Instructions for use FMP energy plus and FMP energy LM 200
ENGLISH
Traction batteries with positive tubular plates type PzS / PzB and PzW
Rating Data
1.
2.
3.
4.
Nominal capacity C5
Nominal voltage
Discharge current
Nominal S.G. of electrolyte*
Type PzS / PzB
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.
The fundamental difference between PzS/PzB (FMP energy plus) and PzW (FMP energy LM 200) batteries is the interval
between water topping up, designed to be 200 cycles. This is achieved through construction design and electrolyte mixing
in the cells as well as a specific charge process.
• 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
EN 50272-3 and 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.
For batteries according to the ATEX directive 94/9 EC, the instructions for maintaining the appropriate protection class
during operation must be complied with (see relevant certificate).
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:
FMP energy LM 200 batteries are fitted with an electrolyte
level indicator. In proper working condition this indicator is
not illuminated. Water topping up occurs after 200 cycles or
at the latest when the light on the level indicator lights up.
2. Operation
EN 50272-3 “Traction batteries for industrial trucks” is the
standard which applies to the operation traction batteries in
industrial trucks.
2.1 Discharging
steel
M 10 perfect connector
25 ± 2 Nm
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 it is below the antisurge baffle or the top of the separator it must first be topped up to this height with purified water (DIN 43530 part 4).
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level
with purified water.
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 for
energy plus batteries and 1,15 kg/l for energy LM 200
batteries. Discharged batteries must be recharged immediately
and must not be left discharged. This also applies to
partially discharged batteries.
2.2 Charging
Only direct current must be used for charging.
For the FMP energy LM 200 range only the charge
characteristics stipulated by the manufacturer are suitable
for recharging, ; for that reason, only the chargers
homologated by FMP can be used.
For the FMP energy plus batteries, all charging procedures
in accordance with DIN 41773-1 and DIN 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 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.
PzW batteries (energy LM 200) are low gas emission, so
some charging gasses are evolved. 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 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. For FMP energy plus batteries a charge is
finished when the specific gravity of the electrolyte and the
battery voltage have remained constant for two hours.
FMP energy LM 200, energy plus with air mixing ranges : If
the warning light on the pump controller is illuminated or if
a defect signal on the electrolyte mixing system appears,
check that the piping system is connected and examine the
piping circuit for leaks or defects.(see 3.4. Maintenance)
The air pipe should never be removed during charge.
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.
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). For PzW batteries also check the air plugs.
3.3 Monthly
At the end of the charge the voltages of all cells or bloc
batteries 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 or
bloc batteries are found further testing and maintenance by
the service department should be requested.
In case of FMP energy LM 200 batteries it is necessary to
carry out a quarterly check. 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
3.4 Annually
In accordance with 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 EN 1987 part1. 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 EN 50272-3. For
batteries up to 20 V nominal voltage the minimum value is
1000 Ω. After approx.200 cycles or when the light of the
electrolyte level indicator is on the FMP energy LM 200
batteries have to be topped up. Please contact the FMP
Service! Proceed to the quarterly maintenance, including the
measurement of electrolyte S.G. at the end of charge.
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 air mixing 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
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 43530 part 2.
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 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
3. Maintenance
3.1 Daily
Charge the battery after every discharge. FMP energy
plus/energy plus with air mixing: towards the end of charge
the electrolyte level should be checked and if necessary
topped up to the specified level with purified water
(according DIN 43530 part 4). The electrolyte level must not
fall below the anti-surge baffle or the top of the separator or
the electrolyte ”min” level mark.
3.1.1 Filling level sensors
In the case of batteries with filling level sensors, the
illuminated display should be observed daily.
Display green = level OK
Display red blinking = level too low. Check the electrolyte
level (visual inspection by opening the vent plug or by the
position of the float indicator of the aqualevel 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.”
If batteries are taken out of service for a lengthy period they
should be stored in the fully charged condition in a dry,
frost-free 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.
For energy LM 200 batteries :
1. After a maximum of 6 weeks storage, proceed to a full
charge (see 2.2)
2. With measurement or control devices, a full charge is
necessary after 14 days rest.
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.
OPTIONS
Aqualevel water refilling system (optional accessory)
1. Application
2.3 Working pressure
The water refilling system is used to automatically maintain
the nominal electrolyte levels.
The charging gasses escape through the vent on each cell.
2. Function
A valve and a float together control the topping up process
and maintain the correct water level in each dell. 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 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 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 mixing. Filling takes place when
the connector (7) from the tank is connected to the
coupling (6) 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 (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
2.1.1
2.1.2
2.1.3
If manual connection is used the battery should only
be connected to the filling system once a week
(FMP energy plus).
If automatic coupling is used (with a magnetic valve
controlled by the charging apparatus) the charger
main switch selects the correct moment for filling.
Note: In this case we recommend a water refilling at
least once a week to ensure the right level of the
electrolyte (FMP energy plus).
In winter, batteries fitted with Aqualevel 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.
In multiple shift and warm ambient temperature
operations, it may be necessary to have shorter
topping up intervals.
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.
1. tank
1
2
9
2. outflow connector with ball valve
8
3. plug with magnetic valve
4. plug with ball valve
5. flow control
6. coupling
4
7. connector
3
8. battery charger
5
7
ct
rfe
pe
9. charger main switch
6
FMP 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 using a charge factor of 1.07. The electrolyte circulation is particularly beneficial for heavy duty use, short
charge times, boost or opportunity charging and in high
ambient temperatures.
2. Function
The FMP electrolyte circulation consists of a pipe system fitted in the cells. A FMP 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 (EN 50272-3).
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 FMP
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 mixing).
Faulty parts and faulty pipe sections must be replaced.
Only FMP original spare parts may be used, as these are
designed for the pump air supply and will ensure correct
functioning of the pump.
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).
Subject to technical modification without any prior notice.
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!
www.enersys-emea.com
09.2008
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