Hawker Water Less 20 traction batteries Instructions for use

Instructions for use Hawker Water Less® / Hawker Water Less® 20
ENGLISH
Traction batteries with positive tubular plates type PzM / PzMB
Rating Data
1.
2.
3.
4.
Nominal capacity C5
Nominal voltage
Discharge current
Nominal S.G. of electrolyte*
Type PzM / PzMB
5. Rated temperature
6. Nominal electrolyte level
: See type plate
: 2.0 V x No of cells
: C5 /5h
: 1.29 kg/l
: 30°C
: up to electrolyte level mark ”max.”
* Will be reached within the first 10 cycles.
• Pay attention to the operation instruction and
fix
them
close
to
the
battery.
• Work on batteries to be carried out by skilled
personnel only!
• Risk of explosion and fire, avoid short circuits!
• Caution: Metal parts of the battery are always
live. Do not place tools or other metal objects
on the battery!
• Use protective glasses and clothes when
working on batteries. Pay attention to the
accident prevention rules as well as
DIN EN 50272-3 and DIN EN 50110-1.
• Electrolyte is highly corrosive.
• No smoking!
• Do not expose batteries to naked flames,
glowing embers or sparks, as it may cause the
battery to explode.
• Acid splashes in the eyes or on the skin must be
washed with water. In case of accident consult
a doctor immediately!
• Clothing contaminated by acid should be
washed in water.
• Batteries and cells are heavy.
• Ensure secure installation! Use only suitable
handling equipment e.g. lifting gear in
accordance with VDI 3616.
• Dangerous electrical voltage!
• Pay attention to the hazards that can be caused
by batteries.
Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render
the warranty void.
1. Commissioning filled and charged batteries
For commissioning of unfilled batteries see separate
instructions! The battery should be inspected to ensure it is in
perfect physical condition. The charger cables must be
connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could
be damaged.
For the assembly of harness cables or in case of the replacement
of a connector the following torque must be applied:
M 10 perfect connector
2.1 Discharging
Be sure that all ventilation holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or
broken in the open circuit condition. To achieve the optimum
life for the battery, operating discharges of more than 80% of
the rated capacity should be avoided (deep discharge). This
corresponds to an electrolyte specific gravity of 1.14 kg/l at
30°C at the end of the discharge. Discharged batteries must
be recharged immediately and must not be left discharged.
This also applies to partially discharged
batteries.
25 ± 2 Nm
2.2 Charging
In case the interval between delivery (see manufacturing date
on type plate) and commissioning is longer than 8 weeks or
the electrolyte level sensor is indicating low electrolyte level
(see table point 3.1.1), the electrolyte level has to be checked.
If the battery is equipped with a single point water topping up
system (optional), for the removal of the BFS plugs only the
appropriate tool must be used. Otherwise the floats of plugs
may be permanently damaged, which can cause overflow of
the cells. If the electrolyte level is below the top of the
separator, it must first be topped up to this height with
purified water (DIN EN 43530-4). Then the battery can be
charged as in item 2.2.
The electrolyte should be topped up to the specified level with
purified water. Hawker Water Less®/Hawker Water Less® 20
batteries are fitted with an electrolyte level indicator.
2. Operation
DIN EN 50272-3 “Traction batteries for industrial trucks” is the
standard which applies to the operation traction batteries in
industrial trucks.
Only direct current must be used for charging.
All charging procedures in accordance with DIN EN 41773-1
and DIN EN 41774 are permitted. Only connect the battery
assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts,
unacceptable gassing and the escape of electrolyte from the
cells. In the gassing stage the current limits given in DIN EN
50272-3 must not be exceeded. If the charger was not
purchased together with the battery it is best to have its
suitability checked by the manufacturers service department.
When charging, proper provision must be made for venting
of the charging gases. Doors, battery container lids and
covers of battery compartments must be opened or removed.
During the charge the battery must be removed from the
closed battery compartment on the truck. The ventilation
must comply to DIN EN 50272-3 standard. The vent plugs
should stay on the cells and remain closed. 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 electrolyte rises by about 10°C, so charging should only
begin if the electrolyte temperature is below 45°C.
