SELECTION GUIDE 1973 TO 2008 Publication No: US-CYC-SG-003 - June 2008 EnerSys(R) Value-Added Services In addition to our manufacturing capability, EnerSys(R) is proud to provide its customers with the following services: Wherever the world needs stored energy, EnerSys(R) is there. Powered by more than 100 years of expertise, EnerSys(R) is the world's largest industrial battery manufacturer, operating 21 facilities worldwide. Along with manufacturing and distributing a wide range of reserve power and motive power batteries, chargers, power equipment, and battery accessories, EnerSys provides unmatched aftermarket and customer support to its customers in over 100 countries worldwide. Customized manufacturing design Battery recycling Online technical information Charging support Product testing On-site technical seminars Battery samples Application engineering Technical documentation Charger evaluation to determine compatibility with CYCLON(R) batteries Applications Batteries from the EnerSys "pure lead" family are used in a wide variety of standby and portable/cyclic applications including those in: Telecommunications Electronics Uninterruptible power supplies Defense installations Aviation (may require FAA or other appropriate agency certification/approval for installation in aircraft) Computer back-up Electric vehicles Medical equipment Solar power Lawn and garden equipment Extreme temperature environments (-65C to +80C or -85F to +176F) for single cells The EnerSys(R) plant in Warrensburg, Missouri covers 32,000 square feet and is situated on 33 acres. 2 C Y C L O N (R) B attery S election G uide Table of Contents Company background EnerSys(R).................................................................................................................... 2 Services and applications.......................................................................................... 2 Features and benefits................................................................................................ 5 Technical information Capacity as a function of temperature...................................................................... 7 State of charge........................................................................................................... 7 Storage time as a function of temperature................................................................ 7 Charging recommendations....................................................................................... 7 CYCLON(R) Battery Single Cells CYCLON(R) product family........................................................................................... 8 CYCLON(R) battery alternate configurations............................................................... 9 CYCLON(R) battery standard descriptions.................................................................. 9 CYCLON(R) battery Single Cell performance specifications..................................... 10 CYCLON(R) battery Single Cell standard assemblies............................................... 11 CYCLON(R) battery BC Single Cell performance specifications............................... 12 CYCLON(R) battery Single Cell mechanical specifications....................................... 13 CYCLON(R) battery BC Single Cell mechanical specifications................................. 13 CYCLON(R) battery Single Cell constant current (CC) and constant power (CP) discharge graphs............................................................ 14 CYCLON Battery Monobloc (R) 4V/6V Monobloc performance specifications......................................................... 15 4V/6V Monobloc standard assemblies.................................................................... 16 4V/6V Monobloc mechanical specifications............................................................ 17 4V/6V Monobloc constant current (CC) and constant power (CP) discharge graphs............................................................ 18 Quick reference list Standard product listing........................................................................................... 