EnerSys Perfect Plus PzS And PzB Owner’s Manual

EnerSys Perfect Plus PzS And PzB

Specifications

• Product: Perfect PlusTM PzS and PzB Dry Pre-charged Traction Batteries
• Charge: Supplied charged but without electrolyte inside the cells
• Storage: Dry and cool zone, protected from moisture, rain, and snow
• Maximum Storage Time: 2 years
• Important: Do not remove the caps from cells during storage

Product Usage Instructions

Checking

• Inspect battery installation and charging equipment for mechanical condition. Ensure all cables are connected with the correct polarity. Tighten threaded connectors and check torque loading of polscrews.

Filling of Cells

• Refer to Table 1 for filling specifications based on cell range.
• Ensure compliance with DIN EN 50272-3 or local standards for installation and ventilation.

Rest Period

• Allow a rest period after filling cells before commissioning.

Commissioning

• Charge the battery using the appropriate charger. Follow charging currents per 100 Ah C5 as per Table 2.

Commissioning with an Equalising Charge

• Perform equalizing charge using the suitable charger. Follow specified charging characteristics and currents.

Electrolyte Level

• Monitor electrolyte level during charge. Adjust levels as necessary to maintain within specified limits.

Electrolyte Specific Gravity

• If the specific gravity of the electrolyte is too high, replace the part with purified water following standards.

Notes

• Carefully manage spilled acid using neutralization agents.
• Dispose of liquid in the battery tray according to regulations. Refer to the Perfect PlusTM Owner’s Manual for continued usage guidance.

FAQ

Q: What should I do if the battery does not reach its rated capacity after the 10th cycle?

A: If the battery does not reach its rated capacity after the 10th cycle, please contact the battery manufacturer for further assistance and evaluation.

Dry pre-charged traction batteries: Perfect PlusTM PzS and PzB

This document is complementary to the Perfect PlusTM Owner’s Manual.

SAFETY INSTRUCTIONS

• Pay attention to the operation instructions and fix them close to the battery.
• Work on batteries is to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries. Pay attention to the accident prevention rules as well as DIN EN 50272-3 and DIN EN 50110-1.
• 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 an 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 battery are always live. Do not place tools or other metal objects on the battery!
• An electrolyte is highly corrosive.
• Batteries and cells are heavy. Ensure secure installation!
• Use only suitable handling equipment e.g. lifting gear under VDI 3616.
• Dangerous electrical voltage!
• Pay attention to the hazards that can be caused by batteries
• Ignoring the operation instructions, repairing with non-original parts, or using additives for the electrolyte will render the warranty void.
• For batteries according to the ATEX directive 94/9 EC, the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate).

Completed commissioning reports should be sent back to the battery manufacturer!

Description

• The dry-charged batteries are supplied and charged but without electrolytes inside the cells. On request containers with electrolytes ready to use can be supplied. The negative plates are protected against oxidation.
• Each cell is closed by a cap during storage.
• Store the cells or the battery in a dry and cool zone, wind moisture, rain, and snow-free. Do not store for more than 2 years. It is very important not to remove the caps.

Checking

• The battery installation and the charging equipment should be inspected to ensure they are in perfect mechanical condition.
• All cables must be connected to ensure good contact, taking care that the polarity is correct. All threaded connectors in the circuit must be tightened to ensure reliable contact.

For bolt-on connectors, check the torque loading of the polscrews:

• M 10 /25 ± 2 Nm
• A check must be made to ensure the charger equipment is ready for operation. Ensure that the polarity is correct ( positive to positive and negative to negative).
• Before filling the cells care should be taken to ensure that the specifications DIN EN 50272-3 or currently applied in the country of use concerning the installation and ventilation have been complied with.

Filling of cells

• If the cells are supplied in bulk, put them in the battery crate according to the connecting instructions. If the filling electrolyte is not supplied by EnerSys®, the impurities levels must respect DIN 43530-2.
• The filling acid must have a specific gravity (S. G.) under the following table. If the s.g. of available filling electrolyte is different from the values mentioned in Table 1, take the required precautions to prepare the mix of acid and water.

Table 1

Cell range| Filling S. G. [kg/l]

30°C           15°C

| Nominal S. G. [kg/l] to be obtained after charge
30°C
---|---|---
PzS and PzB| 1.28             1.29| 1.29

• The temperature of the acid used for filling should be between 15°C and 30°C. The temperature must be measured and recorded before filling.
• After removing the transport plugs, the cells should be filled until the anti-surge baffle or the top of the separator.
• Acid-resistant filling equipment should be used for this.
• Transport plugs are not permissible for use when operating the battery. They must be replaced by vent plugs.
• Higher temperatures reduce the specific gravity of the electrolyte, lower temperatures increase it. The temperature correction factor for the specific gravity is -0.0007 kg/l per °C.
• Example: A specific gravity of the electrolyte of 1.28 kg/l at 45°C corresponds to a S.G. of 1.29 kg/l at 30°C.

Rest period

• After filling the cells the filled battery should stand for 2 hours for impregnation of the plates and separators.
• During this period, for cells supplied in bulk, check with a voltmeter that the battery polarities correspond to those indicated on the terminals or the lids. Place the intercell connectors and tighten the screws to torque loading.
• Place the plugs with a level indicator. Fill in each cell with electrolyte until the anti-surge baffle or the top of the separator.
• Connect the socket on the battery, regarding the polarities to avoid an inversed charge and the destruction of the charger and the battery Next, depending on the number of cells, the temperature and the specific gravity of the electrolyte should be measured, and recorded for at least 2 to 4 cells (pilot cells, see point 6).

Commissioning

• It is important that the first charge be carried out fully and as far as possible without interruption.
• The temperature of the electrolyte however must not exceed 55°C during commissioning and if it does the charge must be discontinued.
• After commissioning is completed, the voltage, the specific gravity of the electrolyte, and the temperature of all cells should be measured and recorded with details of date and time (see point 6).
• During commissioning check if all the cells are gassing at the end of the charge.
• Complete charging has been achieved when the specific gravity of the electrolyte and the cell voltages have not risen in two hours.

Commissioning by normal recharging

• The recharging is carried out on the appropriate charger.
• At the end of the recharging, the nominal specific gravity of the electrolyte should be achieved with a deviation of ± 0.01 kg/l.
• If a uniform specific gravity of the electrolyte is achieved and all cells or blocs release gas identically without raising the voltage in individual cells or bloc batteries (for IU chargers no more drop of charging current value), then the battery is ready for operation.
• During charge, the electrolyte level will still rise.

Commissioning with an equalising charge

The equalizing charge is carried out on the appropriate charger by selecting “equalization” (see Technical manuals)

Table 2

Maximum permissible charging currents per 100 Ah C 5

charging characteristic| charging current
I – charging characteristic| 5A
Wa/WoWa – characteristic at 2.4 V/cell at 2.65 V/cell| 8 A, decreasing to 4 A

• Conditions of end of charge are the same as related in paragraph 4.1.

Electrolyte level

• During charge, the electrolyte level will still rise.
• If then the max. level of the electrolyte is exceeded, the excess must be drawn up.
• However, if then the electrolyte level is below the max. level, top up with electrolyte to the specified. level.

Electrolyte specific gravity

• If the S.G. of the electrolyte at the end of the commissioning is too high, replace a part of the electrolyte with purified water according to DIN EN 43530-4.

Notes

• The acid which escapes or spills must be carefully removed or neutralized. This can be done with a soda solution (1 kg of soda to 10 liters of water) or other neutralization agents. Neutralization agents must not get into the cells.
• The liquid in the battery tray should be sucked out and disposed of under the regulations.
• The Perfect PlusTM Owner’s Manual applies when using the battery. The battery will reach its rated capacity after the 10th cycle at the latest.
• Warning: The dry-charged cells or batteries must not be connected with standard Perfect PlusTM connectors because of the difference in the design of the terminal pillars.
• Use the DRY PERFECT PLUSTM CONNECTOR for cells or batteries dry charged.

Report

• Battery type:- ————————
• Battery no.:– ——————————–(see type plate)
• The specific gravity of the filling acid:- ———————–
• [kg/l] at: ———————————— [°C]
• Commissioning carried out by the Company: —————————
• Name: Signature: ——————————-
• The commissioning charge was carried out under points:- ———————————– 4.1 and 4.2
• The commissioning charge was started on:- ————————————– date time.

Pilot cells1)

Measurement 2 hours after filling

| No.| No.| No.| No.
---|---|---|---|---
Specific gravity of electrolyte [kg/l]|  |  |  |
Temperature of electrolyte [°C]|  |  |  |
The specific gravity of the electrolyte corrected for temperature (see point 2) [kg/l]|  |  |  |

• Cell or bloc no. beginning at the positive terminal of the battery.
• For bloc batteries, the specific gravity of the electrolyte of the cell next to the positive pole must be measured in each case.

Other remarks: Cell/bloc voltage, temperature, and specific gravity of electrolyte for all cells at the end of the commissioning charge.

• Cell or bloc no. beginning at the positive terminal of the battery.
• For bloc batteries, the specific gravity of the electrolyte of the cell next to the positive pole must be measured in each case.
• 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-CIR-HAW-PP-0624

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