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
2 hours.
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 5A/100Ah of rated capacity (see section 2.2).
Pay attention to 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, 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 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 -0.0007kg/l per °C, e.g. an electrolyte
specific gravity of 1.28kg/l at 45°C corresponds to an S.G. of
1.29kg/l at 30°C. The electrolyte must conform to the purity
regulations in IEC 62877-2: 2016.
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Oerlikon Water
Less
®
with electrolyte circulation: at the end of charge the
electrolyte level sensor should be checked (see table 3.1.1)
and if necessary topped up to the specified level with purified
water (according IEC 62877-1: 2016).
NO WATERING IN THE FIRST 10 CYCLES.
3.1.1 Filling level sensors
The LED of the electrolyte level sensor should be observed
daily.
ELECTROLYTE LEvEL INdICATOR
TYPE
(2 - 3)... PzMB
white housing
Green
–
electrolyte level is OK
No indication
–
water topping up should
be carried out
TYPE
(2 - 10)... PzM and (4 - 11)... PzMB
blue housing
Green flashing
–
electrolyte level is OK
Green/red flashing
–
safety cycle limit
countdown
Red flashing
–
water topping up should be
carried out
do not top up the cells even when electrolyte level sensor
shows a red blinking LEd during first 10 cycles.
The electrolyte level checking has to be performed after low
level detection of the sensor or after water topping up interval
(see "Water refilling system") 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. Since the
display always refers to a selected reference cell, please also
pay attention to the additional instructions under section 3.3.
3.2 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.
By special applications with charge with a IU characteristic
curve an equalising charge must be carried out (see sections
2.3 and 7.).
3.3 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 (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
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
(see section 7.)
3.4 Quarterly
Follow section 7.
3.5 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 1987-1. 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 EN 62485-3. For
batteries up to 20V nominal voltage the minimum value is 1000
Ω
.
Proceed to the quarterly maintenance, including the
measurement of electrolyte S.G. at the end of charge.
For batteries equipped with optional electrolyte circulation
system, 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
electrolyte circulation 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.
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 with EN 62485-3 and to prevent tray
corrosion. If it is necessary to remove cells, it is best to call in
our service department 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 it's necessary, use (apply) the
silicone grease with TPFE.
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 section 2.3, or
2. float charging at a charging voltage of 2.27V 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 section 3.3 will facilitate fault finding
and their elimination.
A service contract with us will make it easier to detect and
correct faults in good time.
