5
6. Recommended maintenance
1. Every day:
Recharge the battery after discharge.
• Remember never charge an Ex battery in a zoned area
even if approved charging equipment is available.
Always check that the charger is operating correctly.
• Check the electrolyte levels at the end of charge and top up if
necessary ( respect max level). The correct level is to the top of the
level indicator.
Hawker
®
Perfect Plus
™
If too much water is added, the expansion during recharge will cause
the electrolyte to overflow, therefore weakening the strength of the
electrolyte. If insufficient water is added the top of the plates will be
come exposed, reducing the performance and life of the battery.
Use approved distilled or demineralised water only.
The ‘Standard’ of purity of water required for topping up is given in IEC
62877-1:2016.
Suppliers of topping up water, topping up devices or automatic water
filling systems can be obtained from your local supplier or service
depot. Note that topping up water must only be held in and dispensed
from non-metallic containers.
Never top up with acid. Should it be felt that an acid adjustment is
required, please consult your local service depot.
2. Weekly:
2.1. Please note any cells that are taking too much or too
little water, if this occurs please contact your local
service depot.
2.2. Check all connections and take off leads for any frayed or
worn insulation. If frayed wires or worn insulation is
noted take the battery out of service immediately and
place in a safe area that is outside the zoned area. Do not
attempt to repair a Ex battery. Call your local service
depot.
2.3. Check that all insulators and vent plugs are in place and
that the battery plugs are of sound condition.
Ensure that the top of the battery is clean and dry. Dirt and moisture
can provide tracking paths for the electricity and potentially cause
a spark in a zoned area. Should there be any corrosion of the metal
container, scrape this off and neutralise the area with a solution of
water and baking soda, or diluted ammonia, and protect the part from
further corrosion by painting it with acid proof paint.
3. 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, electrolyte
temperature as well as the filling level 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 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
If significant changes from earlier measurements or differences
between the cells or bloc batteries are found, please contact EnerSys
Service.
• If the discharge time of the battery is not sufficient, check:
• That the work required is compatible with the battery capacity
• The settings of the charger
• The settings of the discharge limiter.
Hawker
®
Perfect Plus and Water Less
®
Water Less
Perfect Plus
Min
Max
Larger electrolyte
capacity
Reduced prism
height
Check the electrolyte level and top up if necessary
(respect maximum level according to drawing above).
Water Less topping up intervals
PzM Variant
Water topping up intervals*
1 shift operation
3 shift operation**
4 Weeks
PzM/PzMB plus 50Hz
20 Cycles (4 weeks)
20 Cycles (2 weeks)
8 Weeks
PzM/PzMB plus HF
40 Cycles (8 weeks)
40 Cycles (5 weeks)
13 Weeks
PzM/PzMB plus EC*** & HF
65 Cycles (13 weeks)
65 Cycles (8 weeks)
80% DOD, 5 operating days per week, and average battery temperatures of 20°C
*
+/- 1 week in the most common applications at 20°C
**
this number of cycles can be reduced if operating 3 shift and with high battery temperatures!
*** Electrolyte Circulation
4. Annually
In accordance with EN 1175-1 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 EN 1987 part1. 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 EN 62485-3. For batteries
up to 120V nominal voltage the minimum value is 1000
Ω
.
Proceed to the maintenance, including the measurement of electrolyte
S.G. at the end of charge. The filter of the air pump has to be checked
during the annual maintenance and eventually to be cleaned or
replaced. 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.