EnerSys Oerlikon Evolution 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 50110-1.
• 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 immobilised
electrolyte (gelled sulphuric acid) is corro-
sive 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.
Oerlikon®Evolution 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.
Oerlikon Evolution battery valves should never be removed. These batteries do not require topping-up with distilled or
demineralized water.
Instructions for use Oerlikon®Evolution
Gas recombination traction batteries with positive tubu ar p ates type PzV
Ignoring the operating instructions, repair with non-original parts, disconnection of the Oerlikon easycontrol 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. Electronic devices
The type of device required must be specified at the time of
ordering the battery from the factory.
Please follow the table:
We encourage to use an electronic device (according the table
as above) on all Evolution batteries to make sure that the
batteries are properly used and to be able to assist with
potential warranty claims.
2. Commissioning
The battery should be inspected to ensure it is in perfect
physical condition. Use special coding systems for mainten-
ance 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 perfect 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 T E WARRANTY OF T E
BATTERY.
Charge before use.
device cha ge mandato y
Easy Control Lifeplus
Wi-IQ®Life IQTM
no device capable Lifetech®, EnerSys®n/a
to communicate approved F chargers

3. 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.
3.1. Discharge
Ventilation openings must not be sealed or covered. Electrical
connections (e.g. plugs) must only be connected or dis-
connected 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 C5when the recharging time is
8 hours). Discharged batteries must be recharged and never
be left in a discharged state for a long time.
Oerlikon®Evolution 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.
3.2. 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 Oerlikon F charger.
After any changing of cables on the charger, our technician
must visit the site to check the charger.
Oerlikon Evolution batteries have a low gas emission.
Nevertheless, when charging, proper provision shall be made
for venting of the charging gases (EN 50272-3). Battery con-
tainer 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.
3.3. 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 Oerlikon F charger.
4. Battery life
The optimum lifetime of the battery depends on the
operating conditions (temperature and depth of discharge)
4.1. 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 Oerlikon service technician. Optimal battery life is obtai-
ned for a battery temperature of 25-30°C igh temperatures
reduce battery life according to IEC 1431 technical report,
lower temperatures reduce the capacity available.
5. 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.
5.1. Daily
• Check that the plugs and sockets are in good condition.
5.2. 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 differen-
ces between the cells or bloc batteries are found, please
contact Oerlikon 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.
5.3. 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 1987-1.
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.
6. 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.
7. 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 p io notice. E&OE
05.2013