19 3 8 Powerful design Resealable safety valve A 50-PSI vent lets gases escape, then automatically reseals, so there's no risk of excessive gas accumulation within the battery, or "dry out" failure from repeated recharges. Pure lead plates Made from 99.99% pure lead, CYCLON(R) battery plates are extremely thin, so they offer more surface area than conventional batteries - and far more power. AGM plate separator High-purity acid is absorbed right into the Absorbed Glass Mat (AGM) plate separators, so the CYCLON battery provides leak-proof operation in any position. Steel can enclosure The CYCLON battery's metal outer jacket offers extreme shock, vibration, temperature, and flammability protection. One-piece plastic cover Direct thru-the-wall intercell connections One-piece plastic case 4 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 Features and Benefits Sealed pure-lead cells were invented by the Gates Corporation in 1973. The purity of the materials used is key to supporting the CYCLON(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(R) technology? 1. Power density - Per unit weight, the power provided by pure lead products offers the greatest high-rate power density for your energy dollar. CYCLON battery's greater volumetric power allows engineers to consider more energy-supporting features or design smaller, lighter packages. At high-rate and pulse discharges, EnerSys(R) CYCLON batteries 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 batteries provide 50% to 200% greater full cycle capability. CYCLON batteries will deliver up to 300 cycles (100% DOD, C/5). And, because CYCLON batteries incorporate 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. CYCLON battery Single Cells, however, offer a ten-year design life at 25C, C/5, to 80% of rated capacity. At 20C, CYCLON battery Single Cells offer a fifteen-year design life. 5. Safety - Since CYCLON battery Single Cells and Monoblocs emit minimal to no gassing under normal charging conditions they are safe for installation in offices, aircraft cabins, hospitals or any other environment occupied by human beings. Underwriters Laboratories (UL) recognizes all CYCLON cells and batteries as components. 6. Widest temperature range - Due to the products' strong construction and high vent pressures, these cells 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 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 lead batteries experience internal moisture loss from venting and case side wall distention, the CYCLON Single Cell battery, with its steel can (jacket) and 50psi vent, does not experience these life-robbing conditions. CYCLON batteries have twice the delivered capacity of conventional sealed-lead batteries at temperatures below -20C, offering unparalleled low-temperature performance. Our batteries have thinner plates, and therefore greater plate surface area than conventional sealed-lead, thick plate 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, thick-plate batteries. This is 50% to 100% overall better performance for your energy dollar. 7. Rugged construction - Due to their strong external packaging and internal pure lead composition, EnerSys products can withstand not only extreme temperatures but also harsh usage. 4. High stable voltage delivery - The high stable voltage delivery of a pure lead 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 construction also gives more watts-per-unit weight at high discharge rates. CYCLON battery Single Cells are available housed in cases constructed of UL 94V-0 rated material. The CYCLON battery Single Cell itself is in a metal jacket giving added flammability protection. CYCLON batteries 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's low grid-corrosion rate, means CYCLON battery cells and Monoblocs provide the longest service life possible. CYCLON(R) Battery Single Cell/Monobloc comparison chart Design Construction Operating range Voltages Single Cells 3 atm venting pressure Metal outer case & spiral construction -65C to +80C 2 volt cells Monobloc 0.5 atm venting pressure Plastic outer case & spiral construction -40C to +40C 4 & 6 volt units www.enersys.com Publication No: US-CYC-SG-003 - June 2008 5 The pure lead advantage Each plastic Monobloc consists of Single Cell elements, internally connected to provide a 4 or 6 volt unit. Monoblocs or Single Cells can be connected in series or parallel to achieve the required voltage or capacity. Monoblocs and Single Cells are supplied with spade terminals making electrical connections quick and easy. Additionally, EnerSys(R) products offer the highest vent pressure in the market. As a result, our batteries are more resistant to venting and dryout from continuous overcharge in standby applications. 