GNB ECSM Series, Instructions For Use Manual

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1. C ommissioning fill ed a n d c h a rg ed ba tt e ri e s.
F or c ommissioning of unfill ed ba tt e ri e s s ee s e p a r a t e instru c tions!
The ba tt e ry s h oul d be i nsp ec t ed to e nsur e i t i s i n p e r fec t p h ys ica l c on di t i on.
The cha r ge r cab l e s must be c onn ec t ed to e nsur e a g oo d c ont ac t , t aki n g ca r e t ha t
t he pol a r i ty i s c orr ec t. O t he rw i s e ba tt e ry , v ehic l e or cha r ge r c oul d be da m aged .
The sp ecified torqu e lo adi n g f or t he pols c r e ws o f t he cha r ge r cab l e s a n d
c onn ec tors a r e:
The l e v e l o f t he e l ec trolyt e must be checked . If i t i s be low t he a nt i sur ge baff l e or t he
top o f t he s e p a r a tor i t must fi rst be topp ed up to t hi s heigh t w i t h pur ified w a t e r ( D IN
4 3 5 30 p a rt 4 ). The ba tt e ry i s t he n cha r ged a s i n i t e m 2.2.
The e l ec trolyt e s h oul d be topp ed up to t he sp ecified l e v e l w i t h pur ified w a t e r.
2. O p e r a tion
D IN E N 5 0272 - 3 «T r ac t i on ba tt e r ie s f or i n d ustr ia l tru ck s » i s t he st a n da r d w hich
a ppl ie s to t he op e r a t i on tr ac t i on ba tt e r ie s i n i n d ustr ia l tru ck s.
2.1 D is c h a rging
B e sur e t ha t a ll b r ea t he r h ol e s a r e not s ea l ed or c ov e r ed .
E l ec tr ica l c onn ec t i ons ( e . g . plu g s) must only be m ade or b ro ke n i n t he op e n ci r c u i t
c on di t i on. T o achie v e t he opt i mum l ife f or t he ba tt e ry , op e r a t i n g di s cha r ge s o f mor e
t ha n 8 0% o f t he r a t ed ca p aci ty s h oul d be a vo ided ( dee p di s cha r ge ).
Thi s c orr e spon d s to a n e l ec trolyt e sp ecific g r a v i ty o f 1.13 kg /l a t t he e n d o f t he
di s cha r ge .
D i s cha r ged ba tt e r ie s must be r echa r ged i mm edia t e ly a n d must not be l ef t di s cha r -
ged . Thi s a lso a ppl ie s to p a rt ia lly di s cha r ged ba tt e r ie s.
2.2 C h a rging
O nly di r ec t c urr e nt must be us ed f or cha r gi n g . A ll cha r gi n g pro ced ur e s i n acc or da n -
ce w i t h D IN 4 1773 a n d D IN 4 177 4 a r e p e rm i tt ed .
O nly c onn ec t t he ba tt e ry a ss ig n ed to a cha r ge r , su i t ab l e f or t he s i z e o f ba tt e ry , i n
or de r to a vo id ov e rlo adi n g o f t he e l ec tr ic cab l e s a n d c ont ac ts , un acce pt ab l e ga s -
s i n g a n d t he e s ca p e o f e l ec trolyt e f rom t he ce lls.
I n t he ga ss i n g st age t he c urr e nt l i m i ts gi v e n i n D IN E N 5 0272 - 3 must not be e x -
ceeded . If t he cha r ge r w a s not pur cha s ed to ge t he r w i t h t he ba tt e ry i t i s be st to
ha v e i ts su i t abi l i ty checked b y t he m a nu fac tur e rs s e rv ice de p a rtm e nt. Whe n cha r -
gi n g, prop e r prov i s i on must be m ade f or v e nt i n g o f t he cha r gi n g ga s e s. B a tt e ry
c ont ai n e r l id s a n d t he c ov e rs o f ba tt e ry c omp a rtm e nts must be op e n ed or r e mov ed .
The v e nt plu g s s h oul d st a y on t he ce lls a n d r e m ai n c los ed . Wi t h t he cha r ge r sw i t -
ched o ff c onn ec t up t he ba tt e ry , e nsur i n g t ha t t he pol a r i ty i s c orr ec t. (pos i t i v e to
pos i t i v e, n ega t i v e to n ega t i v e ).
N ow sw i t ch on t he cha r ge r. Whe n cha r gi n g t he t e mp e r a tur e o f t he e l ec trolyt e r i s e s
b y ab out 10 ° C , so cha r gi n g s h oul d only begi n if t he e l ec trolyt e t e mp e r a tur e i s
be low 45° C .
