GNB EPzS Manual De Instrucciones página 18

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.
The specified torque loading for the polscrews of the charger cables and
connectors are:
steel
M 10 23 ± 1 Nm
The level of the electrolyte must be checked. 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.
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 breather 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 1.13 kg/l at the end of the
discharge.
Discharged batteries must be recharged immediately and must not be left dischar-
ged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordan-
ce 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 gas-
sing and the escape of electrolyte from the cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be ex-
ceeded. If the charger was not purchased together with the battery it is best to
have its suitability checked by the manufacturers service department. When char-
ging, proper provision must be made for venting of 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 swit-
ched 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.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50014, DIN VDE
0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive
areas). During charging and subsequent gassing the container lids must be remo-
ved or opened so that the explosive mixture of gases loses its flammability due to
adequate ventilation. The containers for batteries with plate protection packs must
not be closed until at least half an hour after charging has past.
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 rechar-
ges 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!
Spent Batteries have to be collected and recycled separately from normal household wastes (EWC 160601).
The handling of spent Batteries is described in the EU Battery Directive (91/157/EEC) and their national transitions
(UK: HS Regulation 1994 No. 232, Ireland: Statory Instrument No. 73/2000).
Contact your supplier to agree upon the recollection and recycling of your spent Batteries or contact a local and authorized Waste
Management Company.
We reserve the right make technical modification.
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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 tempera-
ture.
2.5 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 temperature correction factor is -0.0007 kg/l per °C, e.g. an electro-
lyte 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. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with puri-
fied 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 point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measu-
red with the charger switched on, and recorded. After charging has ended the spe-
cific gravity and the temperature of the electrolyte in all cells should be measured
and recorded.
If significant changes from earlier measurements or differences between the cells
or bloc batteries are found further testing and maintenance by the service depart-
ment 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 accor-
dance with DIN EN 60254-1.
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 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 it is best to call in our service department for this.
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 point 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.
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 facilita-
te fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good
time.