8. Fastest recharge - EnerSys pure lead chemistry allows our batteries and cells to offer the highest recharge efficiency of any sealed-lead battery on the market. With pure lead, you can achieve a 95% state of recharge in less than one hour - without loss of capacity or electrolyte using conventional constant-voltage charging techniques. Flexible charging options are possible with CYCLON(R) battery Single Cells and Monoblocs, as no current limit is required when using a constant voltage charger. 9. Orientation/placement/transport - Due to the products' mechanical design, CYCLON batteries can be mounted and operated in any position, an attractive feature for less accessible areas. CYCLON battery Single Cells offer UL 94V-0 flameretardant packaging, thus allowing the mounting of systems in sensitive areas and human environments. Plus, the unique and flexible 2-volt CYCLON battery Single Cell allows you to design your system using an almost infinite number of packaging/design configurations. 6 www.enersys.com Effective September 30, 1995, CYCLON battery Single Cells and Monoblocs were 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". CYCLON battery shipments from the EnerSys plant in Warrensburg, Missouri 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". CYCLON battery Single Cells and Monoblocs have been tested and determined to be in compliance with the vibration and pressure differential tests contained in 49 CFR 173.159(d). Because CYCLON battery Single Cells and Monoblocs are classified as "Nonspillable" and meet the conditions above, [from 173.159(d)] they do not have an assigned UN number nor do they require additional DOT hazard labeling. The regulation change effective September 1995, was to clarify and distinguish to shippers and transporters, all batteries that have been tested and determined to be in compliance with the DOT Hazardous Material Regulations, the International Civil Aeronautics Organization (ICAO), and the International Air Transport Association (IATA) Packaging Instruction 806 and Special Provision A67, and therefore excepted from all other requirements of these regulations and classified as a "nonspillable battery". 10. Shelf life - Pure lead batteries have an extremely low self-discharge rate, thus providing extended storage capability while maintaining high state-of-charge levels for dependable operation. CYCLON battery Single Cells and Monoblocs have 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 2.00 volts per cell, whichever occurs earlier. Inventory should be checked more frequently if storage temperature regularly exceeds 25C. Publication No: US-CYC-SG-003 - June 2008 Capacity as a function of temperature for CYCLON(R) Battery Single Cells & Monoblocs (use graph up to 40C for Monoblocs) Discharge time, hours 10 1 0.1 0.01 -40 -30 -20 -10 0 10 20 30 40 50 Temperature, C 15 MIN RATE C RATE C/5 RATE State of charge for CYCLON(R) Battery Single Cells & Monoblocs 2.17 2.14 2.11 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. 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 CYCLON(R) batteries. 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 2.08 OCV, V Charging recommendations: Constant voltage (CV) charging should be within the following ranges: 2.05 2.02 Fast Chargers, Per cell: 2.45 to 2.50 volts @ 25C 1.99 1.96 1.93 1.90 10 20 30 40 50 60 70 80 90 100 State of Charge, % Storage time as a function of temperature for CYCLON(R) Battery Single Cells & Monoblocs (fully charged cell) www.enersys.com 12 volts: 14.70 to 15.0 volts @ 25C (for a maximum of 16-20 hours) Float Chargers, Per cell: 2.27 to 2.35 volts @ 25C 12 volts: 13.62 to 14.10 volts @ 25C To avoid thermal runaway in warmer temperatures, and to improve charge acceptance in colder temperatures, the charger voltage should be compensated by approximately 3 millivolts per cell per degree Centigrade variance from 25C. This is a negative coefficient, with the voltage being lowered as the temperature increases, and vice versa. Publication No: US-CYC-SG-003 - June 2008 7 There is no need to limit the inrush current to the battery during constant voltage charging. The low internal resistance of EnerSys(R) CYCLON(R) battery Single Cells and Monoblocs allows for large inrush current without damage. Most current waveforms are not pure DC nor are they pure sine waves. Therefore, consult the EnerSys Application Support Department for assistance when evaluating the charger current waveforms for your specific application. 