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Instructions for use
Traction batteries
with positive tubular plates type PzS and PzB
Rating Data:
Nominal capacity C
5
Nominal voltage
Discharge current
Nominal S.G. of electrolyte*
Rated temperature
Nominal electrolyte level
* Will be reached within the first 10 cycles
Pay attention to the operation
instruction and fix them close to the
battery.
Work on batteries has to be carried
out by skilled personnel only!
Use protective glasses and clothes
when working on batteries.
Pay attention to the accident pre-
vention rules as well as EN 50272
and EN 50110-1.
No smoking! Do not expose batte-
ries to naked flames, glowing
embers or sparks, as it may cause
the battery to explode.
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.
Risk of explosion and fire, avoid
short circuits!
Caution: Metal parts of the battery
are always live. Do not place tools
or other metal objects on the bat-
tery!
Electrolyte is highly corrosive
Batteries and cells are heavy. Ensu-
re secure installation! Use only sui-
table handling equipment e.g. lifting
gear in accordance with VDI 3616.
Dangerous electrical voltage!
Ignoring the operation instructions, repair with
non-original parts or using additives for the
electrolyte will render the warranty void.
For batteries according to the Atex directive
94/9/EC the instructions for maintaining the
appropriate protection class during operation
must be complied with (see relevant certifica-
te). Please note the additional instructions.
1. Commissioning filled and charged batte-
ries
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 pol-
screws of the charger cables and connectors
is: 25 ± 1 Nm
6
See type plate
2.0 V x No of cells
C
/5 h
5
1.29 kg/l
30 °C
up to electrolyte level mark "max."
The level of the electrolyte must be checked.
If it is below the anti-surge baffle or the top of
the separator it must first be topped up to this
height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the spe-
cified level with purified water (DIN 43530-4).
2. Operation
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 condi-
tion.
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 gra-
vity 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 batte-
ries.
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 char-
ger, suitable for the size of battery, in order to
avoid overloading of the electric cables and
contacts, unacceptable gassing and the esca-
pe 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 manufacturers service department.
When charging, proper provision must be
made for venting of the charging gases. Bat-
tery container lids and the covers of battery
compartments must be opened or removed.
The ventilation must comply to EN 50272-3.
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).
Now switch on the charger.
When charging the temperature of the electro-
lyte 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.
Pay attention to the separate operating
instruction for EEx batteries.
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 point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30 °C is speci-
fied as the rated temperature. Higher tempe-
ratures 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.
2.5 Electrolyte
The rated specific gravity (S. G.) of the elec-
trolyte 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 corres-
ponds to an S.G. of 1.29 kg/l at 30 °C. The
electrolyte must conform to the purity regula-
tions according to DIN 43530-2.
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 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 point 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.
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