®
TECHNOLOGIES
Instructions for use
Motive
Power Batteries
Instructions for use
Motive Power batteries
with tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5:
2. Nominal voltage:
3. Discharge current:
4. Nominal S.G. of electrolyte**
Type EPzS:
Type EPzB:
train lighting:
5. Rated temperature:
6. Nominal electrolyte level:
see type plate
2,0 V x No of cells
C5/5h
1,29 kg/l
1,29 kg/l
see type plate
30°C
up to electrolyte level mark „max.“
** Will be reached within the first 10 cycles.
• Work on batteries to be carried out by skilled personnel only!
• 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 50110-1!
• No smoking!
• 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.
• Electrolyte is highly corrosive!
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.
Lifting hooks must not cause demage to cells, connectors or connection cables.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
Ignoring the operation instructions, repair with non-original parts of using additives for the electrolyte will render the warranty void.
2
1. Commissioning filled and charged batteries.
2.5 Electrolyte
(For commissioning of unfilled 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.
The specified torque loading for the pole srews of the charger cables and connectors are:
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.
steel
M 10
23 ± 1Nm
3. Maintenance
The level of the electrolyte must be checked. If it is below the anti-surge baffle of
the top of the separator it must first be topped up to this heigt 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.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which
applies to the operation traction batteries in industrial trucks.
2.1. Discharging
Be sure that all air vents 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 1.13 kg/l 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. All charging procedures in accordance with DIN 41773 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 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 the charging gases. Battery container lids and
the covers of battery compartments must be opened or removed. 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 poitive, 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.
3.1. Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level
with purified water. The electrolyte level must not fall below the anti-surge baffle
or the top of the separator or the electrolyte „min“ level mark.
3.2. Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the
battery is charged regularly with a IU characteristic curve an equalising charge
must be carried out (see item 2.3).
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 ended the
specific gravity and the temperature of the electrolyte in all cells should be measured and recorded.
If significant changes from earlier measurements of differences between the cells
or bloc batteries are found further testing and maintenance by the service department should be requested.
3.4. Annually
In accordance with DIN VDE 0117 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 determinated 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.
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 DIN EN 50272-3 and to prevent tray corrosion. If
it is necessary to remove cells to call in our service department for this.
Watch the temperature!
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 equalising charge as in item 2.3.
2. float charging at a charging voltage of 2.23 V x the number of cells.
The storage time should be taken into account when considering the life of the
battery.
2.4. Temperature
An elektrolyte 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 temperrature.
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 item 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.
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 item 2.2).
Spent Batteries have to be collected and recycled separately from normal household waste (EWC 160601).
The handling of spent batteries is described in the EU Battery Directive (2006/66/EC) and their national transitions.
Contact your supplier to agree upon the recollection and recycling of your spent batteries or contact a local and authorized
Waste Management Company.
Subject to alterations
3
Water refilling system BFS III for Motive Power batteries
with tubular plates EPzS and EPzB
Plug assignment BFS III
cell series*
cellEPzS
series*
EPzS
2/160-10/800
float length
plug
type
(in
mm)
BFS
26
cell series*
float
EPzBlength
(in mm)
2/110-10/550
2/180-10/900
2/180-10/900
33
072244
2/130-10/650
2/230-10/1150
2/230-10/1150
33
072234
2/150-10/750
34
2/250-10/1250
2/250-10/1250
33
072224
2/280-10/1400
2/280-10/1400
2/310-10/1550
2/310-10/1550
2/160-10/800
float length
series*
(incell
mm)
EPzB
26
plug type
BFS
float length
(in mm)
-
-
-
2/110-10/550
072224
24
26
2/150-10/750
072224
24
2/160-10/800
24
26
2/160-10/800
072224
24
072244
42
44
2/172-10/860
2/172-10/860
26
072224
24
072234
42
34
2/200-10/1000
2/200-10/1000
29
072224
24
072224
24
26
44
* Cell series cover cells with two to ten positive plates, e.g. column EPzS
2/120 – 10/600.
These are cells with the positve plate 60 Ah. Type designation of a cell is e.g. 2 EPzS 120.
BFS III for Motive Power batteries
Schematic diagramm of installation
of water refilling systems
1
2
3
4
5
Determination of float size
2
T
T2
1
5
T1
=
top of cell
to top of seperator
T1 =
top of cell
to base of float
T2 =
top of cell
to top of electrolyte level
10
9
Net
8
The filling level T2 on the list is an average with a tolerance of +/- 2.0 mm (0.075")
4
3
6
7
4
Minimum Distance
to battery 1 m
T
minimum 3 m
*
*
Illustration: © Eternity Technologies GmbH
Top
seperator
or
anti-surge
buffle
6 Coupling
7 Adaptor
8 Ions Exchange cartridge
9 Raw water connection
10 Conductance with magnetic valve
Water refilling container
Level switch
Tapping point with ball valve
Tapping point with magnetic valve
Charger
1. Design
The BFS battery water refilling system is used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases which
arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostic hole for measuring the temperature and the electrolyte
density. All battery cells of the design series EPzS and EPzB can be equipped with
the BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual BFS plugs.