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. A three-step 6-8 hour charge profile optimized for CYCLON cells and batteries is available on request from the Technical Support Department of EnerSys. CYCLON(R) Battery Product Family (All capacities at 10 hr. rate 25C to 1.67Vpc) CYCLON(R) Battery 2V Single Cell: Products Capacity Part Number Internal Nominal res. of fully short circuit charged cell current for Diameter Height m @ 25C charged cell in. mm in. mm DIMENSIONS Height with terminals in. mm Weight oz. gm in. Tabs mm D cell 2.5Ah 0810-0004 5.0 400A 1.35 34.3 2.41 61.2 2.68 68.1 6.28 178.0 .187x.025 4.75x0.64 DT cell 4.5Ah 0860-0004 5.0 400A 1.35 34.3 3.78 96.0 4.05 102.9 9.68 274.4 .187x.025 4.75x0.64 X cell 5.0Ah 0800-0004 3.5 570A 1.75 44.5 2.87 72.9 3.21 81.5 12.77 362.0 .250x.025 6.35x0.64 E cell 8.0Ah 0850-0004 3.0 665A 1.75 44.5 3.94 100.1 4.28 108.7 17.28 489.9 .250x.025 6.35x0.64 J cell 12.0Ah 0840-0004 2.5 800A 2.04 51.8 4.85 123.2 5.34 135.6 29.60 839.2 .312x.032 7.92x0.81 BC cell 25Ah 0820-0004 1.5 1335A 2.57 65.3 6.25 158.8 6.82 173.2 58.88 1669.2 M6 (-) and M8 (+) terminals CYCLON(R) Battery 4V Monoblocs: Internal res. Nominal of fully charged short circuit Products Capacity Part Monobloc current for Diameter Height Number m @ 25C charged cell in. mm in. mm DIMENSIONS Height with terminals in. mm Weight oz. gm in. Tabs mm D cell 2.5Ah 0819-0010 10.0 400A 3.13 79.5 1.81 46.0 2.75 69.9 .80 .36 .187x.025 4.75x0.64 X cell 5.0Ah 0809-0010 7.0 570A 3.80 96.5 2.12 53.8 3.02 76.7 1.62 .74 .250x.025 6.35x0.64 E cell 8.0Ah 0859-0010 6.0 665A 3.81 96.8 2.13 54.1 4.00 101.6 2.11 .96 .250x0.25 6.35x0.64 (R) CYCLON Battery 6V Monoblocs: Internal res. Nominal of fully charged short circuit Products Capacity Part Monobloc current for Length Width Number m @ 25C charged cell in. mm in. mm 8 DIMENSIONS Height in. mm Weight lb. kg in. Tabs mm D cell 2.5Ah 0819-0012 15.0 400A 4.48 113.8 1.81 46.0 2.75 69.9 1.15 .52 .187x.025 4.75x0.64 X cell 5.0Ah 0809-0012 10.0 570A 5.48 139.2 2.12 53.8 3.02 76.7 2.16 .98 .250x0.25 6.35x0.64 E cell 8.0Ah 0859-0012 8.0 665A 5.48 139.2 2.13 54.1 4.00 101.6 3.15 1.43 .250x0.25 6.35x0.64 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 CYCLON(R) Battery Single Cell CYCLON(R) battery standard descriptions High integrity terminal seal Resealable Safety vent Plastic internal container Positive and negative plates Lead grids Highly retentive separator Metal can enclosure Alternative battery configurations Standard battery configurations are rectangular in overall shape. A sample of other possible configurations are illustrated below. These can be held together with tape (offering the lowest cost and minimum electrical and mechanical protection) or by shrink wrapping. The CYCLON(R) battery Single Cell can be custom configured in virtually an infinite number of designs. CYCLON battery cells are ideal for small ampere-hour applications up to 25Ah. The sealed-lead construction uses a starved-electrolyte system and a patented grid-alloy providing numerous advantages. Standard batteries are offered based on combinations of the previously described CYCLON battery cells and are available in 6 and 12 volt configurations with capacities ranging from 2.5Ah to 25Ah. Battery Packages Rigid plastic cases or shrink wrap packaging are available. Rigid Plastic Cases are available for most designs in either flameretardant ABS material, meeting UL 94V-0 flammability rating, or Styrene (available only in 2X3 D and X battery configurations). Some cases have mounting holes. Rigid plastic cases are recommended for applications in which the battery must withstand vibration, movement or extreme weather conditions. Shrink Wrap Shrink wrap packaging is less expensive and smaller in size and weight. A plastic extrusion insulates the battery top and keeps the cells in line. A heavy duty shrink sleeve holds the cells firmly in place. Shrink wrap packaging is recommended for applications in which the battery remains stationary. Battery Terminations for Single Cell and Monoblocs Tab/Stud Cell size Rectangular Rhomboid Dimensions D DT X E J BC .187" x .025" .187" x .025" .250" x .025" .250" x .025 .312" x .032" 6mm post (negative) 8mm post (positive) Tab Adapters (D, DT, X, and E) Available to convert .187" tabs to .250" tabs, 0.032" thick, and vice versa. Nested Trapezoid BC Quick Disconnect Terminals AMP series 250 Faston terminals are available for BC batteries. Connection Terminations A wide variety of terminations are offered. For recommendations or to specify; contact your EnerSys(R) Territory Manager or battery assembler. Tubular www.enersys.com Flat Pack Fusible Links Specify your requirement. Publication No: US-CYC-SG-003 - June 2008 9 Lead Wires Stranded copper wire with insulation meeting UL1015 specifications (Red +, Black -). Standard