HOPPECKE

Instructions for use

Traction batteries
with positive tubular plates type PzSL* and PzSE
* Also applies to train lighting batteries to DIN 43 579 and batteries to DIN 43 582

Rating Data: for industrial trucks” is the standard which

Nominal capacity C5 See type plate applies to the operation traction batteries
Nominal voltage 2.0 V x No of cells in industrial trucks.
Discharge current C5 / 5 h
Nominal S.G. of electrolyte** 2.1 Discharging
Type PzSL 1,29 kg/l Be sure that all breather holes are not
Type PzSE 1,29 kg/l sealed or covered.
Rated temperature 30°C Electrical connections (e.g. plugs) must
Nominal electrolyte level up to electrolyte level mark ”max.” only be made or broken in the open cir-
** Will be reached within the first 10 cycles. cuit condition. To achieve the optimum life
for the battery, operating discharges of
more than 80% of the rated capacity
Pay attention to the operation in- Ignoring the operation instructions, repair should be avoided (deep discharge). This
with non-original parts or using additives corresponds to an electrolyte specific gra-
struction and fix them close to the vity of 1.13 kg/l at the end of the dischar-
battery. for the electrolyte will render the warranty
void. ge. Discharged batteries must be rechar-
Work on batteries to be carried ged immediately and must not be left di-
out by skilled personnel only! For batteries in classes Ex I and Ex II the
instructions for maintaining the appropria- scharged. This also applies to partially di-
te protection class during operation must scharged batteries.
Use protective glasses and clothes
be complied with (see relevant certificate).
when working on batteries. Pay 2.2 Charging
attention to the accident preven-
tion rules as well as DIN VDE 0510 1. Commissioning filled and char- Only direct current must be used for char-
and VDE 0105 part 1. ged batteries ging. All charging procedures in accor-
dance with DIN 41773 and DIN 41774
No smoking! Do not expose bat- For commissioning of unfilled bat- are permitted.
teries see separate instructions! Only connect the battery assigned to a
teries to naked flames, glowing
charger, suitable for the size of battery, in
embers or sparks, as it may cau- order to avoid overloading of the electric
se the battery to explode. The battery should be inspected to ensure
it is in perfect physical condition. cables and contacts, unacceptable gas-
The charger cables must be connected to sing and the escape of electrolyte from the
Acid splashes in the eyes or on cells. In the gassing stage the current limits
ensure a good contact, taking care that
the skin must be washed with given in DIN VDE 0510 part 3 must not
the polarity is correct.
water. In case of accident consult Otherwise battery, vehicle or charger be exceeded. If the charger was not
a doctor immediately! could be damaged. purchased together with the battery it is
Clothing contaminated by acid The specified torque loading for the polscr- best to have its suitability checked by the
should be washed in water. ews of the charger cables and connectors manufacturers service department.
are: When charging, proper provision must be
Risk of explosion and fire, avoid made for venting of the charging gases.
brass steel Battery container lids and the covers of
short circuits! Caution: Metal
battery compartments must be opened or
parts of the battery are always M 10 20  1 Nm removed. The vent plugs should stay on
live. Do not place tools or other the cells and remain closed.
metal objects on the battery! With the charger switched off connect up
The level of the electrolyte must be
checked. If it is below the anti-surge baffle the battery, ensuring that the polarity is
Electrolyte is highly corrosive. correct. (positive to positive, negative to
or the top of the separator it must first be
topped up to this height with purified wa- negative). Now switch on the charger.
Batteries and cells are heavy. En- ter (DIN 43530 part 4). When charging the temperature of the el-
sure secure installation! Use only The battery is then charged as in item 2.2. ectrolyte rises by about 10°C, so charging
suitable handling equipment e.g. The electrolyte should be topped up to the should only begin if the electrolyte tempe-
lifting gear in accordance with specified level with purified water. rature is below 45°C.
VDI 3616. The electrolyte temperature of batteries
2. Operation should be at least + 10°C before charging
otherwise a full charge will not be achie-
Dangerous electrical voltage! ved.
DIN VDE 0510 part 3 ”Traction batteries
A charge is finished when the specific gra- Towards the end of charge the electrolyte 5. Storage
vity of the electrolyte and the battery volta- level should be checked and if necessary
ge have remained constant for two hours. topped up to the specified level with puri- If batteries are taken out of service for a
fied water. The electrolyte level must not lengthy period they should be stored in the
Special instructions for the opera- fall below the anti-surge baffle or the top fully charged condition in a dry, frost-free
tion of batteries in hazardous of the separator or the electrolyte ”min” room. To ensure the battery is always rea-
areas. level mark. dy for use a choice of charging methods
