EnerSys Oerlikon Perfect Plus User manual

Traction batteries with positive tubular plates type PzS / PzB
ENGLISH
Instructions for use Oerlikon®Perfect PlusTM
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 PzS / PzB : 1.29 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 or using additives for the electrolyte will render the
warranty void.
For batteries according to the AT X directive 94/9 C, the instructions for maintaining the appropriate protection class
during operation must be complied with (see relevant certificate).
• Pay attention to the operation instruction and
fix them close to the battery.
• Work on batteries to be carried out by skilled
personnel only!
• Use protective glasses and clothes when wor-
king on batteries. Pay attention to the accident
prevention rules as well as DIN N 50272-3 and
DIN N 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 in the eyes or on the skin must be
washed with water. In case of accident 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!
• lectrolyte is highly corrosive.
• Batteries and cells are heavy.
• nsure secure installation! Use only suitable
handling equipment e.g. lifting gear in accor-
dance with VDI 3616.
• Dangerous electrical voltage!
• Pay attention to the hazards that can be caused
by batteries.
1. Commissioning filled and charged batteries
For commissioning of unfilled batteries see separate
instructions! The battery should be inspected to ensure it is in
perfect physical condition.
The charger cables must be connected to ensure a good
contact, taking care that the polarity is correct.
Otherwise battery, vehicle or charger could be damaged.
For the assembly of harness cables or in case of the replace-
ment of a connector the following torque must be applied:
M 10 perfect connector 25 ± 2 Nm
In case the interval between delivery (see manufacturing date
on type plate) and commissioning is longer than 8 weeks or
the electrolyte level sensor is indicating low electrolyte level
(see table point 3.1.1 ), the electrolyte level has to be checked.
If the battery is equipped with a single point water topping up
system (optional), for the removal of the BFS plugs only the
appropriate tool must be used. Otherwise the floats of plugs
may be permanently damaged, which can cause overflow
of the cells. If it is below the anti-surge baffle or the top of
the separator it must first be topped up to this height with
purified water (DIN N 43530-4).
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level
with purified water.
2. Operation
DIN N 50272-3 “Traction batteries for industrial trucks” is the
standard which applies to the operation traction batteries in
industrial trucks.
2.1 Discharging
Be sure that all ventilation holes are not sealed or covered.
lectrical 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 should 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.
2.2 Charging
Only direct current must be used for charging.
For the Oerlikon Perfect Plus batteries, procedures in
accordance with DIN N 41773-1 and DIN N 41774 are
permitted. Only connect the battery assigned to a charger,
suitable for the size of battery, in order to avoid overloading
of the electric cables and contacts, unacceptable gassing and
the escape of electrolyte from the cells. In the gassing stage
the current limits given in DIN N 50272-3 must not be
exceeded. If the charger was not purchased together with
the battery it is best to have its suitability checked by the
manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.

Doors, battery container lids and covers of battery
compartments must be opened or removed. During the
charge the battery must be removed from the closed battery
compartment on the truck. The ventilation must comply to
DIN N 50272-3 standard. The vent plugs should stay on the
cells and remain closed. With the charger switched off
connect up the battery, ensuring that the polarity is correct.
(positive to positive, negative to negative). Now switch on the
charger. When charging the temperature of the electrolyte
rises by about 10°C, so charging should only begin if the
electrolyte temperature is below 45°C. 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.
Batteries fitted with electrolyte circulation system: if the warning
light on the pump controller is illuminated or if a defect signal
on the electrolyte mixing system appears, check that the piping
system is connected and examine the piping circuit for leaks or
defects. (see 3.4. Maintenance)
The air pipe should never be removed during charge.
2.3 Equalising charge
qualising 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. qualising 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 DIN N 43530-2.
3. Maintenance
3.1 Daily
Charge the battery after every discharge.
Oerlikon Perfect Plus/Perfect Plus with electrolyte circulation:
towards the end of charge the electrolyte level should be
checked and if necessary topped up to the specified level with
purified water (according DIN N 43530-4). The electrolyte
level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte ”min” level mark.
3.1.1 Filling level sensors
In the case of batteries with filling level sensors, the
illuminated L D should be observed daily.
L D green level OK
L D red blinking level too low
Check the electrolyte level (visual inspection by opening
the vent plug or by the position of the float indicator of the
Aquamatic 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).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc
batteries 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 or
bloc batteries 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
3.4 Annually
In accordance with DIN N 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 DIN N 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
DIN N 50272-3. For batteries up to 20 V nominal voltage
the minimum value is 1000 Ω.
Batteries fitted with electrolyte circulation system: the
filter of the air pump has to be checked during the annual
maintenance and eventually to be cleaned or replaced.
arlier replacement of the filter is necessary if for
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reasons (no leaks in the air pipes) the defect signal of the air
mixing 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 ZV I 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
DIN N 50272-3 and to prevent tray corrosion. If it is
necessary to remove cells it is best to call in our service
department for this.
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.
6. Malfunctions
If malfunctions are found on the battery or the charger our
service department should be called in without delay. The
measurements taken in point 3.3 will facilitate fault finding
and their elimination.
A service contract with us will make it easier to detect and
correct faults in good time.