leads extend 9 inches outside the battery pack. Ends are stripped and dipped in wax, which must be removed before use. Varying lead lengths and gauges are also available; please specify to your EnerSys(R) Territory Manager or battery assembler. Intercell Connections Standard Standard wire gauges are: D batteries DT batteries X batteries E batteries J batteries BC batteries D, DT, X and E batteries--welded tin-plated steel connector J batteries--soldered, stranded wire BC batteries--solid copper For vibration-prone applications 18AWG, UL1015 16AWG, UL1015 16AWG, UL1015 14AWG, UL1015 14AWG, UL1015 12AWG, UL1015 D, DT, X, E and J batteries--soldered, stranded wire BC batteries--braided copper straps CYCLON(R) Battery Single Cell 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 D cell (2.5Ah) 14.8 8.1 5.9 3.4 1.9 1.4 .48 .32 .26 .13 DT cell (4.5Ah) 25.2 15.0 11.2 6.6 3.7 2.6 .85 .55 .45 .24 X cell (5.0Ah) 27.3 17.8 13.2 7.0 3.9 2.8 .96 .61 .50 .26 E cell (8.0Ah) 41.7 26.4 19.0 11.0 6.2 4.4 1.6 1.0 .81 .42 J cell (12.0Ah) 51.7 38.1 29.4 18.0 9.2 6.5 2.3 1.5 1.20 .66 Constant power 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 D cell (2.5Ah) 26.4 16.1 11.6 6.7 3.8 2.7 .94 .61 .50 .25 DT cell (4.5Ah) 45.0 28.1 21.0 12.5 7.1 5.1 1.7 1.1 .90 .46 X cell (5.0Ah) 45.4 31.9 23.9 13.9 7.8 5.6 1.9 1.2 1.0 .51 E cell (8.0Ah) 77.8 51.0 35.5 21.1 12.4 8.9 3.1 2.0 1.6 .85 J cell (12.0Ah) 90.4 68.4 53.4 31.6 18.3 13.2 4.7 3.0 2.3 1.3 Charging/Temperature/Life: TEMPERATURE RANGE CHARGING PER CELL Products Cyclic Float D, DT, X, E & J cell CV 2.45-2.50 CC* Storage & Charge discharge LIFE EXPECTANCY C/5 Cycle life 100% DOD CV 2.27-2.35 -65C to +80C -40C to -80C 300 CC* Float life at 25C (20C) 10 years (15 years) Maximum recommended storage time before recharge - 24 months @ 25C or 2.0Vpc, whichever is earlier Atmospheric pressure range - Vacuum to 8 atmospheres *Users planning to use CC should consult the EnerSys(R) Application Support Department. UL Recognized Component. Meets UL 1989 Caution: Batteries contain toxic materials (Pb and H2SO4) * Avoid short circuit * Do not charge in gas-tight container Sealed-lead rechargeable battery must be recycled or disposed of properly. Contact EnerSys(R) Customer Service for details. 10 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 CYCLON(R) Battery Single Cell standard assemblies CYCLON(R) Battery 6 Volt 1x3 Shrink Wrap Product Number Description 0810-0102 0810-0103 0860-0102 0860-0103 0800-0102 0800-0103 0850-0102 0850-0103 2.5Ah D Dbl. Slot 2.5Ah D 4.5Ah DT Dbl. Slot 4.5Ah DT 5.0Ah X Dbl. Slot 5.0Ah X 8.0Ah E Dbl. Slot 8.0Ah E Length in. mm 4.05 4.05 4.05 4.05 5.25 5.25 5.25 5.25 102.9 102.9 102.9 102.9 133.4 133.4 133.4 133.4 Width in. mm 1.48 1.48 1.48 1.48 1.87 1.87 1.87 1.87 37.6 37.6 37.6 37.6 47.5 47.5 47.5 47.5 Height in. mm 2.66 2.66 4.03 4.03 3.12 3.12 4.19 4.19 67.6 67.6 102.4 102.4 79.2 79.2 106.4 106.4 Weight lbs. kg 1.23 1.25 2.07 2.09 2.48 2.52 3.49 3.53 .56 .57 .94 .95 1.13 1.14 1.58 1.60 Leads No Yes No Yes No Yes No Yes CYCLON(R) Battery 6 Volt 1x3 ABS Case Product Number Description 0810-0011 0810-0077 0800-0011 0800-0071 2.5Ah D Dbl. Slot 2.5Ah D Sing. Slot 5.0Ah X Dbl. Slot 5.0Ah X Sing. Slot Length in. mm 4.23 4.23 5.44 5.44 107.4 107.4 138.2 138.2 Width in. mm 1.55 1.55 1.96 1.96 39.4 39.4 49.8 49.8 Height in. mm 2.75 2.75 3.16 3.16 69.9 69.9 80.3 80.3 Weight lbs. kg 1.33 1.37 2.71 2.74 .60 .62 1.23 1.24 Leads No Yes No Yes CYCLON(R) Battery 12 Volt 2x3 Shrink Wrap Product Number Description 0810-0114 0810-0115 0860-0114 0860-0115 0800-0114 0800-0115 0850-0114 0850-0115 2.5Ah D Dbl. Slot 2.5Ah D 4.5Ah DT Dbl. Slot 4.5Ah DT 5.0Ah X Dbl. Slot 5.0Ah X 8.0Ah E Dbl. Slot 8.0Ah E Length in. mm 4.05 4.05 4.05 4.05 5.25 5.25 5.25 5.25 102.9 102.9 102.9 102.9 133.4 133.4 133.4 133.4 Width in. mm 2.82 2.82 2.82 2.82 3.68 3.68 3.68 3.68 71.6 71.6 71.6 71.6 93.5 93.5 93.5 93.5 Height in. mm 2.67 2.67 4.03 4.03 3.13 3.13 4.19 4.19 67.8 67.8 102.4 102.4 79.5 79.5 106.4 106.4 Weight lbs. kg 2.48 2.50 3.88 3.91 4.93 4.97 6.73 6.77 1.13 1.14 1.76 1.77 2.24 2.26 3.05 3.07 Leads No Yes No Yes No Yes No Yes CYCLON(R) Battery 12 Volt 2x3 ABS and Styrene Cases Product Number Description 0810-0008 0810-0067* 0800-0008 0800-0047* 2.5Ah D Dbl. Slot 2.5Ah D (Styrene) 5.0Ah X Dbl. Slot 5.0Ah X (Styrene) Length in. mm 4.23 4.23 5.44 5.44 107.4 107.4 138.2 138.2 Width in. mm 2.88 2.97 3.70 3.70 73.2 75.4 94.0 94.0 Height in. mm 2.72 2.73 3.14 3.19 69.1 69.3 79.8 81.0 Weight lbs. kg 2.68 2.63 5.34 5.22 1.22 1.19 2.42 2.37 Leads No Yes No Yes