6. BATTERIES / BATTERIES FOR THE MOTOTOK
41
Version SPAC
ER 1
95 EN V1.0 / 362
2-1
6111
7
7
If significant changes from earlier measure-
ments or differences between the cells or bloc
batteries are found further testing and main-
tenance by the service department should
be requested.
3.4 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 elec-
trical 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 50272.
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 Trac-
tion 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 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 leng-
thy 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 cal-
led in without delay. The measurements taken
in point 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.
7. HOPPECKE trak® air
(optional)
1. Ensure that the charger belonging to the
battery is designed for electrolyte circula-
tion.
2. Before initial operation of a trak® air bat-
tery, a system test is absolutely essential.
It should be carried out as follows:
- connect up the air supply
Make a visual examination of the electroly-
te surfaces of all cells for movement and
rising air bubbles.
Initial operation as a trak® air battery may
commence only after all cells have under-
gone adequate thorough mixing
3. The connection sequence of the trak® air
system may not be changed. Ensure that
the individual hoses are pushed far enough
on to the T-pieces at all times, so as to gua-
rantee tight sealing and stability.
Do not bend hoses!
4. Note for use
Only purified air may be supplied to the
cells. This is to be ensured by means of a
suitable filter. HOPPECKE chargers with
EUW usually have such a filter.
8. AquaFill water replenishment systems
(optional)
Function
A valve is moved by the float inside the plug.
This valve controls the amount of water requi-
red for topping up. The water pressure blocks
any further water flow and ensures that the
water is sealed off correctly. To enable the
water replenishment system to operate
smoothly the following points must be obser-
ved:
Filling
Replenishment should be carried out shortly
after the full charge has been completed.
When filling takes place
manually
the reple-
nishment system should be connected once a
week only on completion of the charge.
In
automatic
filling, the HOPPECKE charger
operates the electromagnetic valve (1 ~ 230V)
at the correct refilling time. The required re-
filling time is programmable.
Filling duration
The filling duration depends on the load during
operation and the resulting ambient tempera-
ture generated. Generally, the complete filling
procedure takes about 3 minutes, after which
the water supply to the battery should be
removed.
Working pressure
The water replenishment facility must be
installed such that a water pressure of 0.2 to
0.6 bar is achieved at the upper edge of the
battery. The water tank should be installed at
a height of 3 to 7 m. The pipe dimensions
must take the number of taps and the length
of pipe required into consideration.
Cleanness
The water dispenser must only contain water
which corresponds to water purity according to
DIN 43530-4.Dispensers and pipes must be
free of dirt which could cause the plug to mal-
function. For safety reasons a filter with a
maximum permeability of 100 to 300 µm
must be built into the battery circuit.
Tube linking system on the battery
The individual cells within the battery are
linked according to the electric circuit. It is
not permitted to make any changes.
Operating temperature
The temperature limit for operating lead-acid
batteries is specified at 55 °C. The water
replenishment system can be subjected to a
greater temperature for a short time.
Batteries equipped with AquaFill may only be
stored in rooms with a temperature of > 0 °C
(otherwise danger of system freezing).
Flow control
To control the filling procedure a flow control
can be built into the water pipe in front of the
battery connection coupling. When filling, the
water flow from above pushes the ball to the
bottom of the pipe. After shutting all the plugs
the ball, now floating at the top, indicates the
end of the top-up process.
Plug removers
A special appliance is required to remove the
AquaFill plug. To avoid damage, the plug must
be removed with the utmost care.
Operational data
P
S
Self-closing pressure
> 1.2 bar
D
Flow rate of the open valve
with a water pressure
of 0.1 bar
350 ml/min
D
1
Max. permitted leak rate of
closed valve at 0.1 bar
2 ml/min
t
Temperature range
0 °C to
+65 °C
P
a
Working pressure range
0.2–0.6 bar
Pb
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
1 Water dispenser
2 Outlet nozzle with ball valve
3 Tap with magnetic valve
4 Tap with ball valve
5 Flow control
6 Battery connection coupling
7 Charger
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