The electrolyte temperature of batteries should be at least
+10°C before charging otherwise a full charge will not be
achieved. A charge is finished when the specific gravity of the
electrolyte and the battery voltage have remained constant
for two hours.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the
battery and to maintain its capacity. They are necessary after
deep discharges, repeated incomplete recharges and charges
to an IU characteristic curve. Equalising charges are carried
out following normal charging. The charging current must
not exceed 5 A/100 Ah of rated capacity (end of charge - see
point 2.2). Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated
temperature. Higher temperatures shorten the life of the
battery, lower temperatures reduce the capacity available.
55°C is the upper temperature limit and is not acceptable as
an operating temperature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to
a temperature of 30°C and the nominal electrolyte level in the
cell in fully charged condition.
Higher temperatures reduce the specified gravity of the
electrolyte, lower temperatures increase it. The temperature
correction factor is -0.0007 kg/l per °C, e.g. an electrolyte
specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of
1.29 kg/l at 30°C. The electrolyte must conform to the purity
regulations in DIN EN 43530-2.
3. Maintenance
3.1 Daily
level detection of the sensor or after water topping up interval
(see "water refilling system" point 2.1) Check the electrolyte
level (visual inspection by opening the vent plug or by the
position of the float indicator of the Aquamatic plug) and
top-up with demineralised water at the end of the charge.
Since the display always refers to a selected reference cell,
please also pay attention to the additional instructions under
“3.3 Monthly Maintenance.”
3.2 Weekly
Visual inspection after recharging for signs of dirt and
mechanical damage to all component parts of the battery, pay
particular attention to the battery charging plugs
and cables. By special applications with charge with a IU
characteristic curve an equalising charge must be carried
out (see point 2.3; see point 7. Water topping up interval).
3.3 Monthly
At the end of the charge the voltages of all cells should be
measured with the charger switched on, and recorded. After
charging has been completed, the electrolyte density,
electrolyte temperature as well as the filling level (when
filling level sensors are used) of all cells are to be measured
and recorded. If significant changes from earlier
measurements or differences between the cells are found
further testing and maintenance by the service department
should be requested.
This should be done following a complete charge and
minimum of 2 hours rest time.
Measure and record :
• total voltage
• voltage per cell
• if the voltage readings are irregular, also check
the S.G. of each cell
(see point 7. Water topping up interval)
3.4 Quarterly
Charge
the
battery
after
every
discharge.
Hawker Water Less®/ Water Less® 20: towards the end of
charge the electrolyte level sensor should be checked (see
tables 3.1.1) and if necessary topped up to the specified
level with purified water (according DIN EN 43530-4).
NO WATERING IN THE FIRST 10 CYCLES.
3.1.1 Filling level sensors
The LED of the electrolyte level sensor should be observed
daily.
A
BLINKY-ELECTROLYTE LEVEL INDICATOR
TYPE
2 - 3 positive plates of PzM
white housing
Green = electrolyte level is OK
No indication = water topping up should
be carried out
4 - 11 positive plates of PzM
TYPE
Green flashing = electrolyte level is OK
Green/red flashing = safety cycle limit
countdown
Red flashing = water topping up should be
carried out
blue housing
B
Wi-iQ®-ELECTROLYTE LEVEL
INDICATOR
TYPE
4 and more positive plates
(see point 7. Water topping up interval)
3.5 Annually
In accordance with DIN EN 1175-1 at least once per year, the
insulation resistance of the truck and the battery must be
checked by an electrical specialist. The tests on the insulation
resistance of the battery must be conducted in accordance with
DIN EN 1987-1. The insulation resistance of the battery thus
determined must not be below a value of 50 Ω per Volt
of nominal voltage, in compliance with DIN EN 50272-3. For
batteries up to 20 V nominal voltage the minimum value is
1000 Ω.
Proceed to the quarterly maintenance, including the
measurement of electrolyte S.G. at the end of charge.
For batteries equipped with optional electrolyte circulation
system, the filter of the air pump has to be checked during the
annual maintenance and eventually to be cleaned or
replaced. Earlier replacement of the filter is necessary if
for undefined reasons (no leaks in the air pipes) the defect
signal of the electrolyte circulation system on the charger
or on the battery (on DC air pump or remote signal) is
illuminated. During the annual maintenance, check the
correct operation of the air pump.