This concerns batteries which are used in can be made:
accordance with EN 50014, DIN VDE 3.2 Weekly 1. a monthly equalising charge as in point
0170/0171 Ex (in areas with a firedamp 2.3
hazard) or Ex II (in potentially explosive Visual inspection after recharging for signs 2. float charging at a charging voltage of
areas). During charging and subsequent of dirt and mechanical damage. If the bat- 2.23 V x the number of cells.
gassing the container lids must be remo- tery is charged regularly with a IU charac- The storage time should be taken into ac-
ved or opened so that the explosive mixtu- teristic curve an equalising charge must be count when considering the life of the bat-
re of gases loses its flammability due to carried out (see point 2.3). tery.
adequate ventilation.
The containers for batteries with plate pro- 3.3 Monthly 6. HOPPECKE trak air
tection packs must not be closed until at
least half an hour after charging has past. At the end of the charge the voltages of all 1. Ensure that the charger belonging to the
cells or bloc batteries should be measured battery is designed for electrolyte circu-
2.3 Equalising charge with the charger switched on, and recor- lation.
ded. 2. Before initial operation of a trak air
Equalising charges are used to safeguard After charging has ended the specific gra- battery, a system test is absolutely es-
the life of the battery and to maintain its vity and the temperature of the electrolyte sential. It should be carried out as
capacity. They are necessary after deep in all cells should be measured and recor- follows:
discharges, repeated incomplete rechar- ded. If significant changes from earlier - connect up the air supply
ges and charges to an IU characteristic measurements or differences between the - switch on the air pump using the test
curve. Equalising charges are carried out cells or bloc batteries are found further button
following normal charging. The charging testing and maintenance by the service de- - make a visual examination of the elec-
current must not exceed 5 A/100 Ah of partment should be requested. trolyte surfaces of all cells for move-
rated capacity (end of charge - ment and rising air bubbles.
see point 2.2). 3.4 Annually Initial operation as a trak®air battery
Watch the temperature! may commence only after all cells have
In accordance with DIN VDE 0117 at undergone adequate thorough mixing
2.4 Temperature least once per year, the insulation resi- 3. The connection sequence of the trak
stance of the truck and the battery must be air system may not be changed. Ensure
An electrolyte temperature of 30°C is spe- checked by an electrical specialist. that the individual hoses are pushed far
cified as the rated temperature. Higher The tests on the insulation resistance of the enough on to the T-pieces at all times,
temperatures shorten the life of the battery, battery must be conducted in accordance so as to guarantee tight sealing and sta-
lower temperatures reduce the capacity with DIN EN 60254-1. bility.
available. 55°C is the upper temperature The insulation resistance of the battery thus Do not bend hoses!
limit and is not acceptable as an opera- determined must not be below a value of 4. Note for use
ting temperature. 50  per Volt of nominal voltage, in com- Only purified air may be supplied to
pliance with DIN VDE 0510 part 3. the cells. This is to be ensured by me-
2.5 Electrolyte For batteries up to 20 V nominal voltage ans of a suitable filter. HOPPECKE char-
the minimum value is 1000 . gers with EUW usually have such a fil-
The rated specific gravity (S. G.) of the el- ter.
ectrolyte is related to a temperature of 4. Care of the battery
30°C and the nominal electrolyte level in 7. Malfunctions
the cell in fully charged condition. The battery should always be kept clean
Higher temperatures reduce the specified and dry to prevent tracking currents. Clea- If malfunctions are found on the battery or
gravity of the electrolyte, lower temperatu- ning must be done in accordance with the the charger our service department should
res increase it. The temperature correction ZVEI code of practice ”The Cleaning of be called in without delay. The measure-
factor is - 0.0007 kg/l per °C, e.g. an el- Vehicle Traction batteries”. ments taken in point 3.3 will facilitate fault
ectrolyte specific gravity of 1.28 kg/l at Any liquid in the battery tray must be ex- finding and their elimination.
45°C corresponds to an S.G. of 1.29 kg/l tracted and disposed of in the prescribed A service contract with us will make it
at 30°C. The electrolyte must conform to manner. Damage to the insulation of the easier to detect and correct faults in good
the purity regulations in DIN 43530 part 2. tray should be repaired after cleaning, to time.
ensure that the insulation value complies
3. Maintenance DIN VDE 0510 part 3 and to prevent tray
corrosion. If it is necessary to remove cells
3.1 Daily it is best to call in our service department
for this.
Charge the battery after every discharge.
Teil-Nr. 7240203001/0600/2,5 H

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

HOPPECKE HOPPECKE Batterien GmbH & Co KG

Postfach 11 40
Phone # 49 29 63 61-0 · Fax # 49 29 63) 6 14 49
http://www.HOPPECKE.de
Batterien D-59914 Brilon (Hoppecke) e-Mail: hoppecke.ITt-online.de