EnerSys powerbloc dry XFC Series Manual

Monobloc Type Terminal torque (Nm) Terminal torque (Nm)
Standard Terminal Terminal Adapter
Motive power batteries for small traction valve regulated lead acid (VRLA) monoblocs XFC series:
TPPL (Thin Plate Pure Lead) technology
ENGLISH
Rating data:
1. Nominal capacity C5: see type
2. Nominal voltage : see type
3. Discharge current : C5/5h
4. Rated temperature : 30°C
1. Commissioning
The XFC series monoblocs are supplied in a charged condition.
The battery should be inspected to ensure it is in perfect physical
condition.
Check:
1. The battery cleanliness. Before installing, the battery compartment
has to be cleaned.
2. The battery end cables have a good contact to terminals and the
polarity is correct. Otherwise the battery, vehicle or charger could
be damaged.
Use special coding systems for maintenance free batteries for the char-
ging plug- and- socket devices to prevent accidental connection to the
wrong type of charger. Never directly connect an electrical appliance (for
example: warning beacon) to a part of the battery. This could lead to an
imbalance of the cells during the recharge, i.e. a loss of capacity, the risk
of insufficient discharge time, damage to the cells and this may
EFFECT THE WARRANTY OF THE BATTERY.
Charge the battery (see 2.2) before commissioning. Only blocs with the
same state of discharge should be connected together.
The specified torque loading for the bolts/screws of the end cables and
connectors are detailed in the table below:
Operation and maintenance instructions for powerbloc dry XFC
Powerbloc dry batteries XFC series are valve-regulated lead-acid batteries. Unlike conventional batteries with liquid electrolyte these batteries have
immobilised electrolyte. Instead of a vent plug, a valve is used to regulate the internal gas pressure, preventing the ingress of oxygen from the air and
allowing the escape of excess charging gasses should an overcharged condition occur. When operating valve-regulated lead-acid batteries the same
safety requirements as for vented batteries apply, to protect against hazards from electric current, from explosion of electrolytic gas and - with some
limitations - from the corrosive electrolyte.
Battery valves should never be removed. These batteries do not require topping – up with distilled or demineralised water
• Pay attention to the operating instructions and keep
them close to the battery.
• Work on batteries must only be carried out by skilled
personnel!
• Use protective glasses and wear safety clothing when
working on batteries.
• Adhere to the current accident prevention rules in the
country where the battery is used or EN 50272-3,
EN 50110-1.
• Keep children away from batteries!
• No smoking!
• Do not expose batteries to naked flames, glowing
embers or sparks, as it may cause the battery to
explode
• Avoid sparks from cables or electrical apparatus as
well as electrostatic discharges.
• Acid splashes into the eyes or on the skin must be
washed immediately with an abundance of clean
water. After abundant flushing consult a doctor
immediately!
• Clothing contaminated by acid should be washed in
water.
• Risk of explosion and fire
• Avoid short circuits: do not use non-insulated tools, do
not place or drop metal objects on top of the battery.
Remove rings, wristwatches and articles of clothing with
metal parts that might come into contact with the battery
terminals.
• Electrolyte is highly corrosive.
• In the normal operation of this battery a contact with
acid isn’t possible. If the cell containers are damaged,
the immobilised electrolyte (absorbed in the separator)
is corrosive like the liquid electrolyte.
• Batteries and monoblocs are heavy. Ensure secure
installation! Use only suitable handling equipment.
• Lifting hooks must not damage the blocs, connectors
or cables.
• Do not place batteries in direct sunlight without
protection. Discharged batteries can freeze. For that
reason, always store in a frost-free zone.
• Dangerous electrical voltage!
• Avoid short circuits: powerbloc dry XFC batteries are
capable of high short circuit currents.
• Caution - metal parts of the battery are always live: do
not place tools or other objects on the battery!
• Pay attention to the hazards that can be caused
by batteries
SAFETY PRECAUTIONS
Ignoring the operating instructions, and repair with non-original parts will render the warranty void. All failures, malfunctions or defaults of the battery,
the charger or any other accessories, must be notified to our After Sales Service immediately.
12XFC25 M6 Female 3.9 Nm SAE 3.9 Nm
12XFC35
12XFC48
12XFC60 M6 Female 6.8 Nm SAE 6.8 Nm
12XFC58
12XFC82 M8 Female 5.0 Nm M6 Front 9.0 Nm
12XFC158 Terminal
12XFC177

www.enersys-emea.com
04.2008 - Subject to revisions without prior notice.
2. Operation
EN 50272-3 “Traction batteries for industrial trucks” is the standard
which applies.