CYCLON(R) Battery 12 Volt 1x6 Shrink Wrap Product Number Description 0810-0108 0810-0109 0860-0108 0860-0109 0800-0108 0800-0109 0850-0108 0850-0109 2.5Ah D Dbl. Slot 2.5Ah D 4.5Ah DT Dbl. Slot 4.5Ah DT 5.0Ah X Dbl. Slot 5.0Ah X 8.0Ah E Dbl. Slot 8.0Ah E Length in. mm 8.08 8.08 8.08 8.08 10.48 10.48 10.48 10.48 205.2 205.2 205.2 205.2 266.2 266.2 266.2 266.2 Width in. mm 1.48 1.48 1.48 1.48 1.87 1.87 1.87 1.87 37.6 37.6 37.6 37.6 47.5 47.5 47.5 47.5 Height in. mm 2.66 2.66 4.03 4.03 3.12 3.12 4.19 4.19 67.6 67.6 102.4 102.4 79.2 79.2 106.4 106.4 Weight lbs. kg 2.49 2.52 3.88 3.91 4.99 5.03 6.73 6.77 1.13 1.14 1.76 1.77 2.27 2.28 3.05 3.07 Leads No Yes No Yes No Yes No Yes CYCLON(R) Battery 12 Volt 1x6 ABS Case Product Number Description 0810-0016 0810-0075 0800-0016 0800-0072 2.5Ah D Dbl. Slot 2.5Ah D Sing. Slot 5.0Ah X Dbl. Slot 5.0Ah X Sing. Slot Length in. mm 8.25 8.25 10.66 10.66 209.6 209.6 270.8 270.8 Width in. mm 1.55 1.55 1.96 1.96 39.4 39.4 49.8 49.8 Height in. mm 2.74 2.74 3.15 3.15 69.6 69.6 80.0 80.0 Weight lbs. kg 2.74 2.76 5.20 5.24 1.24 1.25 2.36 2.38 Leads No Yes No Yes All dimensions, excluding weight, are maximum *Due to special assembly, consult the EnerSys(R) Customer Service Department for availability. www.enersys.com Publication No: US-CYC-SG-003 - June 2008 11 CYCLON(R) Battery BC Single Cell 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 BC cell (2.5Ah) 118.3 72.8 54.3 32.2 19.3 14.0 4.85 3.14 2.55 1.33 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 BC cell (2.5Ah) 197.3 142.4 105.5 63.5 36.8 25.6 9.20 6.04 4.95 2.60 Charging/Temperature/Life: TEMPERATURE RANGE CHARGING PER CELL Products Cyclic Float BC cell (2.5Ah) CV 2.45-2.50 CC* LIFE EXPECTANCY Storage & Charge discharge C/5 Cycle life 100% DOD CV 2.27-2.35 -65C to +80C -40C to -80C 300 CC* Float life at 25C (20C) 10 years (15 years) Maximum recommended storage time before recharge - 24 months @ 25C or 2.0Vpc, whichever is earlier Atmospheric pressure range - Vacuum to 8 atmospheres Mounting - Terminal torque must not exceed 35 in-lbs. (3.95 Nm) *Users planning to use CC should consult the EnerSys(R) Application Support Department CYCLON(R) Battery 12 Volt 2x3 25.0Ah Case Product Number Description Length in. mm Width in. mm Height in. mm Weight lbs. kg Leads 0820-2018 BC Double Slot, Copper Straps 8.05 204.5 5.45 138.4 7.25 184.2 22.86 10.4 Yes 0820-0020 BC Double Slot, Copper Straps 8.05 204.5 5.45 138.4 7.25 184.2 22.86 10.4 No All dimensions, excluding weight, are maximum UL Recognized Component. Meets UL 1989 Caution: Batteries contain toxic materials (Pb and H2SO4) * Avoid short circuit * Do not charge in gas-tight container Sealed-lead rechargeable battery must be recycled or disposed of properly. Contact EnerSys(R) Customer Service for details. 12 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 CYCLON(R) Battery Single Cell mechanical specifications (E, G, H & J - Maximum) DIMENSIONS Products D cell in. A mm 0.27 6.9 in. B mm 0.51 13.0 in. C D E mmin. mm 0.187 4.75 22 0.27 6.9 F mm in. 0.025 0.64 in. G mm 2.41 61.2 H in. 0.05 mm 1.3 I in. mm 0.13 3.3 in. J mm 1.35 34.3 Weight lb. kg 6.28 178.0 DT cell 0.27 6.9 0.51 13.0 0.187 4.75 22 0.27 6.9 0.025 0.64 3.78 96.0 0.05 1.3 0.13 3.3 1.35 34.3 9.68 274.4 X cell 0.29 7.4 0.61 15.5 0.250 6.35 22 0.34 8.6 0.025 0.64 2.87 72.9 0.06 1.5 0.14 3.6 1.75 44.5 12.77 362.0 E cell 0.29 7.4 0.61 15.5 0.250 6.35 22 0.34 8.6 0.025 0.64 3.94 100.1 0.06 1.5 0.14 3.6 1.75 44.5 17.28 489.9 J cell 0.32 8.1 0.74 18.8 0.312 7.92 22 0.49 12.4 0.032 0.81 4.85 123.2 0.05 1.3 0.15 3.8 2.04 51.8 29.60 839.2 CYCLON(R) Battery BC Single Cell mechanical specifications (F, G & I - Maximum) DIMENSIONS Products A in. mm BC cell 0.65 16.5 www.enersys.com B C in. mm 1.30 33.0 22 D in. mm 0.57 14.5 E in. mm 0.22 5.6 F in. mm 6.25 158.8 G in. mm H in. mm 0.06 1.5 0.13 3.3 in. I mm 2.57 65.3 Weight lb. kg 3.68 1.67 Publication No: US-CYC-SG-003 - June 2008 13 CYCLON(R) Battery Single Cell constant current (CC) discharge CYCLON(R) Battery Single Cell constant power (CP) discharge 14 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 CYCLON(R) Battery 4V/6V Monobloc performance specifications 4V & 6V Constant current discharge/amps to 1.67Vpc @ 25C DURATION Products D cell (2.5Ah) 5 min 10 min 15 min 30 min 60 min 90 min 5 hr 8 hr 10 hr 20 hr 14.3 8.1 5.9 3.4 1.9 1.4 .48 .32 .26 .13 X cell (5.0Ah) 28.9 18.1 13.5 7.1 4.0 2.8 1.0 .61 .52 .26 E cell (8.0Ah) 41.7 26.4 19.0 11.0 6.2 4.4 1.6 1.0 .81 .42 4V & 6V Constant power 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 