Instructions for Use
Motive Power (Traction) Batteries with Positive Tubular Plates
PzS and PzB, HydroSave Batteries
Rating Data
1. Nominal capacity C5 : See battery label
2. Nominal voltage : 2.0 V x number of cells
3. Discharge current : C
4. Final discharge voltage : 1.7 V x number of cells
/5h
5
Safety Instructions
Read the instructions carefully and place
them close to the battery.
Work on batteries to be carried out by
skilled personnel only!
Use protective glasses, protective gloves
and apron when working on batteries.
Pay attention to the accident prevention
rules as well as EN 50272-3 and
EN 50110-1.
5. Nominal electrolyte density*: 1.29 g/ml at 30°C
6. Rated temperature : 30°C
7. Nominal electrolyte level : upper step of plug**
* will be reached within the first 10 cycles
** see picture in point 3.1
Risk of explosion and fire.
Caution: Metal parts of the battery are
always under voltage. Do not place tools
or other metal objects on the battery!
Avoid short circuits!
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.
No smoking!
Do not expose batteries to naked flames,
glowing embers or sparks, as it may
cause an explosion.
Do not expose batteries to naked flames,
glowing embers or sparks, as it may
cause an explosion.
Clothing contaminated by acid should be
washed in water.
Disregarding the operation instructions, repair with non-original parts or using additives for the electrolyte will render
the warranty void.
Dangerous voltage!
Batteries with this symbol can be recycled.
Treat batteries as special waste.
Do not mix them with other industrial
or household waste. Recycling can be
achieved through a recognized company
for battery recycling or by returning them
to the manufacturer, depending on the
agreement you have made.
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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 condition.
he charger cables must be connected to ensure a good contact,
T
paying attention to the polarities. Otherwise battery, vehicle or
charger could be damaged. The tigheting torque for all the
connector bolts must be 25±2 N·m.
The level of the electrolyte must be checked after removing the
plugs. Plugs should be removed only by using the appropriate tool
to avoid damage. In case aqua filling plugs are installed the use of
the appropriate tool helps to avoid hitting the floating body and
cause damage in the floating mechanism . If the level is below the
top of the separator, it must first be topped up to the upper level
of the separator with purified water (DIN 43530 part 4). The battery
is then charged as in point 2.2. After charging, the electrolyte
should be topped up to the nominal level with purified water.
2. Operation
The standard which applies to the operation of traction batteries
is EN 50272-3: “Safety requirements for secondary batteries and
battery installations. Traction batteries” and provides requirements
on safety aspects associated with the installation, use, inspection,
maintenance and disposal of batteries.
2.1 Discharging
Be sure that all ventilation openings of the battery container,
compartment or cover are not blocked, so suitable ventilation of
the battery is achieved. Do not connect or disconnect the battery
socket under discharging or charging. To achieve battery's
optimum life, operating discharges of more than 80% of the rated
capacity should be avoided (deep discharge). This corresponds to
an electrolyte density of 1.14 g/ml 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.
Connect only the battery assigned to a charger, suitable for the
size of battery, in order to avoid overloading of the electric cables
and contacts and prevent unacceptable gassing and escaping 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 charger’s supplier. When charging, proper
provision must be made for venting of the charging gases. The
removable covers provided for the battery must be removed prior
to charging so that the explosive mixture of gases loses its
flammability due to adequate ventilation. 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). Then 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 electrolyte density and the battery voltage have remained constant for two hours.
Batteries fitted with airlift system:
Please verify that the airlift system is in good operating condition
before beginning the recharge process. Do not recharge a battery
ith a damaged system. Contact your charger’s supplier for further
w
details. The air pipe should never be removed during charging.
.3 Equalizing Charge
2
Equalizing charges are used to safeguard battery's life and to maintain its capacity. They are necessary after deep discharges,
repeated opportunity 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
ated capacity (End of charge: when there is no further increase of
r
cell voltage within 2 hours). 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,
whilst lower temperatures reduce the available capacity. The upper
temperature limit is 55°C and is not acceptable as an operating
temperature.
2.5 Electrolyte
The rated electrolyte density is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the electrolyte density, whilst
lower temperatures increase it. The temperature correction factor
is -0.0007 g/ml per °C, e.g. an electrolyte density of 1.28 g/ml at
45°C corresponds to an electrolyte density of 1.29 g/ml at 30°C.
3. Maintenance
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.
Do not fill the battery with electrolyte. The electrolyte level must
not fall below the anti-surge baffle or the top of the separator.
In the case of HydroSave batteries with electrolyte level sensors,
the illuminated lamp should be observed daily. See relevant
instructions of electrolyte level sensor. Fill-in with water immediately after the lamp blinks red. 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. Τhe level sensor monitors a
selected pilot cell. This means that attention should be paid to the
rest of the cells according to the additional instructions under "3.3
Monthly Maintenance".
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