EnerSys TP Series Troubleshooting guide

Rating data
1. Nominal capacity C5: See type
2. Nominal voltage : See type
3. Discharge current : C5/5h
4. Nominal S . of electrolyte* : 1.29 kg/l
5. Rated temperature : 30°C
6. Nominal electrolyte level : up to electrolyte level mark “max”
*reached in the 10 first cycles
Operation and maintenance instructions powerbloc
Motive power batteries or small traction. Flooded monoblocs
TP series : tubular plate monoblocs FP and FTP series : lat plate monoblocs
Ignoring the operating instructions, 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.
DESCRIPTION
The traction batteries powerbloc are suitable to equip all types of small traction.
ENGLISH
SAFETY PRECAUTIONS
1. Commissionning
The battery should be inspected to ensure it is in perfect physical
condition.
Check
• the battery cleanliness. Before installing the battery compartment
has to be cleaned.
• the battery end cables have a good contact to terminals and the
polarity is correct. Otherwise battery, vehicle or charger could be
destroyed.
• the electrolyte level and the presence of the plugs.
• in the case of water refilling system option, verify the presence of
the specific plugs and of the piping system. The electrolyte level
must always be above the top of the separators.
Top up with demineralised water to the nominal level. Charge the battery
(see 2.2.2) before commissioning. Only blocs with the same state of
discharge (the same voltage, tolerance as shown in the following table)
should be connected together.
Bloc voltage (V) Max. tolerance from
average value - Ubloc
6 ± 0.035
12 ± 0.049
After connecting, the terminals must be covered with grease as protection
against external corrosion.
The specified torque loading for the bolts/screws of the end cables and
connectors are :
DIN conic post
8 ± 1 Nm
2. Operation
DIN EN 50272-3 “Traction batteries for industrial trucks” is the standard
which applies. The nominal operating battery temperature is 30°C. Higher
temperatures shorten the life of the battery, lower temperatures reduce
the available capacity. 55°C is the upper temperature limit and batteries
should not be used above this operating temperature. The capacity of the
battery changes with temperature and falls considerably 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 10
charging and discharging cycles.
2.1. Discharge
Vent plugs on the battery must not be 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 should be avoided
• Pay attention to the operating instructions and keep
them close to the battery.
• Works 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 DIN EN 50272-3,
DIN 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.
• Do not tip the battery over.
• Batteries and monoblocs are heavy. Ensure secure
installation! Only use 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 frostfree zone.
• Dangerous electrical voltage!
• Pay attention to the hazards that can be caused by
batteries

Back to the manu acturer!
Batteries with this sign must be recycled.
Batteries wich are not returned or the recycling prozess must be disposed o as hazardous waste!
(deep discharge). A minimum S. . of the electrolyte of 1.13 kg/l is to be
checked at the end of the discharge. Discharged batteries must be
recharged immediately and must not be left in a discharged condition.:
Discharge Recharge
>40% Every day
<40% Every second day
This also applies to partially discharged batteries. Discharged batteries
can freeze.
2.2. Charge
Powerbloc batteries can be recharged with 50 Hz or HF charger. If you wish
to use an existing charger with Wa, WoWa,, IUIa, WUIa…profile, you
should check that the profile is approved by our Technical Department. Only
direct current must be used for charging. Only connect the battery to the
correctly assigned charger, suitable for the battery size in order
to avoid overloading of the electric cables and contacts, electrolyte
overflow and unacceptable gassing of the cells. When gassing the
current limits must not be exceeded according to DIN EN 50272-3.
Before starting the charge, make sure of:
• the presence of the plugs.
•in the case of water refilling system, check the good condition of the
filling up circuit and specific plugs, the water tube connection for the
filling device (fast connection between the battery and the system
with water supply).
When charging, proper provision must be made for venting of the charging
gases. Battery container lids and the covers of battery compartments must
be opened or removed. Keep vent plugs closed. 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. In the case of
automatic filling up, with manual command, press the push –button of the
electrovalve box to release the supply of demineralized water, at the end
of charge. When charging the temperature of the battery rises by about
10°C, so charging should only begin if the electrolyte temperature is below
45°C. The electrolyte temperature of the battery should be at least +10 °C
before charging, otherwise a full charge will not be achieved without
specific settings of the charger.
The charge is considered as achieved when the electrolyte S. . and the
battery voltage remain constant for 2 hours. During the recharge, the cells
emit hydrogen and oxygen gas. It is necessary to ensure ventilation in the
room, especially during the recharge. All installations must comply with
the current regulations in force in the country of operation.
2.2.1 Normal charge
It is applied further to a « normal » discharge of the battery (up to 80% of
C5), it is not interrupted until the end of charge indication by the charger
display.
It is not necessary to recharge the battery immediately if after a use cycle,
the residual capacity is still more or equal to 60% of its capacity. In that
case it is necessary to recharge the day after, at the latest.