D cell (2.5Ah) 25.3 15.9 11.7 6.8 3.8 2.7 .93 .60 .49 .25 X cell (5.0Ah) 48.8 32.3 24.2 13.8 7.8 5.6 2.0 1.2 1.0 .52 E cell (8.0Ah) 77.8 51.0 35.5 21.1 12.4 8.9 3.1 2.0 1.7 .85 Charging/Temperature/Life CHARGING PER CELL TEMPERATURE RANGE Products Cyclic Float Storage, discharge & charge Safety pressure relief valve LIFE EXPECTANCY C/5 Cycle life 100% DOD Float life at 25C (20C) 4V D, X, & E Monobloc CV 4.90-5.00 CC* CV 4.54-4.70 -40C to +40C 8 psi 300 CC* Up to 8 yrs (Up to 8 yrs) 6V D, X, & E Monobloc CV 7.35-7.50 CC* CV 6.81-7.05 -40C to +40C 8 psi 300 CC* Up to 8 yrs (Up to 8 yrs) Maximum recommended storage time before recharge - 24 months @ 25C or 2.0Vpc, whichever is earlier Atmospheric pressure range - Vacuum to 2 atmospheres Mounting - Each Monobloc is equipped with mounting holes in the cover. The tightening torque for mounting the Monobloc is 25 in-lbs. When using 4 mounting bolts, small spacers (washers) 1 to 3 mm thick should be placed between the battery and the mounting surface to prevent bowing or stressing the battery case. *Users planning to use CC should consult the EnerSys(R) Application Support Department. UL Recognized Component. Meets UL 1989 Caution: Batteries contain toxic materials (Pb and H2SO4) * Avoid short circuit * Do not charge in gas-tight container Sealed-lead rechargeable battery must be recycled or disposed of properly. Contact EnerSys(R) Customer Service for details. www.enersys.com Publication No: US-CYC-SG-003 - June 2008 15 CYCLON(R) Battery 4V/6V Monobloc standard assemblies CYCLON(R) Battery 4 Volt Monoblocs Product Number Description Length in. mm Width in. mm Height in. mm Weight lbs. kg 0819-0010 4V, 2.5Ah Monobloc 3.13 79.5 1.81 46.0 2.75 69.9 .80 0809-0010 4V, 5.0Ah Monobloc 3.80 96.5 2.12 53.8 3.02 76.7 1.62 .36 .74 0859-0010 4V, 8.0Ah Monobloc 3.81 96.8 2.13 54.1 4.00 101.6 2.11 .96 CYCLON(R) Battery 6 Volt Monoblocs Product Number Description Length in. mm Width in. mm Height in. mm Weight lbs. kg 0819-0012 6V, 2.5Ah Monobloc 4.48 113.8 1.81 46.0 2.75 69.9 1.15 0809-0012 6V, 5.0Ah Monobloc 5.48 139.2 2.12 53.8 3.02 76.7 2.16 .52 .98 0859-0012 6V, 8.0Ah Monobloc 5.48 139.2 2.13 54.1 4.00 101.6 3.15 1.43 CYCLON(R) Battery 12 Volt 2x3 Monoblocs Product Number Description Length in. mm Width in. mm Height in. mm Weight lbs. kg 0819-0030 12V, 2.5Ah, 2x3 4.48 113.8 3.52 89.4 2.77 70.4 2.30 1.04 0809-0030 12V, 5.0Ah, 2x3 5.48 139.2 4.18 106.2 3.04 77.2 4.32 1.96 0859-0030 12V, 8.0Ah, 2x3 5.48 139.2 4.18 106.2 4.02 102.1 6.30 2.86 CYCLON(R) Battery 12 Volt 1x6 Monoblocs Product Number Description Length in. mm Width in. mm Height in. mm Weight lbs. kg 0819-0016 12V, 2.5Ah, 1x6 8.84 224.5 1.81 46.0 2.77 70.4 2.30 1.04 0809-0016 12V, 5.0Ah, 1x6 10.88 276.4 2.12 53.8 3.04 77.2 4.32 1.96 0859-0016 12V, 8.0Ah, 1x6 10.88 276.4 2.13 54.1 4.02 102.1 6.30 2.86 All dimensions, excluding weight, are maximum One-piece plastic cover High integrity terminal seal One-piece plastic case Resealable Safety vent Direct thru-the-wall intercell connections Positive and negative plates Highly retentive separator Lead grids 16 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 CYCLON(R) Battery 4V Monobloc mechanical specifications (A, B & C - maximum) DIMENSIONS Products A in. mm in. B D Monobloc 2.75 69.9 3.13 79.5 1.81 46.0 .61 15.5 1.23 31.2 .80 .36 .187x.025 4.75x0.64 X Monobloc 3.02 76.7 3.80 96.5 2.12 53.8 .73 18.5 1.45 36.8 1.62 .74 .250x.025 6.35x0.64 E Monobloc 4.00 101.6 3.81 96.8 2.13 54.1 .73 18.5 1.45 36.8 2.11 .96 .250x.025 6.35x0.64 mm in. C mm D in. mm in. E Weight lb. kg mm in. Tabs mm CYCLON(R) Battery 6V Monobloc mechanical specifications (A, B & C - maximum) DIMENSIONS Products A in. mm in. B mm in. C mm D in. mm in. E mm lb. F kg G in. mm Weight lb. kg in. Tabs mm D Monobloc 2.75 69.9 4.48 113.8 1.81 46.0 .61 15.5 1.23 31.2 1.33 33.8 .67 17.0 1.15 .52 .187x.025 4.75x0.64 X Monobloc 3.02 76.7 5.48 139.2 2.12 53.8 .73 18.5 1.45 36.8 1.71 43.4 .86 21.8 2.12 .98 .250x.025 6.35x0.64 E Monobloc 4.00 101.6 5.48 139.2 2.13 54.1 .73 18.5 1.45 36.8 1.71 43.4 .86 21.8 3.15 1.43 .25x.025 6.35x0.64 D Monobloc A E C D B .216 DIA. TYP (5.49) X & E Monobloc A G F C E D B www.enersys.com Publication No: US-CYC-SG-003 - June 2008 17 4V/6V Monobloc constant current (CC) curves to 1.67Vpc 4V/6V Monobloc constant power (CP) curves to 1.67Vpc 18 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 EnerSys(R) standard product list SINGLE CELL (sc) PART NUMBER DESCRIPTION VOLTAGE 10 Hr RATE 0810-0004 D Single Cell (Dsc) 2V 2.5Ah PERFORMANCE SPECIFICATIONS