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measurements or differences between the cells
or bloc batteries are found further testing and
maintenance by the service department should
be requested.
3.4 Annually
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 must be conducted in accordance with
EN 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 EN 62485-3. For batteries up to 20 V nominal
voltage the minimum value is 1000 Ω.
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 ZVEI 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 com-
plies EN 62485-3 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
2. float charging at a charging voltage of
2.23 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 eliminati-
on. A service contract with us will make it easier to
detect and correct faults in good time.
7. HOPPECKE trak | uplift air (optional)
1. Ensure that the charger belonging to the battery
is designed for electrolyte circulation.
2. Before initial operation of a trak | uplift air
battery, a system test is absolutely essential. It
should be carried out as follows:
- connect up the air supply
Make a visual examination of the electrolyte surfa-
ces of all cells for movement and rising air bubbles.
Initial operation as a trak | uplift air may com-
mence only after all cells have undergone ade-
quate thorough mixing
3. The connection sequence of the trak | uplift air
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.
Pb
system may not be changed. Ensure that the
individual hoses are pushed far enough on to
the T-pieces at all times, so as to guarantee tight
sealing and stability.
Do not bend hoses!
4. Note for use
Only purified air may be supplied to the cells.
This is to be ensured by means of a suitable
filter. HOPPECKE chargers with EUW usually have
such a filter.
8. AquaFill water replenishment systems
(optional)
1 Water dispenser
2 Outlet nozzle with ball valve
3 Tap with magnetic valve
4 Tap with ball valve
5 Flow control
6 Battery connection coupling
7 Charger
Function
A valve is moved by the float inside the plug. This
valve controls the amount of water required for
topping up. The water pressure blocks any further
water flow and ensures that the water is sealed
off correctly. To enable the water replenishment
system to operate smoothly the following points
must be observed:
Filling
Ideally refill ½ hour before the end of the full char-
ge. The battery must be topped up immediately
after the end of the charging process at the latest.
Topping up batteries every day is no t permitted, as
overfilling can cause the electrolyte to leak out. We
recommend topping up on a weekly basis.
In electronically controlled filling, the HOPPECKE
charger operates the electromagnetic valve (1 ~
230V) at the correct refilling time. The required
refilling time is programmable.
Filling duration
The filling duration depends on the load during
operation and the resulting ambient tempera-
ture generated. The filling procedure generally
takes around 3 minutes. When the flow indicator
stops moving, this indicates the end of the top-up
process. At this point, the water supply must be
disconnected immediately to prevent overfilling
of the battery.
Working pressure
The water replenishment facility must be installed
such that a water pressure of 0.2 to 0.6 bar is achie-
ved at the upper edge of the battery. The water
tank should be installed at a height of 3 to 7 m.
The pipe dimensions must take the number of taps
and the length of pipe required into consideration.
Batteries that are designed especially for the North
American market must be topped up with a water
pressure of 1.7 to 2.4 bar.
Cleanness
The water dispenser must only contain water
which corresponds to water purity according to
DIN 43530-4. Dispensers and pipes must be free
of dirt which could cause the plug to malfunction.
For safety reasons a filter with a maximum per-
meability of 100 to 300 µm must be built into the
battery circuit.
Tube linking system on the battery
The individual cells within the battery are linked
according to the electric circuit. It is not permitted
to make any changes.
Batteries equipped with AquaFill may only be
stored in rooms with a temperature of > 0 °C
(otherwise danger of system freezing).
Flow control
To control the filling procedure a flow control can
be built into the water pipe in front of the battery
connection coupling. When filling, the water flow
from above pushes the ball to the bottom of the
pipe. After shutting all the plugs the ball, now
floating at the top, indicates the end of the top-up
process.
Plug removers
A special appliance is required to remove the
AquaFill plug. To avoid damage, the plug must be
removed with the utmost care.
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