The nominal operating temperature is 30°C. The optimum lifetime of the
battery depends on the operating conditions (temperature and depth of
discharge). The temperature range of use for the battery is between
+15°C and +35 °C, any use outside of this range must be approved by the
EnerSys Technical department. Optimal battery life is obtained with the
battery at a temperature of 25-30°C. Higher temperatures shorten the life
of the battery (according to IEC1431 technical report), lower temperatu-
res reduce the available capacity. The upper temperature limit is 45°C
and batteries should not be operated above this temperature.
The capacity of the battery changes with temperature and falls consider-
ably under 0 °C. The optimum lifetime of the battery depends on the
operating conditions (moderate temperature and discharges equal to or
lower than 80% of the nominal capacity C5). The battery obtains its full
capacity after about 3 charging and discharging cycles.
2.1. Discharging
The valves on the top of the battery must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the
open circuit condition. Discharges over 80% of the rated capacity are
categorised as deep discharges and are not acceptable as they reduce
considerably the life expectancy of the battery. Discharged batteries
MUST be recharged immediately and MUST not be left in a discharged
condition.
Note: The following statement only applies to partially discharged
batteries.
Discharged batteries can freeze.
Limit the discharge to a maximum of 80% DOD.
The cycle life of the battery will depend on the DOD,
the higher the DOD, the shorter the cycle life.
The presence of a discharge limiter on the vehicle is imperative,
The following energy cut-off settings must be used :
• 60% DOD set at 1.93 Volts per cell.
• 80% DOD set at 1.88 Volts per cell.
when discharged with I5(or higher currents).
2.2. Charging
Powerbloc dry XFC batteries must be charged using an approved speci-
fied EnerSys XFC charger. An approved charger MUST be used on these
batteries; failure to do so will affect the performance and life of the bat-
tery and invalidate any warranty.
The specific charging profile developed for recharging the powerbloc dry
XFC blocs allows a rapid recharge in 3 hours from 60% DOD and oppor-
tunity charging as often as needed without damaging the blocs.
The powerbloc dry XFC batteries have an extremely low gas emission.
Nevertheless, provision must be made for venting of the charging gases.
Battery container lids and the covers must be opened or removed.
With the charger switched off, connect the battery to the charger, ensu-
ring that the polarity is correct. (Positive to positive, negative to negati-
ve). Now switch the charger ON.
2.3. Equalising Charge
Equalising charge is not necessary for this technology of battery.
3. Maintenance
The electrolyte is immobilised. The density of the electrolyte can not be
measured.
Never remove the safety valves from the monobloc.
In case of accidental damage to the valve, contact our After Sales
Service for replacement.
3.1. Daily
• Recharge the battery after every discharge.
• Check the condition of the plugs, cables and that all insulation covers
are in place and in good condition.
3.2. Weekly
• Visual inspection for signs of dirt and mechanical damage.
3.3. Quarterly
At the end of the charge, carry out end of charge voltage readings,
measure and record:
• The voltage of the complete battery
• The voltages of each monobloc
If significant changes from earlier measurements or differences between
the monoblocs are found, please contact our Service Department.
If the discharge time of the battery is not sufficient, check:
• That the required work is compatible with the battery capacity
• The settings of the charger
• The settings of the discharge limiter on the vehicle.
3.4. Annually
Internal dust removal from the charger.
Electrical connections: test all connections (sockets, cables, and contacts).
Monoblocs having terminals with insert: Check the torque loading of the
bolts/screws.
According to EN 1175-1 when necessary, but at least once a year, the
insulation resistance of the vehicle and of the battery must be checked
by an electrical specialist.
4. Storage
Batteries are despatched from the manufacturer in a fully charged
condition. The state of charge will decrease with storage.
All batteries lose their stored energy when allowed to stand open-circuit,
due to parasitic chemical reactions.
The rate of self-discharge is non-linear and decreases with decreasing
state of charge. It is also strongly influenced by temperature.
High temperatures greatly reduce storage life.
It is recommended that the fully charged battery should be stored in a
cool dry place, ideally below 20°C.
The battery has a maximum inspection-free storage life of 2 years, if sto-
red at or below 20°C, after which a refresh charge should be administe-
red. However, it is advisable to conduct an inspection and open circuit
voltage check after 12 months and recharge if the OCV is less than 2.10
Volts per cell.
The battery may be stored for up to 5 years without degradation of per-
formance provided that an open circuit voltage (OCV) check is conducted
every 12 months. When stored in temperatures in excess of 30°C (86°F),
the battery should be OCV checked every 6 months.
The graph below shows the relationship between temperature, storage
time and OCV.
5. Disposal
Powerbloc dry XFC batteries are recyclable. Scrap batteries must be
packaged and transported in accordance with prevailing transportation
rules and regulations. Scrap batteries must be disposed of in compliance
with local and national laws by a licensed or certified lead acid battery
recycler.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries wich are not returned for the recycling process must be disposed of as hazardous waste!