1. Application
The water refilling system is used to automatically maintain
the nominal electrolyte levels.
The charging gasses escape through the vent on each cell.
NO WATERING IN THE FIRST 10 CYC ES
2. Function
A valve and a float together control the topping up process
and maintain the correct water level in each dell. The valve
allows the flow of water into each cell and the float closes the
valve when the correct water level has been reached.
For fault-free operation of the water refilling system, please
note the instructions below:
2.1 Manual or automatic connection
The battery should be topped up shortly before completion
of a full charge, as at this point the battery has reached a
defined operational state resulting in satisfactory electrolyte
mixing. Filling takes place when the connector (7) from the
tank is connected to the coupling (6) on the battery.
2.1.1 If manual connection is used the battery should only
be connected to the filling system once a week.
2.1.2 If automatic coupling is used (with a magnetic valve
controlled by the charging apparatus) the charger
main switch selects the correct moment for filling.
Note: In this case we recommend a water refilling
at least once a week to ensure the right level of the
electrolyte.
2.1.3 In multiple shift and warm ambient temperature
operations, it may be necessary to have shorter
topping up intervals.
2.2 Filling time
Filling time depends on the utilisation rate and the
corresponding battery temperature. Generally speaking, the
top up process takes a few minutes and can vary according
to the battery range; after this, if manual filling is being used,
the water supply to the battery should be turned off.
2.3 Working pressure
The water refilling system should be installed in such a way
that a water pressure of 0.2 to 0.6 bar is obtained (with at least
2 m height difference between the upper edge of the battery
and the lower edge of the tank). Any deviation from this
means that the system will not function properly.
2.4 Purity
The topping up water must be purified. The water used to
refill the batteries must have a conductance of not more
than 30 µS/ cm. The tank and pipes must be cleaned before
operating the system.
2.5 Pipe system on the battery
The pipe system to the individual battery cells must follow
the battery’s electrical circuit. This reduces the risk of current
leakage in the presence of electrolytic gas causing an
explosion (DIN N 50272-3). A maximum of 20 cells may be
connected in a series.
The system should not be modified in any way.
2.6 Working temperature
In winter, batteries fitted with Aquamatic should only be
charged or refilled in a room temperature above 0°C.
2.7 Flow control
A flow indicator built into the water supply pipe to the
battery monitors the filling process. During filling the water
flow causes the built-in disc in the flow indicator to turn.
When all the plugs are closed the disc stops, indicating that
the filling process is complete.
OPTIONS
Aquamatic water refilling system (optional accessory)
1. tank
2. outflow connector with ball valve
3. plug with magnetic valve
4. plug with ball valve
5. flow control
6. coupling
7. connector
8. battery charger
9. charger main switch
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1. Application
The electrolyte circulation system is based on the principle of
pumping air into the individual battery cells. This system
prevents electrolyte stratification and the battery charge
is optimised using a charge factor of 1.07. The electrolyte
circulation is particularly beneficial for heavy duty use, short
charge times, boost or opportunity charging and in high
ambient temperatures.
2. Function
The electrolyte circulation consists of a pipe system fitted in
the cells. An Aeromatic diaphragm pump is fitted in the
charger or separately mounted on the battery or vehicle.
This diaphragm pump sends a low rate airflow into each cell
which creates a circulating air stream inside the cell box. The
air stream is continuous or pulsed depending on the battery
voltage and pump type. The air supply is adjusted in accor-
dance to the number of cells in the battery.
The pipe system to the individual battery cells must follow
the existing electrical circuit. This reduces the risk of current
leakage in the presence of electrolytic gas causing an
explosion (DIN N 50272-3).
2.1 Use with separate pipe system
Air is supplied when the charger pipe system is connected to
the battery pipe system (with blue ring).
2.2 Use with automatic connection of the pipe system
Connecting the charge plug with integrated air supply auto-
matically supplies air to the battery.
2.3 Maintenance of air filter
Depending on the working conditions, the pump air filter
should be changed at least once a year. In work areas with
high levels of air-pollution, the filter should be checked and
replaced more frequently.
2.4 Repair and maintenance
The system must be checked for leakage. The charger will dis-
play an error message to indicate leakage. Sometimes in the
case of leakage the characteristic charging curve is switched
over to the characteristic standard curve (without electrolyte
mixing).
Faulty parts and faulty pipe sections must be replaced.
Only Oerlikon original spare parts may be used, as these are
designed for the pump air supply and will ensure correct
functioning of the pump.
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!
When using motive power batteries and chargers, the operator must comply with the current standards, laws,
rules, and regulations in force in the country of use!
www.enersys-emea.com
Electrolyte circulation system (optional accessory)
11.2014
Subject to technical modification without any prior notice. E&OE
Wi-I ®(optional accessory)
The Wi-IQ is the electronic device that communicates
wirelessly to download the battery key information for
better diagnostics & service. The device is fitted to a main DC
cable on the battery to monitor and record data of current,
voltage, temperature and electrolyte level (via optional
external sensor). The L Ds on the Wi-IQ provide real time
status of battery’s condition.
The information is transferred to the PC via USB by wireless
communication.
1. Operation
The Wi-IQ is suitable for use on all battery technologies
voltage range is 24V – 80V
The device records global data during the life of the battery. It
will store data for 2,555 cycles (complete history stored by
PC). The data can be analysed by the PC software program:
state of charge, temperature warnings and low electrolyte
level warnings.
2. Clear visibility
Selecting the xception & Detailed Reports will provide
information on the condition of your battery and any actions
that are necessary. Wi-IQ Report will quickly enable you to
get a handle on your battery fleet charging & discharging
characteristics. With information by battery family (truck
type) you can see depth of discharge charts, cycles, charging
and much more.
3. Very easy to use
Plug in USB modem to the PC, scan the Wi-IQ and
up-load the data. Wi-IQ Report is a PC Software running on
Windows 7, 8, XP or Vista. A USB wireless key is used for
downloading Wi-IQ data in to a SQL database.
Rapid blinking = wireless identification
Slow blinking = voltage balance warning
OFF - Flashing = electrolyte level is OK
Light is constantly on =
electrolyte level is low - please top up
Blue ED
Green blinking = hardware OK
Blue rapid blinking = wireless identification
Red blinking = temperature warning > 55° C
Tricolour ED
Tricolour L D Blue L D