ENGLISH
Instructions for use IRONCLAD®
Rating Data
1. Nominal capacity C5: 2. Nominal voltage: 3. Discharge current: 4. Nominal S.G. of electrolyte* Type PzQ: 5. Rated temperature: 6. Nominal electrolyte level: See type plate
2.0 V x No of cells
C5 /5h
1.32 kg/l
30°C
up to electrolyte level mark ”max.”
* Will be reached within the first 10 cycles.
• O
bserve operating instructions and display in
a visible place near the battery. Work on batteries to be carried out by qualified personal
only.
• Risk of explosion and fire, avoid short circuits.
• Avoid electrostatic charges and discharges/
sparks.
• N
o smoking! No open flame, embers or
sparks in the vicinity of the battery to avoid
risk of explosion and fire.
• Electrolyte is highly corrosive!
• W
hile working on batteries wear protective
eyeglasses and clothing!
• Observe accident prevention regulations as
well as DIN EN 50272-3 and DIN EN 50110-1.
• Caution! Dangerous electrical voltage!
• Metal parts of the battery are always live;
therefore do not place items or tools on the
battery!
• O
nly use suitable handling equipment, e.g.
lifting gear in accordance with VDI 3616.
• Cells are very heavy. Make sure they are installed securely.
• Only use suitable means of transport.
• A
cid splashes in the eyes or on the skin must
be washed with plenty of clean water.
• Then consult a doctor immediately!
• Clothing contaminated by acid should be
washed in water.
• Warning of battery hazards.
Ignoring the operation instructions, repair with non-original parts, unauthorized modifications or using additives for the
electrolyte will render the warranty void.
1. Commissioning filled and charged batteries
2. Operation
The battery should be inspected to ensure it is in perfect
physical condition; the battery harness has to have reliable
contact and has to be connected with correct polarity.
Otherwise the battery, vehicle or battery charger may be
damaged.
For the assembly of cables and harness cables only use the
original bolts. Attach the harness to the strain release cable
clamp.
Harness and connector bolts should be tightened to the
following torque settings:
DIN EN 50272-3 “Safety requirements for secondary batteries
and battery installations Traction batteries” is the standard,
which applies for the operation of traction batteries in
industrial trucks.
M 10 connector
25 ± 2 Nm
Bolts with thread lock may be used up to 5 times. For safety
reasons new bolts with thread lock are recommended.
In case the interval between delivery (see manufacturing date
on type plate) and commissioning is longer than 8 weeks or
the electrolyte level sensor float indicator is indicating low
electrolyte level (see table, point 3.1.1), the electrolyte level
has to be checked. For the removal of the water refilling
plugs, only the appropriate tool must be used. Otherwise,
the floats of plugs may be permanently damaged, which can
cause overflow of the electrolyte. 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).
The battery is then charged (see point 2.2). The electrolyte
should be topped up to the specified level with purified water.
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 must 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.
2.2 Charging
Only direct current must be used for charging. For Ironclad®
batteries, procedures in accordance with DIN EN 41773-1 and
DIN EN 41774 are permitted.
Connect the battery to an assigned charger, suitable for
the rating and specification of the battery (e.g. cable cross
section, etc.), 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 the charger’s, cables and plugs suitability
checked by the manufacturer’s service department. When
charging, proper provision must be made for venting of the
charging gases.
Truck doors, battery container lids and covers of battery compartments must be opened or removed.
During the charge in the truck, those from the manufacturers’
specified vents have to be opened.
In all cases, the ventilation must comply with DIN EN 50272-3
standard. The vent plugs should remain on the cells and
be kept closed. With the charger switched off, connect the
battery, ensuring that the polarity is correct (positive to
positive, negative to negative).
Then switch on the charger. During the charging process,
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 would not be
achieved. A charge is finished when the specific gravity of the
electrolyte and the battery voltage have remained constant
for two hours. EnerSys chargers automatically indicate end
of charge.
Batteries fitted with electrolyte circulation system (optional):
in case a pump fault is indicated, check that the piping system
is connected and examine the piping circuit for leaks or
defects (see point 3.4).
