OWNER’S MANUAL
www.enersys.com
CONTENTS
Rating Data........................................ 4
Charged Batteries.............................. 5
Operation........................................... 5
Discharging........................................ 5
Charging............................................. 6
Equalizing Charge.............................. 6
Temperature....................................... 6
Electrolyte.......................................... 6
Maintenance...................................... 7
Care of the Battery............................ 7
Storage............................................... 8
Malfunctions...................................... 8
Standard and Optional Equipment.. 8
Water Refilling System..................... 8
Electrolyte Circulation System......... 10
Wi-iQ® Battery Monitoring Device... 10
2
INTRODUCTION
The information contained in this document is critical for safe
handling and proper use of the IRONCLAD® battery for powering
electrical industrial trucks. It contains a global system specification
as well as related safety measures, codes of behavior, a guideline for
commissioning and recommended maintenance. This document must
be retained and available for users working with and responsible for the
battery. All users are responsible for ensuring that all applications of the system
are appropriate and safe, based on conditions anticipated or encountered during
operation.
This owner’s manual contains important safety instructions. Read and understand
the sections on safety and operation of the battery before operating the battery and the
equipment into which it is installed.
It is the owner’s responsibility to ensure the use of the documentation and any activities related
thereto, and to follow all legal requirements applicable to themselves and the applications in the
respective countries.
This owner’s manual is not intended to substitute for any training on handling and operating
the industrial truck or IRONCLAD® battery that may be required by local laws and/or
industry standards. Proper instruction and training of all users must be ensured prior
to any contact with the battery system.
For service, contact your sales representative or call:
EnerSys EMEA
EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10
EnerSys Asia
152 Beach Road
#11-08 Gateway East Building
Singapore 189721
Tel: +65 6416 4800
www.enersys.com
Your Safety and the Safety of Others is Very Important
w WARNING
You can be killed or seriously injured if you
don’t follow instructions.
3
RATING DATA
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:
* Will be reached within the first 10 cycles.
See type plate
2.0 V x no. of cells
C5 /5h
1.32 kg/l
30°C
Up to electrolyte level mark ”max.”
• Observe operating instructions and display in a visible place near the battery. Work on
batteries to be carried out by qualified personnel only.
• No smoking! No open flame, embers, or sparks in the vicinity of the battery to avoid
risk of explosion and fire.
• While working on batteries, wear protective eyeglasses and clothing!
• Observe accident prevention regulations as well as IEC 62485-3 and EN 50110-1.
• Acid splashed into the eyes or on the skin must be washed immediately with an
abundance of clean water. After abundant flushing, consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Warning of battery hazards.
• Only 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.
• Risk of explosion and fire; avoid short circuits.
• Avoid electrostatic charges and discharges/sparks.
• Electrolyte is highly corrosive!
• Caution! Dangerous electrical voltage!
• Metal parts of the battery are always live; therefore do not place items or tools on the
battery!
U >75 V
Ignoring the operation instructions, repair with non-original parts, unauthorized modifications or using
additives for the electrolyte will render the warranty void.
4
CHARGED BATTERIES
Commissioning Filled and Charged Batteries
The battery should be inspected to ensure it is in
perfect physical condition; the battery harness
must have reliable contact and must 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:
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 Filling Level
Sensors), the electrolyte level must be checked.
For 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 (IEC 62877-1: 2016). The battery is then
charged (see Charging section). The electrolyte
should be topped up to the specified level with
purified water.
Operation
Discharging
EN 62485-3 “Safety requirements for secondary
batteries and battery installations-Traction
batteries” is the standard, which applies to the
operation of traction batteries in industrial trucks.
Ensure that NO ventilation holes ARE sealed
or covered. Electrical connections (e.g. plugs)
must only be made or broken in the open circuit
condition. To achieve optimum life for the battery,
operating discharges of more than 70% of the
rated capacity must be avoided (deep discharge).
This corresponds to an electrolyte-specific
gravity of 1.16 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. The
discharge indicator on the truck/vehicle must be
set correctly. The setting depends on the discharge
indicator brand and must be equivalent to a
discharge with a current of I_5 to a final voltage
of 1.92Vpc for 70% DOD. Please refer to EnerSys®
application engineer in case of AGV applications.
5
CHARGING
Charging
Only direct current must be used for charging. For
IRONCLAD® batteries, procedures in accordance with
EN 41773-1 and EN 41774 are permitted. All batteries
with a nominal energy >12kWh should be recharged
with Air mixing profiles. 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 EN 62485-3 must
not be exceeded. If the charger was not purchased
together with the battery, it is best to have the
suitability of the charger, cables and plugs checked
by the manufacturer’s service department. When
charging, proper provision must be made for venting
the charging gases. Truck doors, battery container
lids and battery compartment covers must be
opened or removed. During the charge in the truck,
those from the manufacturers’ specified vents must
be opened. In all cases, the ventilation must comply
with EN 62485-3 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.
Equalizing Charge
Temperature
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— Charging). Watch the 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.
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 cannot 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: in case a pump fault is indicated, check that
the piping system is connected and examine the
piping circuit for leaks or defects (see “Annually” in
the Maintenance section). The air pipe should never
be removed during charge.
