EnerSys TP Series Operation And Maintenance Instructions

Operation and maintenance instructions powerbloc
Motive power batteries for small traction.
TP series : tubular plate monoblocs

Rating data

1. Nominal capacity C
5
2. Nominal voltage
3. Discharge current
4. Nominal SG. of electrolyte*
5. Rated temperature
6. Nominal electrolyte level
*reached in the 10 first cycles

SAFETY PRECAUTIONS

• 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.
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.

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)
6
12
Flooded monoblocs
FP and FTP series : flat plate monoblocs
Max. tolerance from
average value - U
bloc
± 0.035
± 0.049
: See type
: See type
: C /5h
5
: 1.29 kg/l
: 30°C
: up to electrolyte level mark "max"
• 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
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 C ). The battery obtains its full capacity after about 10
5
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
ENGLISH