ENGLISH
Instructions for use Hawker Water Less®
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
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.
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:
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.
steel
2.2 Charging
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. Hawker Water Less® batteries are fitted
with an electrolyte level indicator.
2. Operation
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 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. 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. 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.
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
2.5 Electrolyte
(see point 7. Water topping up interval)
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.
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Hawker Water
Less®/ Water Less with electrolyte circulation: towards the
end of charge the electrolyte level sensor should be checked
(see table 3.1.1) and if necessary topped up to the specified
level with purified water (according DIN 43530 part 4).
3.1.1 Filling level sensors
The LED of the electrolyte level sensor should be observed
daily.
3.5 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.
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
ELECTROLYTE LEVEL INDICATOR
TYPE
(2 - 3)... PzMB
grey housing
Green = electrolyte level is OK
No indication = water topping up should
be carried out
TYPE
(2 - 10)... PzM and (4 - 11)... PzMB
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
Green flashing = electrolyte level is OK
Green/orange flashing = safety cycle limit
countdown
Red flashing = water topping up should be
carried out
blue housing
The electrolyte level checking has to be performed after low
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
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.
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
PzM Variant
Water topping up intervals
1 shift operation*
3 shift operation**
20 Cycles (4 weeks)
20 Cycles (2 weeks)
PzM - 8 W (PzM + Hf Cf = 1.10)
40 Cycles (8 weeks)
40 Cycles (5 weeks)
PzM - 13 W (PzM EC***+ Hf Cf = 1.07)
65 Cycles (13 weeks)
65 Cycles (8 weeks)
PzM - 4 W (PzM + 50 Hz Cf = 1.2)
Remark
*
80% DOD, 5 operating days per week, and average battery temperatures of 30°C
** this number of cycles can be reduced if operating 3 shift and with high battery temperatures!
*** Electrolyte Circulation
OPTIONS
Water refilling system
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.
2. Function
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.
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:
1
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.)
9
2
8
2.2 Filling time
4
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.
3
5
7
6
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 (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.
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
Hawker® Electrolyte circulation system
1. Application
2.2 Use with automatic connection of the pipe system
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 Hawker electrolyte circulation consists of a pipe system
fitted in the cells. A Hawker 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).
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.
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).
easyplus
The easyplus is an on-board electronic device, installed on
the battery, for checking temperature, electrolyte level and
voltage balance, recording data of the battery. If connected
with HF communicating chargers (Lifeplus) it allows the
communication.
1. Commissioning
The easyplus must be reconnected immediately in case of
disconnection (due to installation of battery plug)
(max.delay 24 hours)
2. Operation
In normal working condition, the green led on easyplus is
ON, with fixed or flashing light. The easyplus contains data
LED
on the battery (serial number, capacity, technology), records
data during the operation (number of cycles, temperature,
capacity …) and transmits information to the charger if it is
used with a Lifeplus HF charger, with warnings appearing
on the charger’s display (low electrolyte level, topping up
needed, overdischarge, daily cycle, excessive temperature,
voltage balance abnormality). Some of the information is
already indicated through the LEDs on the top of the
easyplus.
When the blue led is ON and stays fixed, topping up must
be carried out.
The easyplus will indicate when the battery requires topping-up. It also communicates this requirement to the HF
charger, if the topping-up is not carried out within the specified time period, the charging process will be stopped until
the topping-up has been carried out.
Definition
OFF
No power
Green LED flashing (slowly)
Power and Hardware OK
Action
Check connection
Fixed green LED
Complete charge
Fixed red LED
Overdischarge
Charge immediately
Red LED flashing
Excessive temperature
Cool down until normal temperature
Blue LED flashing
Difference of voltage balance
Hawker Service action
Blue LED ON
Low electrolyte level
Topping up
is reached
3. Maintenance
If the blue LED on the Hawker easyplus is ON, the battery
needs to be topped up without delay.
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-emea.com 01.2012
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