4. Care of the battery
The battery should always be kept clean and dry to prevent
tracking currents. Cleaning must be done in accordance with
the ZVEI code of practice “The Cleaning of Vehicle Traction
batteries”.
Any liquid in the battery tray must be extracted and disposed
of in the prescribed manner. Damage to the insulation of the
tray should be repaired after cleaning, to ensure that the
insulation value complies with DIN EN 50272-3 and to prevent
tray corrosion. If it is necessary to remove cells it is best to
call in our service department for this.
5. Storage
Blue LED
Flashing =
electrolyte level is OK
Light is constantly on =
Electrolyte level is low please top up
Do not top up the cells even when electrolyte level sensor
shows a red blinking LED during first 10 cycles.
The electrolyte level checking has to be performed after low
If batteries are taken out of service for a lengthy period they
should be stored in the fully charged condition in a dry, frostfree room. To ensure the battery is always ready for use a
choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3, or
2. float charging at a charging voltage of 2.27 V x the number
of cells.
The storage time should be taken into account when
considering the life of the battery.
6. Malfunctions
If malfunctions are found on the battery or the charger, our
service department should be called in without delay. The
measurements taken in point 3.3 will facilitate fault finding
and their elimination.
A service contract with us will make it easier to detect and
correct faults in good time.
7. Water topping up interval
Water Less® variant
Water toping up intervals
Charger
Charge factor
1 shift operation
3 shift operation
Water Less
50 Hz
1.20
20 cycles (4 weeks)
20 cycles (2 weeks)
Water Less
HF
1.10
40 cycles (8 weeks)
40 cycles (5 weeks)
Water Less with Airmix
HF
1.07
65 cycles (13 weeks)
65 cycles (8 weeks)
HF/50Hz
1.04
100 cycles (20 weeks)
100 cycles (12 weeks)
Battery
Water Less 20
STANDARD AND OPTIONAL EQUIPMENT
Water Less
Water Less 20
+
+
+
Aquamatic
Airmix
Wi-iQ®
+
Blinky
+
1)
1)
x
Standard
Option
not available
batteries with 2 and 3 positive plates are supplied with blinky, not with Wi-iQ as standard
Aquamatic - Water refilling system (optional accessory)
1. Application
The water refilling system is used to automatically maintain
the nominal electrolyte levels.
The charging gasses escape through the vent on each cell.
NO WATERING IN THE FIRST 10 CYCLES.
2. Function
A valve and a float together control the topping up process
and maintain the correct water level in each cell. The valve
allows the flow of water into each cell and the float closes the
valve when the correct water level has been reached.
For fault-free operation of the water refilling system, please
note the instructions below:
2.1 Manual or automatic connection
The battery should be topped up shortly before completion of
a full charge, as at this point the battery has reached a
defined operational state resulting in satisfactory electrolyte
circulation. Filling takes place when the connector (7) from
the tank is connected to the coupling (6) on the battery.
Manual or automatic coupling has to be done in the intervals
according point 7. (see point 7.)
2.2 Filling time
Filling time depends on the utilisation rate and the
corresponding battery temperature. Generally speaking, the
top up process takes a few minutes and can vary according
to the battery range; after this, if manual filling is being used,
the water supply to the battery should be turned off.
2.3 Working pressure
The water refilling system should be installed in such a way
that a water pressure of 0.2 to 0.6 bar is obtained (with at least
2 m height difference between the upper edge of the battery
and the lower edge of the tank). Any deviation from this
means that the system will not function properly.
2.4 Purity
The topping up water must be purified. The water used to
refill the batteries must have a conductance of not more than
30 µS/ cm. The tank and pipes must be cleaned before
operating the system.
2.5 Pipe system on the battery
The pipe system to the individual battery cells must follow
the battery’s electrical circuit. This reduces the risk of
current leakage in the presence of electrolytic gas causing an
explosion (DIN EN 50272-3). A maximum of 18 cells may be
connected in a series.
The system should not be modified in any way.
2.6 Working temperature
In winter, batteries fitted with Aquamatic should only be
charged or refilled in a room temperature above 0 °C.
