HOPPECKE HPzS Serie Mode D'emploi page 6

Operating manual Traction batteries
Traction batteries with positive tubular plates type HPzS and HPzB
Rating Data:
Nominal capacity C
5
Nominal voltage
Discharge current
Nominal S.G. of electrolyte*
Rated temperature
Nominal electrolyte level
* Will be reached within the first 10 cycles
Pay attention to the operating manual
and fix them close to the battery. Work
on batteries has to be carried out by
skilled personnel only.
Face shields (impact-resistant visor in
accordance with EN 166, class F), safety
goggles and protective clothing must
be worn when working* on batteries.
Accident prevention regulations as well
as EN 62485-3 and EN 50110-1 must be
observed.
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 bat-
tery are always live. Do not place tools
or other metal objects on the battery.
Electrolyte is highly corrosive.
Batteries and cells are heavy. Ensu-
re secure installation!
suitable handling equipment e.g. lifting
gear in accordance with VDI 3616.
Dangerous electrical voltage.
Ignoring the operating Manual, repair with
non-original parts or using additives for the elec-
trolyte will render the warranty void.
For batteries according to the ATEX directive
2014/34/EU the instructions for maintaining the
appropriate protection class during operation
must be complied with (see relevant certificate).
Please note the additional instructions.
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.
6
See type plate
2.0 V x No of cells
C /5 h
5
1.29 kg/l
30 °C
up to electrolyte level mark "max."
Only terminal clamp systems approved by HOP-
PECKE may be used. The specified torque loa-
ding for the polscrews of the charger cables and
connectors is: 25 ± 1 Nm.
The level of the electrolyte must be checked. 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. The battery is then
charged as in item 2.2. The electrolyte should be
topped up to the specified level with purified water
(DIN 43530-4).
2. Operation
EN 62485-3 "Traction batteries for industrial
trucks" is the standard which applies to the ope-
ration traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or
covered. Electrical connections (e. g. plugs) must
only be made or broken in the open circuit condi-
tion. To achieve the optimum life for the battery,
operating discharges of more than 80 % of the
rated capacity should be avoided (deep dischar-
ge). This corresponds to an electrolyte specific
gravity of 1.13 kg/l at the end of the discharge.
Discharged batteries must be recharged imme-
diately and must not be left discharged. Partially
discharged batteries must not be left in a partial
state of charge for long periods of time.
Use only 2.2 Charging
Only direct current must be used for charging.
All charging procedures in accordance with
DIN 41773 and DIN 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 elec-
trolyte from the cells. In the gassing stage the
current limits given in EN 62485-3 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.
Battery container lids and the covers of battery
compartments must be opened or removed.
The ventilation must comply to EN 62485-3.
The vent plugs should stay on the cells and
remain closed. With the charger switched off
connect up the battery, ensuring that the pola-
rity 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 batte-
ries 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.
Pay attention to the separate operating manual
for Ex batteries.
2.3 Equalising charge
Equalising 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. Equalising charges are
carried out following normal charging. The char-
ging 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 ope-
rating temperature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the elec-
trolyte is related to a temperature of 30 °C and the
nominal electrolyte level in the cell in fully charged
condition. Higher temperatures reduce the speci-
fied 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 according to DIN 43530-2.
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Before
charging, the electrolyte level must be checked.
The electrolyte level must never fall below the
top of the separator. When a flip top plug is used,
the need to top up water is indicated by the level
falling below the min. level mark, and when an
Aquafill plug is used, this is indicated by the level
indicator. When an electrolyte level indicator is
used, a visual signal is provided when the elect-
rolyte level is too low.
3.2 Weekly
Visual inspection after recharging for signs
of dirt and mechanical damage. If the battery is char-
ged regularly with a IU characteristic curve an equa-
lising 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 ended the specific gravity and the temperature
of the electrolyte in all cells should be measured
and recorded. If significant changes from earlier
* Installation/commissioning, servicing, cleaning and disassembly