Chapter 10
Annexes
- 68 -
English
241-547-2.fmIDM
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Batteries w it h this sign m ust be recycled.
Batteries w ich are not returned for t he recycling prozess m ust be disposed of as hazardous w ast e!
2. Operation
DIN EN 50272-3 “ Traction batteries for industrial trucks” is the standard
which applies.
The nom inal operating tem perature is 30°C.
The optimum lifetime of the battery depends on the operating conditions
(temperature and depth of discharge)
The tem perature range of use for the battery is betw een +15°C and
+35 °C. Any use outside of this range must be approved by a Service
Technician.
Optimal battery life is obtained with the battery at a temperature of
25-30°C
Higher temperatures shorten the life of the battery (according to IEC
1431 technical report), lower tem peratures reduce the available capacity.
45°C is the upper temperature limit and batteries should not be operated
above this temperature.
The capacity of the battery changes with temperature and falls consider-
ably under 0 °C.
The optimum lifetime of the battery depends on the operating conditions
(moderate temperature and discharges equal to or lower than 80% of the
nominal capacity C
5
).
The battery obtains its full capacity after about 10 charging and
discharging cycles.
2.1. Discharging
The valves on the top of the battery must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the
open circuit condition.
Discharges over 80% of the rated capacity are deep discharges and are
not acceptable. They reduce considerably the life expectancy of the
battery Discharged batteries must be recharged immediately and must
not be left in a discharged condition.:
Discharge Recharge
>40% Every day
<40% Every second day
This also applies to partially discharged batteries.
Discharged batteries can freeze.
Limit the discharge to 80% DOD. The presence of a discharge lim iter is
imperative with an energy cut-off set at 1.90Volts per cell.
2.2. Charging
Pow erbloc dry batteries can be recharged with 50 Hz or HF chargers.
If you wish to use an existing charger with WUIa or IUIa profile, you
should check that the profile is approved by our Technical Department.
Only connect the battery to the correctly assigned charger, which is
suitable for the battery type.
After any changing of cables on the charger, our Technician must visit
the site to check the charger setting.
XP and MFP bat teries have a low gas em ission.
Nevertheless, when charging, correct provision must be made for
venting of the charging gases. Battery container lids and the covers
of battery compartments must be opened or removed.
With the charger switched off connect up the battery, ensuring that the
polarity is correct. (Positive to positive, negative to negative). Now
switch on the charger.
When charging the temperature of the battery rises by about 10°C, so
charging should only begin if the battery temperature is below 35°C.
The electrolyte temperature of the battery should be at least +15 °C
before charging, otherwise a full charge will not be achieved without
specific settings of the charger.
Use the correction factor according to DIN VDE 0510-1 (draft)
with –0.005 Vpc per °C.
2.3. Equalising Charge
Equalising charges are used to safeguard the life of the battery and to
maintain its capacity. Equalising charges are carried out following nor-
mal charging. They are necessary after deep discharges and repeated
incomplete recharges. For the equalising charges, only the chargers
prescribed by the battery manufacturer can be used.
3. M aintenance
The electrolyte is immobilised. The density of the electrolyte can not be
measured.
Never remove the safety valves from the monobloc.
In case of accidental damage to the valve, contact our After Sales
Service for replacem ent.
3.1. Daily
• Recharge the battery after every discharge of m ore than 40% C
5
.
• check: the condition of the plugs, cables and that all insulation covers
are in place and in good condition.
3.2. Weekly
Visual inspection after recharging for signs of dirt and mechanical
damage.
3.3. Quarterly
At the end of the charge, carry out end of charge voltage readings,
measure and record :
• the voltage of the battery
• the voltages of each cell
If significant changes from earlier measurem ents or differences between
the monoblocs are found, please contact our Service.
If the discharge time of the battery is not sufficient, check:
• that the required work is compatible with the battery capacity
• the settings of the charger
• the settings of the discharge limiter.
3.4. Annually
Internal dust removal from the charger.
Electrical connections: test all connections (sockets, cables, and con-
tacts).
Monoblocs having terminals with insert :
Check the torque loading of the bolts/screws.:
According to DIN EN 1175-1 w hen necessary, but at least once a year, the
insulation resistance of the truck and of the battery must be checked by
an electrical specialist.
The test on the insulation resistance of the battery must be conducted in
accordance w ith DIN EN 1987-1. The average insulation resistance of the
battery must not be lower than 50 Ω per Volt nominal voltage
(DIN EN 50272-3)
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. St orage and Transport at ion
Store the battery in a fully charged condition in a dry, clean and frost
free area.
Always disconnect the battery from the electric vehicle before storage.
For easy recharge of the batteries, it is advised not to store without
recharge for more than 3 months at 20°C and 2 m onths at 30°C.
To ensure the battery is always ready for use a choice of charging
methods can be m ade :
• monthly equalising charge according to 2.3.
• float charge w ith 2.27 V x num ber of cells
Always recharge before putting the battery into service.
The storage time should be taken into account when considering the life
of the battery.
www.enersys-em ea.com
01.2009 Subject to technical modification w ithout any prior notice.
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