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.
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 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 -0.0007 kg/l per °C, e.g. an electrolyte
specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of
1.29 kg/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.
Fiamm Motive Power Water Less
®
/ Water Less
®
20: towards the
end of charge the electrolyte level sensor should be checked
(see tables 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.
A
BLINkY-ELECTROLYTE LEvEL INdICATOR
TYPE
2 - 3 positive plates of PzM
white housing
Green = electrolyte level is OK
No indication = water topping up should
be carried out
TYPE
4 - 11 positive plates of PzM
blue housing
Green flashing = electrolyte level is OK
Green/red flashing = safety cycle limit
countdown
Red flashing = water topping up should
be carried out
B
Wi-iQ
®
-ELECTROLYTE
LEvEL INdICATOR
TYPE
4 and more positive plates
Flashing =
electrolyte level is OK
Light is constantly on =
Electrolyte level is low
- please top up
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" point 2.1) Check the electrolyte
level (visual inspection by opening the vent plug or by the
position of the float indicator of the Aqualevel 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
“3.3 Monthly Maintenance.”
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 point 2.3;
see point 7. Water topping up interval).
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 point 7. Water topping up interval)
3.4 Quarterly
(see point 7. Water topping up interval)
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 20 V 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 point 2.3, or
2. float charging at a charging voltage of 2.27 V x the number
of cells.
The storage time should be taken into account when
considering the life of the battery.
Blue LED
