EnerSys Fiamm energy dry User manual

•Pay attention to the operating
instructions and keep them close to the
battery.
Work on batteries should be carried out
by skilled personnel only!
•Use protective glasses and clothes when
working on batteries. Pay attention to
the accident prevention rules as well as
EN 50272-3 and EN 501110-1.
•No smoking! Do not expose batteries to
naked flames, glowing embers or sparks,
as it may cause the battery to explode.
•Acid splashes into the eyes or on the
skin must be washed with plenty of
water. In case of accident after abundant
flushing consult a doctor immediately!
Clothing contaminated by acid should be
washed in water.
•Risk of explosion and fire, avoid short
circuits! Caution: metal parts of the
battery are always live. Do not place
tools or other metal objects on the
battery!
Do not remove the plugs.
•Electrolyte is highly corrosive.
In the normal operation of this battery
contact with acid isn’t possible. If the cell
containers are damaged, the immobili-
sed electrolyte (gelled sulphuric acid) is
corrosive like liquid electrolyte.
•Batteries and cells are heavy.
Ensure secure installation!
Use only suitable handling equipment.
Lifting hooks must not damage the cells,
connectors or cables.
•Dangerous electrical voltage!
•Pay attention to the hazards that can be
caused by batteries.
Fiamm energy dry batteries are valve-regulated, maintenance free batteries. Unlike conventional batteries with liquid
electrolyte they have immobilised electrolyte (gelled sulphuric acid). 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.
When operating valve-regulated lead-acid batteries the same safety requirements as for vented cells apply, to protect against
hazards from electric current, from explosion of electrolytic gas and – with some limitations – from the corrosive electrolyte.
Fiamm energy dry battery valves should never be removed. These batteries do not require topping-up with distilled or
demineralized water.
Instructions for use Fiamm energy dry
Gas recombination traction batteries with positive tubular plates type PzV
Ignoring the operating instructions, repair with non-original parts, disconnection of the Fiamm energycom will render the
warranty void. All the failures, malfunctions or defaults of the battery, the charger or any other accessories, must be
notified to our After Sales Service.
ENGLISH
Rating Data
1. Nominal capacity C5:See type plate
2. Nominal voltage : 2.0 V x No of cells
3. Discharge current : C5/5h
4. Nominal S.G. of electrolyte* Type PzV : 1.29 kg/l
5. Rated temperature : 30°C
*Will be reached within the first 10 cycles
1. Commissioning
The Fiamm energy dry battery is equipped with a Fiamm
energycom, electronic device, installed on battery
connectors. The presence of this feature is mandatory on
each Fiamm energy dry battery. The battery should be
inspected to ensure it is in perfect physical condition. Use
special coding systems for maintenance free batteries for
the charging plug- and- socket devices to prevent accidental
connection to a wrong type of charger. The battery end
cables must have a good contact to terminals, check that the
polarity is correct. Otherwise battery, vehicle or charger
could be damaged. The specific torque loading for the bolts
of the charger cables and connectors are:
Steel
M10 connector 25 ± 2 Nm
Never directly connect an electrical appliance (for example:
warning beacon) to some cells 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 before use.
2. Operation
EN 50272-3 “Safety requirements for secondary batteries
and battery installations Part 3: Traction batteries” is the
standard which applies to the operation traction batteries
in industrial trucks.
2.1. Discharge
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be connected
or disconnected 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). They reduce the battery service life.
To measure the state of discharge use only the battery

manufacturer’s recommended discharge indicators
(imperative presence of a discharge limiter with an energy
cut-off at 1.83 vpc operating voltage at 80% DOD C5, when
the recharging time is 12 hours, and 1.87 vpc at 60 % DOD
C5 when the recharging time is 8 hours). Discharged
batteries must be recharged and never be left in a
discharged state for a long time.
Fiamm energy dry batteries can be used in normal duty
applications for a maximum 6 days per week.
Avoid applications where:
• no rest time is available allowing the battery to cool
• battery duty leads to a high increase of temperature
during operation.
2.2. Charging
A full charge shall be carried out every working day.
The charging time for a 80 % discharged battery shall be
12 hours, or 8 hours for a 60% discharged battery with the
appropriately assigned Fiamm Premium HF com/Premium
HF flex high frequency charger.
After any changing of cables on the charger, our technician
must visit the site to check the charger.
Fiamm energy dry batteries have a low gas emission.
Nevertheless, when charging, proper provision shall be
made for venting of the charging gases (EN 50272-3).
Battery container lids and the covers of battery
compartments shall be opened or removed. With the
charger switched off connect the battery, ensuring that the
polarity is correct. (Positive to positive, negative to
negative). Now switch on the charger.
2.3. Equalising charge
Equalising charges are used to optimise the life of the
battery and to maintain its capacity. A unique equalisation
charge is automatically carried out weekly 8 hours after the
end of the charge with a Fiamm Premium HF com/Premium
HF flex charger.
3. Battery life
The optimum lifetime of the battery depends on the
operating conditions (temperature and depth of discharge)
3.1. Temperature
The temperature range of use for the battery is between
+5 °C and + 35 °C. Any use outside of this range shall be
approved by a Fiamm service technician. Optimal battery
life is obtained for a battery temperature of 25-30 °C High
temperatures reduce battery life according to IEC 1431
technical report, lower temperatures reduce the capacity
available.
4. Maintenance
The electrolyte is immobilised in a gel.
The density of the electrolyte cannot be measured.
• Never refill with water!
• Never remove the safety valve from the cell
In case of accidental damage of the valve, contact our After
Sales Service for replacement.
The battery should always be kept clean and dry to prevent
current leakage. Any liquid in the battery tray shall be
extracted. Damage to the insulation of the tray should be
repaired after cleaning, to ensure a good insulation and to
prevent tray corrosion. If it is necessary to remove cells it is
best to call in our service department for this.
4.1. Daily
• Check that the plugs and sockets are in good condition.
4.2. Monthly / quarterly
• Carry out end of charge voltage readings at C5/100,
measure and record:
• the voltage of the battery
• the voltages of each cell
If significant changes from earlier measurements or
differences between the cells or bloc batteries are found,
please contact Fiamm Service.
• If the discharge time of the battery is not sufficient,
check:
• That the work required is compatible with the battery
capacity
• The settings of the charger
• The settings of the discharge limiter.
4.3. Annually or biannually
Internal dust removal from the charger.
Check with attention:
• the state of the plugs :be sure to have a good contact
between the plugs without trace of overheating.
• the state of the output cables.
If you check the torque loading, you shall use a torque
wrench with respect of recommended value : 25+/- 2 Nm.
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 shall
be conducted in accordance with EN 1987 part 1.
The insulation resistance of the battery thus determined
must not be below a value of 50 Ωper Volt of nominal
voltage, in compliance with EN 50272-3. For batteries up
to 20 V nominal voltage the minimum value is 1000 Ω.
5. Storage
If batteries are taken out of service for a lengthy period they
should be stored, disconnected from the truck, in the fully
charged condition in a dry, frost-free room.
Batteries shall be recharged after a maximum storage time
of :
• 2 months at 30 °C
• 3 months at 20 °C
Effect a recharge before putting the battery into service. A
monthly refreshing charge is recommended. The storage
time should be taken into account when considering the life
of the battery. Never leave a battery connected to a truck for
a long time.
Storage at open circuit is not allowed when in discharged
state.
6. Malfunctions
If malfunctions are found on the battery or the charger our
service department should be called without delay. A
service contract with us makes it easier to detect and correct
faults in good time.
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!
www.enersys-emea.com
Subject to technical modification without any prior notice.
08/2005