MECHANICAL SPECIFICATIONS Page 10 Page 13 0860-0004 DT Single Cell (DTsc) 2V 4.5Ah Page 10 Page 13 0800-0004 X Single Cell (Xsc) 2V 5.0Ah Page 10 Page 13 0850-0004 E Single Cell (Esc) 2V 8.0Ah Page 10 Page 13 0840-0004 J Single Cell (Jsc) 2V 12.0Ah Page 10 Page 13 0820-0004 BC Single Cell (BCsc) 2V 25.0Ah Page 12 Page 13 SINGLE CELL STANDARD BATTERY DESIGNS PART NUMBER DESCRIPTION VOLTAGE 10 Hr RATE PERFORMANCE SPECIFICATIONS MECHANICAL SPECIFICATIONS 0810-0102 1x3 Dsc, double slot, shrink wrap 6V 2.5Ah Page 10 Page 11 0810-0103 1x3 Dsc, shrink wrap, leads 6V 2.5Ah Page 10 Page 11 0810-0011 1x3 Dsc, double slot, ABS case 6V 2.5Ah Page 10 Page 11 0810-0077 1x3 Dsc, single slot, ABS case, leads 6V 2.5Ah Page 10 Page 11 0860-0102 1x3 DTsc, double slot, shrink wrap 6V 4.5Ah Page 10 Page 11 0860-0103 1x3 DTsc, shrink wrap, leads 6V 4.5Ah Page 10 Page 11 0800-0102 1x3 Xsc, double slot, shrink wrap 6V 5.0Ah Page 10 Page 11 0800-0103 1x3 Xsc, shrink wrap, leads 6V 5.0Ah Page 10 Page 11 0800-0011 1x3 Xsc, double slot, ABS case 6V 5.0Ah Page 10 Page 11 0800-0071 1x3 Xsc, single slot, ABS case, leads 6V 5.0Ah Page 10 Page 11 0850-0102 1x3 Esc, double slot, shrink wrap 6V 8.0Ah Page 10 Page 11 0850-0103 1x3 Esc, shrink wrap, leads 6V 8.0Ah Page 10 Page 11 0810-0108 1x6 Dsc, double slot, shrink wrap 12V 2.5Ah Page 10 Page 11 0810-0109 1x6 Dsc, shrink wrap, leads 12V 2.5Ah Page 10 Page 11 0810-0016 1x6 Dsc, double slot, ABS case 12V 2.5Ah Page 10 Page 11 0810-0075 1x6 Dsc, single slot, ABS case, leads 12V 2.5Ah Page 10 Page 11 0810-0114 2x3 Dsc, double slot, shrink wrap 12V 2.5Ah Page 10 Page 11 0810-0115 2x3 Dsc, shrink wrap, leads 12V 2.5Ah Page 10 Page 11 0810-0008 2x3 Dsc, double slot, ABS case 12V 2.5Ah Page 10 Page 11 0810-0067* 2x3 Dsc, Styrene case, leads 12V 2.5Ah Page 10 Page 11 0860-0108 1x6 DTsc, double slot, shrink wrap 12V 4.5Ah Page 10 Page 11 0860-0109 1x6 DTsc, shrink wrap, leads 12V 4.5Ah Page 10 Page 11 0860-0114 2x3 DTsc, double slot, shrink wrap 12V 4.5Ah Page 10 Page 11 0860-0115 2x3 DTsc, shrink wrap, leads 12V 4.5Ah Page 10 Page 11 0800-0108 1x6 Xsc, double slot, shrink wrap 12V 5.0Ah Page 10 Page 11 0800-0109 1x6 Xsc, shrink wrap, leads 12V 5.0Ah Page 10 Page 11 0800-0016 1x6 Xsc, double slot, ABS case 12V 5.0Ah Page 10 Page 11 0800-0072 1x6 Xsc, single slot, ABS case, leads 12V 5.0Ah Page 10 Page 11 0800-0114 2x3 Xsc, double slot, shrink wrap 12V 5.0Ah Page 10 Page 11 0800-0115 2x3 Xsc, shrink wrap, leads 12V 5.0Ah Page 10 Page 11 www.enersys.com Publication No: US-CYC-SG-003 - June 2008 19 SINGLE CELL STANDARD BATTERY DESIGNS (continued) PART DESCRIPTION VOLTAGE NUMBER 10 Hr RATE SPECIFICATIONS PERFORMANCE SPECIFICATIONS MECHANICAL 0800-0008 2x3 Xsc, double slot, ABS case 12V 5.0Ah Page 10 Page 11 0800-0047* 2x3 Xsc, Styrene case, leads 12V 5.0Ah Page 10 Page 11 0850-0108 1x6 Esc, double slot, shrink wrap 12V 8.0Ah Page 10 Page 11 0850-0109 1x6 Esc, shrink wrap, leads 12V 8.0Ah Page 10 Page 11 0850-0114 2x3 Esc, double slot, shrink wrap 12V 8.0Ah Page 10 Page 11 0850-0115 2x3 Esc, shrink wrap, leads 12V 8.0Ah Page 10 Page 11 0820-0030 2x3 BCsc, double slot, copper strap 12V 25.0Ah Page 12 Page 12 PERFORMANCE SPECIFICATIONS MECHANICAL SPECIFICATIONS MONOBLOC (mb) PART DESCRIPTION VOLTAGE 10 Hr RATE NUMBER 0819-0010 D Monobloc (Dmb) 4V 2.5Ah Page 15 Page 17 0809-0010 X Monobloc (Xmb) 4V 5.0Ah Page 15 Page 17 0859-0010 E Monobloc (Emb) 4V 8.0Ah Page 15 Page 17 0819-0012 D Monobloc (Dmb) 6V 2.5Ah Page 15 Page 17 0809-0012 X Monobloc (Xmb) 6V 5.0Ah Page 15 Page 17 0859-0012 E Monobloc (Emb) 6V 8.0Ah Page 15 Page 17 PERFORMANCE SPECIFICATIONS MECHANICAL SPECIFICATIONS MONOBLOC STANDARD BATTERY DESIGNS PART DESCRIPTION VOLTAGE 10 Hr RATE NUMBER 0819-0016 1x6 Dmb 12V 2.5Ah Page 15 Page 16 0819-0030 2x3 Dmb 12V 2.5Ah Page 15 Page 16 0809-0016 1x6 Xmb 12V 5.0Ah Page 15 Page 16 0809-0030 2x3 Xmb 12V 5.0Ah Page 15 Page 16 0859-0016 1x6 Emb 12V 8.0Ah Page 15 Page 16 0859-0030 2x3 Emb 12V 8.0Ah Page 15 Page 16 CAPACITY RATINGS BASED ON END OF DISCHARGE VOLTAGE OF 1.67 VOLTS/CELL AT 25C *Due to special assembly, consult the EnerSys(R) Customer Service Department for availability. Distributed by: www.enersys.com EnerSys P.O. Box 14145 Reading, PA 19612-4145 USA Tel: +1-610-208-1991 +1-800-538-3627 Fax: +1-610-372-8613 EnerSys Europe Zurich, Switzerland Tel: +41 (0) 44 215 74 10 EnerSys Asia Guangdong, China Tel: +86-755-2689 3639 Publication No. US-CYC-SG-003 June 2008 - Subject to revision without prior notice. E.&O.E. (c) 2008 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted.