EnerSys TP series Motive power Batteries for Small Traction Owner’s Manual

EnerSys TP series Motive power Batteries for Small Traction

Specifications

• Nominal capacity C5
• Nominal voltage
• Discharge current
• Nominal SG. of electrolyte*
• Rated temperature
• Nominal electrolyte level

The PowerblocTM Batteries are motive power batteries designed for small traction applications. They come in various series including the TP series with tubular plate monoblocs, the FP and FTP series with flat plate monoblocs. These batteries are suitable for equipping all types of small traction vehicles.

Product Usage Instructions

• Commissioning:
  • After connecting, cover the terminals with grease for protection against corrosion. Follow specified torque loading for bolts/screws of end cables and connectors.
• Operation:
  • Discharge:
  • Do not seal or cover vent plugs on the battery. Only make or break electrical connections in open circuit conditions. Avoid operating discharges of more than 80% of rated capacity (deep discharge). Check electrolyte-specific gravity at the end of discharge.
  • Electrolyte:
  • Maintain electrolyte levels within the specified range.
  • Battery Check:
  • Regularly measure and record voltages and electrolyte-specific gravity to ensure optimal performance.
• Maintenance:
  • Daily Maintenance:
  • Check and clean terminals, and ensure proper ventilation.
  • Weekly Maintenance:
  • Check electrolyte level, and ensure automatic filling up is functioning properly.
  • Monthly or Quarterly Maintenance:
  • Perform end-of-charge control, measure voltages and electrolyte specific gravity of all blocs, and contact Service for any anomalies.
  • Annual Maintenance:
  • Perform scheduled maintenance tasks as recommended by the manufacturer.
• Storage and Transportation:
  • Recycle batteries with the designated sign. Dispose of batteries not returned for recycling as hazardous waste. Comply with relevant standards and regulations during use.

FAQs

• Q: What should I do if I notice traces of electrolyte overflowing?
  • A: In case of electrolyte overflowing, wash the battery with clean water at low pressure with the vent plugs in place and closed.

Rating Data

1. Nominal capacity C5: See type
2. Nominal voltage: See type
3. Discharge current: C5/5h
4. Nominal SG. 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

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 EN 62485-3, 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, and 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.
• The 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 frost-free zone.
• Dangerous electrical voltage!
• Pay attention to the hazards that can be caused by batteries.

Ignoring the operating instructions, and repairing 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.

Commissioning

• 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 good contact with the 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 the 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 demineralized 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, and tolerance as shown in the following table) should be connected.

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

Operation

• EN 62485-3 “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.

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 (deep discharge).
• A minimum S.G. 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.:

• This also applies to partially discharged batteries. Discharged batteries can freeze.

Charge

Powerbloc™batteries can be recharged with a 50 Hz or HF charger. If you wish to use an existing charger with Wa, WoWa, IUIa, or 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 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 EN 62485-3.

Before starting the charge, make sure of:

• the presence of the plugs.
• in the case of a water refilling system, check the good condition of the filling-up circuit and specific plugs, the water tube connection for the filling device (the fast connection between the battery and the system with water supply).

When charging, proper provision must be made for venting 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 the 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.G. 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.

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.

Equalising charge

Equalizing 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 homogenization of the specific gravity of the electrolyte:

• to compensate for the self-discharge due to the storage period.
• to compensate for the eventual lack of charge with normal charges.
• to quickly homogenize the electrolyte, following the addition of distilled or demineralized water.
• to compensate for 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 liter) 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 equalizing charge may be interrupted if the specific gravities are homogenized. When the nominal electrolyte specific gravity is not obtained after an equalizing charge, and when this low specific gravity is not the consequence of electrolyte overflowing, a recharge in completion with the equalizing 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 sufficient ventilation!

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 an equalizing 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.

Electrolyte

The electrolyte nominal S.G. is 1.29 kg/l at 30°C when in fully charged condition. According to temperature, S.G. correction, concerning 30°C, will be applied:

• Example: SG 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 IEC 62877-2: 2016.

Battery check After a normal charge, measure:

• the total voltage
• the voltage per cell
• the electrolyte specific gravity on several cells or the whole battery. NB: measure at the constant intensity of I=0.033 C5 or 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.

Maintenance

Daily maintenance

• keeps the battery, clean and dry to avoid self-discharging and current leakage.
• check the condition of the plugs and cables and that all insulation covers are in place and good condition.

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 be 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 cell vent plugs in place and closed.

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.G. 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 SG), and the settings of the charger.

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 EN 1175-1 when necessary, but at least once a year, the insulation resistance of the truck and the battery must be checked by an electrical specialist.
• The test on the insulation resistance of the battery must be conducted per EN 1987-1. The average insulation resistance of the battery must not be lower than 50 Ω per Volt nominal voltage. (EN 62485-3)
• For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

Storage and transportation

Batteries must always be stored and transported securely in the vertical position 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 equalizing charge according to 2.2.2.
• float charge with 2.27 V x number of cells.
• Back to the manufacturer!
• Batteries with this sign must be recycled.
• Batteries that are not returned for the recycling process must be disposed of as hazardous waste!
• When using motive power batteries and chargers, the operator must comply with the current standards, laws, rules, and regulations in force in the country of use!

Subject to technical modification without any prior notice. E.&O.E. © 2024 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. Subject to revisions without prior notice. E.&O.E EMEA-EN-OM-PB-0524 www.enersys.com.

Motive power batteries for small traction.

• TP series: tubular plate monoblocks

Flooded monoblocs

• FP and FTP series: flat plate monoblocs

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