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 Instructions for use IRONCLAD

®

ENGLISH

 Rating Data                                                                                                                                                                                                     

1. Nominal capacity C

5

:  

See type plate

2. Nominal voltage:  

2.0 V x No of cells

3. Discharge current:  

C

5

 /5h

4. Nominal S.G. of electrolyte* Type PzQ:  

1.32 kg/l

5. Rated temperature:  

30°C

6. Nominal electrolyte level:  

up to electrolyte level mark ”max.”

* Will be reached within the first 10 cycles.

Ignoring the operation instructions, repair with non-original parts, unauthorized modifications or using additives for the 
electrolyte will render the warranty void.

 1. Commissioning filled and charged batteries                         

The battery should be inspected to ensure it is in perfect 

physical condition; the battery harness has to have reliable 

contact and has to be connected with correct polarity.  

Otherwise the battery, vehicle or battery charger may be 

damaged.

For the assembly of cables and harness cables only use the 

original bolts. Attach the harness to the strain release cable 

clamp.  

Harness and connector bolts should be tightened to the  

following torque settings:

M 10 connector

25 ± 2 Nm

Bolts with thread lock may be used up to 5 times. For safety 

reasons new bolts with thread lock are recommended.

In case the interval between delivery (see manufacturing date 

on type plate) and commissioning is longer than 8 weeks or 

the electrolyte level sensor float indicator is indicating low 

electrolyte level (see table, point 3.1.1), the electrolyte level 

has to be checked. For the removal of the water refilling 

plugs, only the appropriate tool must be used. Otherwise, 

the floats of plugs may be permanently damaged, which can 

cause overflow of the electrolyte. If the electrolyte level is 

below the top of the separator, it must first be topped up to 

this height with purified water (IEC 62877-1: 2016).

The battery is then charged (see point 2.2). The electrolyte 

should be topped up to the specified level with purified water.

 2. Operation                                                                                  

EN 62485-3 “Safety requirements for secondary batteries 

and battery installations Traction batteries” is the standard, 

which applies for the operation of traction batteries in  

industrial trucks.

 2.1 Discharging                                                                             

Be sure that all ventilation holes are not sealed or covered. 

Electrical connections (e.g. plugs) must only be made or 

broken in the open circuit condition. To achieve the optimum 

life for the battery, operating discharges of more than 80% 

of the rated capacity must be avoided (deep discharge). This 

corresponds to an electrolyte specific gravity of 1.14 kg/l at 

30°C at the end of the discharge.

Discharged batteries must be recharged immediately and 

must not be left discharged. This also applies to partially 

discharged batteries.

The discharge indicator on the truck/vehicle must be set  

correctly. The setting depends on the discharge indicator 

brand and must be equivalent to a discharge with a current 

of I

5

 to a final voltage of 1.89Vpc for 80% DOD. Please refer 

to EnerSys application engineer in case of AGV applications.

 2.2 Charging                                                                                  

Only direct current must be used for charging. For IRONCLAD

®

 

batteries, procedures in accordance with EN 41773-1 and  

EN 41774 are permitted.

Connect the battery to an assigned charger, suitable for the 

rating and specification of the battery (e.g. cable cross

 

•   Observe  operating  instructions  and  display 

in a visible place near the battery. Work on 

batteries to be carried out by qualified 

personal only.

 

•   No  smoking!  No  open  flame,  embers  or 

sparks in the vicinity of the battery to avoid 

risk of explosion and fire.

 

•   While  working  on  batteries  wear  protective 

eyeglasses and clothing!

 

•   Observe  accident  prevention  regulations  as 

well as EN 62485-3 and EN 50110-1.

 

•   Acid splashes in the eyes or on the skin must 

be washed with plenty of clean water.

 

•  Then consult a doctor immediately!

 

•   Clothing  contaminated  by  acid  should  be 

washed in water.

 

•  Warning of battery hazards.

 

•  Risk of explosion and fire, avoid short circuits.

 

•   Avoid  electrostatic  charges  and  discharges/ 

sparks .

 

•  Electrolyte is highly corrosive!

 

•  Caution! Dangerous electrical voltage!

 

•   Metal  parts  of  the  battery  are  always  live; 

therefore do not place items or tools on the 

battery!

 

•   Only  use  suitable  handling  equipment,  e.g. 

lifting gear in accordance with VDI 3616.

 

•   Cells  are  very  heavy.  Make  sure  they  are 

installed securely.

 

•  Only use suitable means of transport.

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