2.7 Flow control
A flow indicator built into the water supply pipe to the battery
monitors the filling process. During filling the water flow
causes the built-in disc in the flow indicator to turn. When all
the plugs are closed the disc stops, indicating that the filling
process is complete.
1
9
2
8
4
1.
tank
2.
outflow connector with ball valve
3.
plug with magnetic valve
4.
plug with ball valve
5.
flow control
6.
coupling
7.
connector
8.
battery charger
9.
charger main switch
3
5
7
6
Electrolyte circulation system (optional accessory)
1. Application
The electrolyte circulation system is based on the principle of
pumping air into the individual battery cells. This system
prevents electrolyte stratification and the battery charge is
optimised. The electrolyte circulation is particularly beneficial
for short charge times, boost or opportunity charging.
2. Function
The electrolyte circulation consists of a pipe system fitted in
the cells. The Aeromatic diaphragm pump is
fitted in the charger or separately mounted on the battery or
vehicle. This diaphragm pump sends a low rate airflow into
each cell which creates a circulating air stream inside the cell
box. The air stream is continuous or pulsed depending on the
battery voltage and pump type. The air supply is adjusted in
accordance to the number of cells in the battery.
The pipe system to the individual battery cells must follow
the existing electrical circuit. This reduces the risk of current
leakage in the presence of electrolytic gas causing an
explosion (DIN EN 50272-3).
2.1. Use with separate pipe system
Air is supplied when the charger pipe system is connected
to the battery pipe system (with blue ring).
2.2 Use with automatic connection of the pipe system
Connecting the charge plug with integrated air supply
automatically supplies air to the battery.
2.3 Maintenance of air filter
Depending on the working conditions, the pump air filter
should be changed at least once a year. In work areas with
high levels of air-pollution, the filter should be checked and
replaced more frequently.
2.4 Repair and maintenance
The system must be checked for leakage. The Hawker
charger will display an error message to indicate leakage.
Sometimes in the case of leakage the characteristic charging
curve is switched over to the characteristic standard curve
(without electrolyte circulation).
Faulty parts and faulty pipe sections must be replaced. Only
Hawker original spare parts may be used, as these are
designed for the pump air supply and will ensure correct
functioning of the pump.
Wi-iQ ® (optional accessory)
Wi-iQ – the elevtronic device – will provide indications
according to the table below.
The information is transferred to the PC via USB by Wireless
communication.
1. Operation
Tricolour LED
Blue LED
Tricolour LED
Green blinking = Hardware OK
Blue rapid blinking = Wireless identification
Red blinking = Temperature warning > 55° C
Blue LED
Rapid blinking = Wireless identification
Slow blinking = Voltage balance warning
Flashing - electrolyte level is OK
Light is constantly on =
Electrolyte level is low - please top up
The Wi-iQ is the electronic device that communicates
wirelessly to download the battery key information for
better diagnostics & service. The device is fitted to a
main DC cable on the battery to monitor and record data
of current, voltage, temperature and electrolyte level (via
optional external sensor). The LEDs on the Wi-iQ provide
real time status of battery’s condition.
The Wi-iQ is suitable for use on all battery technologies
Voltage range is 12V – 120V
The device records global data during the life of the battery. It
will store data for 2,555 cycles (complete history stored by
PC). The data can be analysed by the PC software program:
state of charge, temperature warnings and low electrolyte
level warnings.
2. Clear visibility
Selecting the Exception & Detailed Reports will provide
information on the condition of your battery and any actions
that are necessary. Wi-iQ Report will quickly enable you to get
a handle on your battery fleet charging & discharging
characteristics. With information by battery family (truck
type) you can see depth of discharge charts, cycles, charging
and much more.
3. Very easy to use
Plug in USB modem to the PC, scan the Wi-iQ and
up-load the data. Wi-iQ Report is a PC Software running on
Windows 7, 8, XP or Vista. A USB wireless key is used for
downloading Wi-iQ data in to a SQL database.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
When using motive power batteries and chargers, the operator must comply with the current standards, laws,
rules, and regulations in force in the country of use!
Subject to technical modification without any prior notice.
www.enersys.com 06.2016
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