EnerSys Hawker Perfect Plus Instructions For Use page 2

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
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 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 IEC 62877-2 : 2016.
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Hawker 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 IEC 62877-1 : 2016). The electrolyte level must not
fall below the top of the separator or the electrolyte "min"
level mark.
NO WATERING IN THE FIRST 10 CYCLES.
3.1.1 Filling level sensors
In the case of batteries with filling level sensors, the
illuminated LED should be observed daily.
LED green
LED red blinking
Do not top up the cells even when electrolyte level sensor
shows a red blinking LED during first 10 cycles.
Check the electrolyte level (visual inspection by opening the
vent plug or by the position of the float indicator of the Aqua-
matic 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).
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
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 batte-
ries 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. Earlier
replacement of the filter is necessary if for undefined 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.
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 complies with 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.
Never use (apply ) mineral grease on the battery, the sealing
material of the terminal is incompatible and it can be per-
manently damaged. If it's necessary, use (apply) the silicone
grease with TPFE.
If batteries are taken out of service for a lengthy period they
should be stored in the fully charged condition in a dry, frost-
level OK
free room. To ensure the battery is always ready for use a
choice of charging methods can be made:
level too low
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
The storage time should be taken into account when
considering the life of the battery.
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.
3.3 Monthly
the S.G. of each cell
3.4 Annually
4. Care of the battery
5. Storage
of cells.
6. Malfunctions