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
6
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 IEC 62877-2: 2016.
MAINTENANCE
Maintenance
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. DO NOT
ADD WATER IN THE FIRST 10 CYCLES.
Filling Level Sensors
In the case of batteries with filling level sensors, the
LED should be observed daily.
LED green
level OK
LED red blinking
level too low
Do not top up the cells during the first 10 cycles, even
when electrolyte level sensor shows a red blinking
LED.
Check the electrolyte level by the position of the float
indicator 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
below under “Monthly”.
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. For special applications with charge
with a IU characteristic curve an equalizing charge
must be carried out (see Equalizing Charge).
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 and 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 a 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
Annually
In accordance with 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 EN 1987-1. The insulation
resistance of the battery thus determined must not be
below a value of 50 ohms per voltt of nominal voltage,
in compliance with EN 62485-3. For batteries up to
20 V nominal voltage, the minimum value is 1,000
ohms.
Batteries fitted with electrolyte circulation system: the
filter of the air pump must be checked at least during
the annual maintenance, and eventually must be
cleaned or replaced. Depending on the environment,
you may need to perform a filter check more
frequently than once per year. 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.
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 EN 62485-3
and to prevent tray corrosion. If it is necessary to
remove cells, it is best to call in EnerSys® service for
this. Never use (apply) mineral grease on the battery;
the sealing material of the terminal is incompatible
and it can be permanently damaged. If necessary,
use (apply) silicone grease containing TPFE.
7
STORAGE
Storage
Malfunctions
If batteries are taken out of service for a lengthy
period, they should be stored in a 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. Monthly equalizing charge as described in
“Equalizing Charge”, 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.
If malfunctions are found on the battery or the
charger, EnerSys® service should be called in
immediately. The measurements taken in Monthly
Maintenance will facilitate fault finding and their
elimination.
A service contract with Enersys will make it easier
to detect and correct faults in good time.
Standard and Optional Equipment
Water refilling system
Electrolyte circulation*
Wi-iQ® battery monitoring device
Level sensor
+
Standard
+ Option
* Optional for the battery below 12kWh
Water Refilling System
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.
8
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 on
the next page.
WATER REFILLING SYSTEM
Water Refilling System (cont.)
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 mixing. Filling takes place
when the connector (7) from the tank is connected to
the coupling (6) on the battery.
• If manual connection is used, the battery should
only be connected to the filling system once per
week.
• 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 water refilling at
least once per week to ensure the correct level of the
electrolyte.
• In multiple shift and warm ambient temperature
operations, it may be necessary to have shorter
topping-up intervals.
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.
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.
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 62485-3). A maximum
of 20 cells may be connected in a series.
The system should not be modified in any way.
Working Temperature
In winter, batteries fitted with a water refilling
system should only be charged or refilled in a room
temperature above 0°C.
Flow Control
A flow indicator built into the water supply pipe to
the battery monitors the filling process. While 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.
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.
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
9
ELECTROLYTE CIRCULATION SYSTEM
Electrolyte Circulation System
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.
Use with Separate Pipe System
Air is supplied when the charger pipe system is
connected to the battery pipe system (with blue ring).
Function
The electrolyte circulation system 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, creating 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 62485-3).
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.
Use with Automatic Connection of the Pipe System
Connecting the charge plug to the integrated air
supply automatically supplies air to the battery.
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.
Wi-iQ® Battery Monitoring Device
Wi-iQ® battery monitoring device will provide
indications according to the table below.
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
10
The Wi-iQ monitoring device is the electronic device
that communicates wirelessly to download the
battery key information for better diagnostics and
service. The device is fitted to a main DC cable on the
battery to monitor and record the values of current,
voltage, temperature and electrolyte level (via optional
external sensor). The LEDs on the Wi-iQ monitoring
device provide real-time status of battery’s condition.
The information is transferred to the PC via USB by
wireless communication.
Operation
The Wi-iQ® monitoring device is suitable for use on all
battery technologies. Voltage range is 24V – 120V.
The PC software program can analyze the data: state
of charge, temperature warnings and low electrolyte
level warnings.
Wi-iQ® BATTERY
Wi-iQ® Battery Monitoring Device (cont.)
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 and discharging characteristics. With
information by battery family (truck type), you can see
depth of discharge charts, cycles, charging and much
more.
Very Easy to Use
Plug in USB modem to the PC; scan the Wi-iQ battery
monitoring device close to you and select the one you
need to be connected to, then upload the data. Wi-iQ
Report is a PC software running on Windows. A USB
wireless key is used for downloading Wi-iQ data in to
a SQL database.
Subject to technical modification without any prior notice. E.&O.E.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries that are not returned for 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!
11
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Subject to technical modification without any prior notice. E.&O.E.
© 2024 EnerSys. All rights reserved. Trademarks and logos are the property
of EnerSys and its affiliates, except for Bluetooth and CE, which are not the
property of EnerSys. Subject to revisions without prior notice. E.&O.E.
EMEA-EN-IU-IRON-0724
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