The e l ec trolyt e t e mp e r a tur e o f ba tt e r ie s s h oul d be a t l ea st +10 ° C bef or e cha r gi n g
ot he rw i s e a f ull cha r ge w i ll not be achie v ed . A cha r ge i s fi n i s hed w he n t he sp ecific
g r a v i ty o f t he e l ec trolyt e a n d t he ba tt e ry volt age ha v e r e m ai n ed c onst a nt f or two
h ours.
S p ecia l i nstru c t i ons f or t he op e r a t i on o f ba tt e r ie s i n ha z a r d ous a r ea s.
Thi s c on ce rns ba tt e r ie s w hich a r e us ed i n acc or da n ce w i t h E N 5 001 4, D IN V DE
0170/0171 E x ( i n a r ea s w i t h a fi r eda mp ha z a r d ) or E x II ( i n pot e nt ia lly e xplos i v e
a r ea s). D ur i n g cha r gi n g a n d su b s e qu e nt ga ss i n g t he c ont ai n e r l id s must be r e mo -
v ed or op e n ed so t ha t t he e xplos i v e m i xtur e o f ga s e s los e s i ts f l a mm abi l i ty d u e to
ade qu a t e v e nt i l a t i on. The c ont ai n e rs f or ba tt e r ie s w i t h pl a t e prot ec t i on p ack s must
not be c los ed unt i l a t l ea st ha l f a n h our af t e r cha r gi n g ha s p a st.
2.3 E qu a lising c h a rg e
E qu a l i s i n g cha r ge s a r e us ed to s afeg u a r d t he l ife o f t he ba tt e ry a n d to m ai nt ai n i ts
ca p aci ty. The y a r e n ece ss a ry af t e r dee p di s cha r ge s , r e p ea t ed i n c ompl e t e r echa r -
ge s a n d cha r ge s to a n IU cha r ac t e r i st ic c urv e .
E qu a l i s i n g cha r ge s a r e ca rr ied out f ollow i n g norm a l cha r gi n g . The cha r gi n g c urr e nt
must not e x ceed 5 A /100 A h o f r a t ed ca p aci ty ( e n d o f cha r ge - s ee po i nt 2.2).
Wa t c h th e t e mp e r a tur e !
2.4 Te mp e r a tur e
A n e l ec trolyt e t e mp e r a tur e o f 30 ° C i s sp ecified a s t he r a t ed t e mp e r a tur e . Highe r
t e mp e r a tur e s s h ort e n t he l ife o f t he ba tt e ry , low e r t e mp e r a tur e s r ed u ce t he ca p aci ty
a v ai l ab l e .
55° C i s t he upp e r t e mp e r a tur e l i m i t a n d i s not acce pt ab l e a s a n op e r a t i n g t e mp e r a-
tur e .
2.5 E l ec trolyt e
The r a t ed sp ecific g r a v i ty ( S . G .) o f t he e l ec trolyt e i s r e l a t ed to a t e mp e r a tur e o f
30 ° C a n d t he nom i n a l e l ec trolyt e l e v e l i n t he ce ll i n f ully cha r ged c on di t i on. Highe r
t e mp e r a tur e s r ed u ce t he sp ecified g r a v i ty o f t he e l ec trolyt e, low e r t e mp e r a tur e s
i n c r ea s e i t. The t e mp e r a tur e c orr ec t i on fac tor i s - 0.0007 kg /l p e r ° C , e . g . a n e l ec tro -
lyt e sp ecific g r a v i ty o f 1.2 8 kg /l a t 45° C c orr e spon d s to a n S . G . o f 1.29 kg /l a t 30 ° C .
The e l ec trolyt e must c on f orm to t he pur i ty r eg ul a t i ons i n D IN 4 3 5 30 p a rt 2.
3. Ma int e n a n ce
3.1 D a ily
C ha r ge t he ba tt e ry af t e r e v e ry di s cha r ge . T ow a r d s t he e n d o f cha r ge t he e l ec trolyt e
l e v e l s h oul d be checked a n d if n ece ss a ry topp ed up to t he sp ecified l e v e l w i t h pur i-
fied w a t e r. The e l ec trolyt e l e v e l must not fa ll be low t he a nt i- sur ge baff l e or t he top
o f t he s e p a r a tor or t he e l ec trolyt e „m i n“ l e v e l m a r k .
3.2 Wee kly
Vi su a l i nsp ec t i on af t e r r echa r gi n g f or s ig ns o f di rt a n d m echa n ica l da m age . If t he
ba tt e ry i s cha r ged r eg ul a rly w i t h a IU cha r ac t e r i st ic c urv e a n e qu a l i s i n g cha r ge
must be ca rr ied out (s ee po i nt 2.3).
3.3 M onthly
A t t he e n d o f t he cha r ge t he volt age s o f a ll ce lls or b lo c ba tt e r ie s s h oul d be m ea su -
r ed w i t h t he cha r ge r sw i t ched on , a n d r ec or ded . A f t e r cha r gi n g ha s e n ded t he sp e-
cific g r a v i ty a n d t he t e mp e r a tur e o f t he e l ec trolyt e i n a ll ce lls s h oul d be m ea sur ed
a n d r ec or ded .