8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
2. Application
The BFS battery water refilling system is used in Motive Power batteries for forklift
trucks. The water refilling system is provided with a central water connection for
the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put into the hose connection
sleeves located on the T-pieces.
CAUTION:
Batteries with automatic water refilling systems may only be operated in
rooms with temperatures > 0°C (as there is otherwise a danger that the
systems may freeze).
3. Function
The quantity of water required in the refilling process is controlled by the valve
located in the plug in combination with the float and the float rods.
When the maximum filling level is reached in the BFS system, the float and the
float rods through a lever system close the valve with 2.5 times the buoyant force
and consequently interrupt the water supply reliably.
4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the
battery charging comes to an end; this ensures that the refilled water quantity is
mixed with the electrolyte. In normal operation it is usually sufficient to fill once
a week.
5. Connenction pressure
The water refilling unit is to be operated in such a way that the water pressure in
the water pipe is between 0.3 bars and 1.8 bars. The BFS-System has an operating pressure range of between 0.3 bars and 3.8 bars.
Deviations from the pressure ranges impair the system‘s functional reliability. This
wide pressure range permits three types of filling.
5.1 Falling water
The heigt of the tank is chosen to suit whichever water refilling system is used.
The BFS system installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the BFS-System is set from 0.3 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley
The submersible pump located in the water refilling tank generates the necessary
filling pressure. No difference in heigh is permitted between the standing level of
the water refilling and the standing level of the battery.
6. Filling duration
The period of time needed to fill the batteries depends on the conditions under
which the battery is used, the ambient temperatures and the type of filling and/or
the filling pressure. The filling time is approx. 0.5 to 4 minutes. The water feed line
must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used
to fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain
any kind of dirt which could impair the functional reliability of the BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery‘s main suppy pipe.
9. Operating temperature
The temperature limit for battery operation is set at 55°C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within
a temperature range of > 0°C to a maximum of 55°C.
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling
systems must have a diagnostic hole with a 7.5
7.0mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water.
No parts of the plugs may come in contact with soap or fabrics which contain
solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling prozess, a flow indicator can be inserted into the water feed
pipe on the battery side. During the filling process, the paddlewheel is turned by
the flowing water. When the filling process ends, the wheel stops and this indicates the end of the filling process.
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug
systems (plug lifter). The utmost degree of care must be employed when prising
out the plug to prevent any damage to the plug systems.
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact
pressure of the hose connection on the plug‘s hose couplings and to loosen it
again.
10.3 Filter element
For safety reasons a filter element can be fitted into the battery‘s main supply pipe
for supplying battery water. This filter element has a maximum passage crosssection of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (BFS) through a central supply
pipe. This is connected to the water supply system at the battery charging station
by means of a sealing coupler system.
On the battery side a nipple is mounted and the customer must place a sealing
coupler construction on the water supply side.
11. Functional data
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when pressure is at
0.1 bars: 2 ml/min
Physical requirement of purified water
- electrical conductivity at 20°C
_ 10 µS/cm
<
- freshly prepared
_ 30 µS/cm
<
- until fill up into cell
T - permissible temperature range: 0°C to a maximum of 65°C
Pa - operating pressure range: 0.3 to 1.8 bars in the BFS system
5
Electrolyte circulation
Additional equipment required
Battery:
A small air supply tube for each battery cell along with the relevant piping and
coupling system.
Charger:
A pump module which is built into the charger with pressure monitoring system for
switching the charge factor from nominal 1.20 to 1.05 up to 1.07.
Principle of operation:
When the battery is being charged, dust-free air is introduced into each cell via the
small air supply tube. The electrolyte is circulated by a “liquid pump” following the
mammoth pump principle. This ensures that the same electrolyte density values
are set for the whole electrode length as soon as charging starts.
Structure:
The electrically driven oscillating piston pump which is built into the charger produces the necessary compressed air which is fed to the battery cells via a tube
system. Here, the air is conveyed via T-connection pieces into the small air supply
tubes of the battery cell. Charging plug systems which have specifically been adapted for electrolyte circulation guarantee the simultaneous safe coupling of the
electrical connection and air connection. The air connection can also be realised
by separate coupling systems.
Pump:
Depending on the number of cells in the battery pack, the delivery rates of the
pumps can be 800; 1000; 1500 l/h. Other than having to change the air filters
(2–3 times a year depending on the air pollution level), the pumps are completely
maintenance-free. When required, e.g. if the pressure monitoring system is activated for no apparent reason, the filters must be checked and the filter wadding
must be changed if necessary. The pump is actuated when the battery starts to
charge and remains intermittently active until the battery is fully charged.
Battery connection:
The pump module has two hose connections with an internal diameter of 6 mm.
These are joined to a hose with a 9 mm internal diameter via a Y-hose manifold.
