 0766-2001 G42EP (42Ah) 12V 42Ah Page 8 Page 8 0766-2003 G42EPX (42Ah) 12V 42Ah Page 8 Page 8 0771-2001 G70EP (70Ah) 12V 70Ah Page 9 Page 9 0771-2003 G70EPX (70Ah) 12V 70Ah Page 9 Page 9 www.enersys-emea.com VOLTAGE 10 Hr RATE PERFORMANCE SPECIFICATIONS MECHANICAL SPECIFICATIONS Publication No: EN-GPL-SG-003 - November 2008 11 www.enersys-emea.com EnerSys Europe Zurich, Switzerland EnerSys Asia Guangdong, China Tel: +86-755-2689 3639 EnerSys Ltd. Rake Lane, Clifton Junction, Swinton, Manchester M27 8LR, UK Tel: +44 (0)161 794 4611 Fax: +44 (0)161 727 3809 (c) 2008 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. Publication No: EN-GPL-SG-003 - November 2008 - Subject to revisions without prior notice. E.&O.E. Contact: EnerSys P.O. Box 14145 Reading, PA 19612-4145 USA Tel: +1-610-208-1991 +1-800-538-3627 Fax: +1-610-372-8613