If s ig n ifica nt cha n ge s f rom ea rl ie r m ea sur e m e nts or diffe r e n ce s be tw ee n t he ce lls
or b lo c ba tt e r ie s a r e f oun d f urt he r t e st i n g a n d m ai nt e n a n ce b y t he s e rv ice de p a rt -
m e nt s h oul d be r e qu e st ed .
3.4 A nnu a lly
I n acc or da n ce w i t h D IN V DE 0117 a t l ea st on ce p e r y ea r , t he i nsul a t i on r e s i st a n ce
o f t he tru ck a n d t he ba tt e ry must be checked b y a n e l ec tr ica l sp ecia l i st.
The t e sts on t he i nsul a t i on r e s i st a n ce o f t he ba tt e ry must be c on d u c t ed i n acc or -
da n ce w i t h D IN E N 602 54- 1.
The i nsul a t i on r e s i st a n ce o f t he ba tt e ry t h us de t e rm i n ed must not be be low a v a lu e
o f 5 0 Ω p e r V olt o f nom i n a l volt age, i n c ompl ia n ce w i t h D IN E N 5 0272 - 3.
F or ba tt e r ie s up to 20 V nom i n a l volt age t he m i n i mum v a lu e i s 1000 Ω .
4. C a r e of th e ba tt e ry
The ba tt e ry s h oul d a lw a ys be ke pt c l ea n a n d d ry to pr e v e nt tr acki n g c urr e nts.
C l ea n i n g must be d on e i n acc or da n ce w i t h t he ZV E I c o de o f pr ac t ice «The
C l ea n i n g o f Vehic l e T r ac t i on ba tt e r ie s » .
A ny l i qu id i n t he ba tt e ry tr a y must be e xtr ac t ed a n d di spos ed o f i n t he pr e s c r ibed
m a nn e r.
D a m age to t he i nsul a t i on o f t he tr a y s h oul d be r e p ai r ed af t e r c l ea n i n g, to e nsur e t ha t
t he i nsul a t i on v a lu e c ompl ie s D IN E N 5 0272 - 3 a n d to pr e v e nt tr a y c orros i on. If i t i s
n ece ss a ry to r e mov e ce lls i t i s be st to ca ll i n our s e rv ice de p a rtm e nt f or t hi s.
5. S tor a g e
If ba tt e r ie s a r e t ake n out o f s e rv ice f or a l e n g t h y p e r i o d t he y s h oul d be stor ed i n t he
f ully cha r ged c on di t i on i n a d ry , f rost -f r ee room. T o e nsur e t he ba tt e ry i s a lw a ys
r ead y f or us e a ch o ice o f cha r gi n g m e t h o d s ca n be m ade:
1. a mont h ly e qu a l i s i n g cha r ge a s i n po i nt 2.3
2. f lo a t cha r gi n g a t a cha r gi n g volt age o f 2.23 V x t he num be r o f ce lls.
The stor age t i m e s h oul d be t ake n i nto acc ount w he n c ons ide r i n g t he l ife o f t he
ba tt e ry.
6. Ma lfun c tions
If m a l f un c t i ons a r e f oun d on t he ba tt e ry or t he cha r ge r our s e rv ice de p a rtm e nt
s h oul d be ca ll ed i n w i t h out de l a y. The m ea sur e m e nts t ake n i n po i nt 3.3 w i ll faci l i t a-
t e fa ult fi n di n g a n d t hei r e l i m i n a t i on.
A s e rv ice c ontr ac t w i t h us w i ll m ake i t ea s ie r to de t ec t a n d c orr ec t fa ults i n g oo d
t i m e .
S p e nt B a tt e r ie s ha v e to be c oll ec t ed a n d r ec y c l ed s e p a r a t e ly f rom norm a l h ous eh ol d w a st e s ( E W C 160601).
The ha n d l i n g o f sp e nt B a tt e r ie s i s de s c r ibed i n t he E U B a tt e ry D i r ec t i v e (91/1 5 7/ EEC ) a n d t hei r n a t i on a l tr a ns i t i ons
( UK: HS Reg ul a t i on 199 4 N o. 232 , I r e l a n d: S t a tory I nstrum e nt N o. 73/2000).
C ont ac t your suppl ie r to ag r ee upon t he r ec oll ec t i on a n d r ec y c l i n g o f your sp e nt B a tt e r ie s or c ont ac t a lo ca l a n d a ut h or i z ed Wa st e
Ma n age m e nt C omp a ny.
st ee l
M 10 23 ± 1 N m
We r e s e rv e t he r igh t m ake t ech n ica l mo difica t i on.