Together with the charging cables, this hose is fed from the charger to the charger
plug. Air is redirected to the battery via the electrolyte circulation coupling duct
which is integrated in the plug. When installing, special care must be taken to
ensure that the hose is not kinked.
Pressure monitoring module:
The electrolyte circulation pump is activated when charging starts. The pressure
monitoring module monitors the build-up in pressure when charging starts. This
ensures that the necessary air pressure is available when charging with electrolyte circulation.
In case of possible incidents, e.g.:
• Air coupling of battery not connected to circulation module
(where coupling is separate) or defective.
• Leaking or defective hose connections on the battery.
• Intake filter dirty, visual error message appears.
Caution:
If an installed electrolyte circulation system is not used or is used infrequently or if
the battery is subject to significant fluctuations in temperature, this can cause the
electrolyte to flow back into the hose system. In this case, the air supply line must
be fitted with a separate coupling system.
– Lock coupling on battery side
– Straight through coupling on air supply side.
Electrolyte circulation installation on the battery and air supply via the charger.
6
Cleaning batteries
A clean battery is essential, not only for the sake of appearance but also to avoid
accidents and damage to property as well to prevent a reduction in service life and
battery availability.
Batteries and trays must be cleaned in order to ensure that the cells have the
required insulation from each other and from earth and from external conductive
parts. Furthermore, cleaning prevents damage caused by corrosion and leakage
currents.
Under DIN EN 50272-3, the insulation resistance of Motive Power batteries must
be at least 50 Ω per volt of nominal voltage. In accordance with DIN EN 1175-1,
the insulation resistance of batteries for electric forklift trucks may not be less
than 1,000 Ω sein.
The battery is a piece of electrical equipment with external connections protected
against accidental contact by means of an insulating covering.
However, because of the presence of voltage between the terminals and the connections led out through a non-conducting plastic cover, this cannot be equated
with electric insulation.
It is not possible to prevent dust depositing on the battery, whereby the extent depends on the site of installation and length of use. During battery charging, small
quantities of electrolyte particles above the gassing voltage escape and form a
layer on the cells or the battery block covers which is more or less weakly conductive. Leakage current flows through this layer then, leading to increased and
varying self-discharging. This is one of the reasons why drivers of electrical vehicles complain about inadequate capacity after a weekend of the battery being idle.
Where leakage currents are higher, it is not possible to rule out electrical sparks,
which can cause the charging gas (oxyhydrogen gas) coming from the cell plugs
or cell valves to explode.
This means that cleaning the batteries not only ensures high availability but it is
also an essential factor in compliance with accident prevention regulations.
The following items must be observed in order to avoid damage to the plastic
parts, such as the cell connectors, cell connector insulation and the plugs:
• The cell connectors must be tightened securely or pushed in firmly.
• The cell plugs must be put on, i. e. closed.
• No cleaning additives may be used.
• The maximum permissible temperature setting for the cleaning is:
140°C. This usually ensures that the temperature at a distance of 30 cm behind
the outlet nozzle does not exceed 60°C.
• There should be at least 30 cm space between the jet cleaner‘s outlet nozzle
and the batters‘s surface.
• The maximum operating pressure should be 50 bars.
• To avoid local overheating, the je cleaner should spray over a large surface on
the batteries.
• Do not expose any point to the jet spray for longer than 3 seconds at a time.
• After cleaning, the battery surface must be dried by suitable means, e.g. with
compressed air or cleaing cloths.
• No hot air devices with open flame or glow wires may be employed.
• The battery surface temperature may not exceed a maximum of 60°C.
Cleaning vehicle Motive Power batteries
• The danger warnings in the operating instructions for vehicle Motive Power
batteries must be observed.
• Before cleaning the battery, remove it from the vehicle.
• The site for setting up the battery for cleaning must be chosen to ensure that
rinsing water, which contains electrolytes, is passed on to a suitable waste
water treatment unit. When disposing of the used electrolytes or rinsing
water, observe the industrial safety and accident prevention regulations as
well as the regulations relating to the use of water and treatment of waste.
• Safety goggles and protective clothing must be worn.
• The cell plugs may not be removed or opened but must keep the cells closed.
Follow the manufacturer‘s cleaning directives.
• The plastic parts of the battery, in particular the cell boxes, may only be cleaned with water and/or water-soaked cleaned rags without additives.
• After cleaning, the battery surface must be dried by suitable means, e.g. with
compressed air or cleaning cloths.
• If liquid gets into the battery tray, it must be extracted by suction and disposed
of an compliance with the above rules (for the relevant details see DIN EN
50272-3, or the ZVEI leaflet „Precautionary measures when dealing with electrolytes for lead-acid storage batteries“.
Motive Power Batteries can also be cleaned with high-pressure cleaning equipment. Here, the directions for use of the high-pressure cleaning units must be
followed also.
7
• If liquid gets into the battery tray, it must be extracted by suction and disposed
of an compliance with the above rules (for the relevant details see draft DIN EN
50272-1, or the ZVEI leaflet „Precautionary measures when dealing with electrolytes for lead-acid storage batteries“.
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