The air pipe should never be removed during charge.
2.3 Equalizing charge
Equalizing 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. Equalizing 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 equalizing charge must be carried out (see point 2.3).
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
3.4 Annually
In accordance with DIN EN 1175-1 at least once per year, an
electrical specialist must check the insulation resistance of the
truck and the battery. 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 Ohm per Volt of nominal voltage,
in compliance with DIN EN 50272-3. For batteries up to
20 V nominal voltage, the minimum value is 1,000 Ohm.
Batteries fitted with electrolyte circulation system: the
filter of the air pump has to be checked at least during the
annual maintenance and eventually to be cleaned or
replaced. Depending on the environment, a higher frequency
for filter check than once per year may be necessary. 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.
2.5 Electrolyte
4. Care of the battery
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 1.31 kg/l at 45°C corresponds to an S.G. of
1.32 kg/l at 30°C. The electrolyte must conform to the purity
regulations in DIN EN 43530-2.
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 DIN EN 50272-3 and to prevent tray corrosion. If it is
necessary to remove cells, it is best to call in EnerSys service
department for this.
3. Maintenance
3.1 Daily
Charge the battery after every discharge.
The electrolyte level must not fall below the top of the
separator or the electrolyte ”min” level mark.
NO WATERING IN THE FIRST 10 CYCLES.
3.1.1 Filling level sensors
In the case of batteries with filling level sensors, the LED
should be observed daily.
5. Storage
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 equalizing charge as in point 2.3, or
2. float charging at a charging voltage of 2.29 V x the number
of cells.
The storage time should be taken into account when considering the life of the battery.
LED green
level OK
6. Malfunctions
LED red blinking
level too low
If malfunctions are found on the battery or the charger,
EnerSys service should be called in immediately. 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.
Do not top up the cells even when electrolyte level sensor
shows a red blinking LED during first 10 cycles.
Check the electrolyte level by the position of the float
indi­
cator of the water filling plug and top-up with
demineralized 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
point 3.3.
Standard and optional equipment
Water refilling system
Electrolyte circulation
2.2 Filling time
+
Filling time depends on the utilization rate and the corresponding battery temperature. Generally speaking, the top up
process takes a few minutes and can vary according to the
battery range.
Wi-iQ®
Level sensor
2.1.3
In multiple shift and warm ambient temperature
operations, it may be necessary to have shorter
topping up intervals.
+
2.3 Working pressure
Standard
+Option
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.
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.
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:
2.4 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 20 cells may be
connected in a series.
The system should not be modified in any way.
2.1 Manual or automatic connection
2.6 Working temperature
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.
In winter, batteries fitted with a water refilling system should
only be charged or refilled in a room temperature above 0°C.
2.1.1If manual connection is used the battery should only
be connected to the filling system once a week.
2.1.2If 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 water refilling at
least once a week to ensure the correct level of the
electrolyte.
1
2
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. Tank
9
2. Outflow connector with ball valve
8
3. Plug with magnetic valve
4. Plug with ball valve
5. Flow control
4
5
6. Coupling
3
7. Connector
6
7
8. Battery charger
9. Charger main switch
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. The electrolyte circulation is particularly beneficial
for short charge times, boost or opportunity charging.
Connecting the charge plug with integrated air supply automatically supplies air to the battery.
2. Function
The electrolyte circulation consists of a pipe system fitted
in the cells. A 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
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 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
EnerSys original spare parts may be used, as these are
designed for the pump air supply and will ensure correct
functioning of the pump.
Air is supplied when the charger pipe system is connected to
the battery pipe system (with blue ring).
Wi-iQ ®
Wi-iQ – the elevtronic device – will provide indications
according to the table below.
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
OFF – Flashing = electrolyte level OK
Light is on constantly = electrolyte level low
1. Operation
The Wi-iQ is suitable for use on all battery technologies
Voltage range is 24V – 80V.
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 PC software program can analyze the data: 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.
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 information is transferred to the PC
via USB by wireless communication.
Subject to technical modification without any prior notice. E&OE
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries that 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.com
06.2016
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