2.2.2. Equalising charge
Equalising charges are used for insuring the service life and to maintain
the capacity. They are necessary after deep discharges and after repeated
uncomplete charges. They allow homogenisation of the specific gravity of
the electrolyte:
• to compensate the self discharge due to the storage period.
• to compensate the eventual lack of charge with normal charges.
• to quickly homogenise the electrolyte, following the addition of
distilled or demineralised water.
• to compensate stratification, following partial charges without
mixing of the electrolyte (not recommended).
To be carried out after a normal charge when a variation (differences more
than 10 grams per litre) of specific gravity is recorded.
It is carried out using a constant current with a low value near C5/30 (C5/20
max) and after a normal charge of the battery (end of charge, see 2.2). The
recommended duration is 8 hours. The equalising charge may be
interrupted if the specific gravities are homogenised. When the nominal
electrolyte specific gravity is not obtained after an equalising charge, and
when this low specific gravity is not the consequence of electrolyte over-
flowing, a recharge in completion with the equalising charge can be
carried out. It must be done with constant current, near C5/60 A, and after
a complete charge for 72 hours. Watch the temperature and a sufficient
ventilation!
2.2.3. Desulphation charge
Should be carried out after a very deep discharge of the battery (> 80% C5)
when the charger does not start the recharge due to an over discharge of
the battery. It must carried out with constant current, near C5/60, for 2
hours minimum. It is followed by a normal charge and equalising charge
(desulphation if necessary). The best result is obtained with the lowest
value of current. In any case, stop the charge if the electrolyte
temperature reaches 45°C.
2.3. Electrolyte
The electrolyte nominal S. . is 1.29 kg/l at 30°C when in fully charged
condition. According to temperature, S. . correction, in respect to 30°C,
will be applied :.
T°C Correction per °C
If T °C > 30°C - 0,0007
If T °C < 30°C + 0,0007
Example : S reading 1.285 at 36°C :
1.285 + (0,0007 X 6) = 1.289 at 30°C
The purity of the electrolyte must correspond to DIN 43530-2.
2.4. Battery check
After a normal charge, measure :
•the total voltage
• the voltage per cell
•the electrolyte specific gravity on several cells or on the whole battery.
NB: measure at the constant intensity of I=0.033 C5or if the charger can
do it, at “equalising charge”. The voltages for a new battery will be
greater than or equal to 2.65 Volts per cell under I=0,033C5.
3. Maintenance
3.1. Daily maintenance
•keep the battery, clean and dry in order to avoid self-discharging and
current leakage.
•check : the condition of the plugs, cables and that all insulation
covers are in place and in good condition.
3.2. Weekly maintenance
If necessary, adjust the electrolyte level of each cell, only use demineralized
or distilled water. The level must never be lower than the minimum level,
in other words, always above the plates. It is carried out:
• at the end of charge and without over exceeding the maximum level
if the battery has standard filling plugs.
• by connection to the water circuit if the battery is equipped with
automatic filling up. The pressure must be between 0.2 and 0.6 bar.
VERY IMPORTANT
In difficult conditions, high room temperature for example, the electrolyte
level must be checked as often as necessary.
If there are traces of electrolyte-overflowing, in general, lead sulphate
trails, wash the battery with clean water at low pressure, with the cells
vent plugs in place and closed.
3.3. Monthly or quarterly maintenance
Carry out an end-of-charge control : measure and record the voltages of
all blocs with the charger switched on. Measure and record the electrolyte
S. . of all blocs.If significant variations to the earlier measurements or big
variations between the blocs or cells are noticed, please contact our
Service. If the battery autonomy is not sufficient, check that the work
required is compatible with the battery capacity, the battery condition
(end of charge S ), and the settings of the charger.
3.4. Annual maintenance
Battery: for bolt on connectors, check the torque settings of the terminal
bolts/screws, the terminals must be covered with grease as protection
against external corrosion. Charger: internal dust removal, check all
connections (plugs, cables and contacts) and charging parameters.
According to DIN EN 1175-1 when necessary, but at least once a year,
the insulation resistance of the truck and of the battery must be checked
by an electrical specialist.
The test on the insulation resistance of the battery must be conducted in
accordance with DIN EN 1987-1. The average insulation resistance of the
battery must not be lower than 50 Ωper Volt nominal voltage.
(DIN EN 50272-3)
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Storage and transportation
Batteries must always be stored and transported securely in the vertical
position in order to avoid any electrolyte leakage. Store the battery in a
fully charged condition in a dry, clean and frost free area.
Always disconnect the battery from the electric vehicle before storage. For
easy recharge of the batteries, it is advised not to store without recharge
for more than 3 months at 20°C and 2 months at 30°C.
The storage time is to be considered within the battery life expectancy.
To ensure the battery is always ready for use a choice of charging methods
can be made :
• monthly equalising charge according to 2.2.2.
• float charge with 2.27 V x number of cells.
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09.2015 Subject to technical modification without any prior notice.