Powerbloc Battery User Manual

Introduction

The information contained in this document is essential for the safe handling and correct use of Powerbloc™ batteries. It provides a global system specification, associated safety measures, code of conduct, a guide for commissioning, and recommended maintenance. This document should be kept and made available to users working with the battery and responsible for it. All users are responsible for ensuring that all system applications are adequate and safe, based on anticipated or encountered conditions during operation.

This user manual contains important safety indications. Read and understand the safety and operation sections before using the battery and the equipment it is installed in.

It is the owner's responsibility to ensure the use of the documentation and any associated activities, and to comply with all applicable legal requirements for themselves and their applications in the respective countries.

This user manual is not intended to replace the training on handling and operating Powerbloc™ batteries, which may be necessary in accordance with local laws and/or industry standards. Before contact with the battery system, adequate theoretical and practical training for all users must be ensured.

For service, contact your sales representative or call:

EnerSys EMEA

EH Europe GmbH
Baarerstrasse 18
6300 Zug, Switzerland
Tel: +41 44 215 74 10

World Headquarters

EnerSys
2366 Bernville Road
Reading, PA 19605, USA
Tel: +1-610-208-1991
+1-800-538-3627

EnerSys APAC

No. 85, Tuas Avenue 1
Singapore 639518
+65 6558 7333

www.enersys.com

⚠ WARNING: Failure to follow instructions may lead to death or serious bodily injury.

Specifications and Safety

Traction batteries for reduced traction. TP Series: tubular plate monoblocs. FTP Series: flat plate monoblocs.

Specifications

*achieved in the first 10 cycles.

The Powerbloc TP series consists of robust tubular positive plates with free electrolyte to ensure a long service life. The Powerbloc FPT series features advanced flat grid plates and a free electrolyte paste formulation, offering extended service life. It is particularly suitable for demanding semi-traction deep cycle applications.

Safety Instructions

• Follow the usage instructions and keep them near the battery.
• Battery work must be performed by qualified personnel only!
• Wear safety glasses and protective clothing when working on batteries.
• Comply with accident prevention regulations and standards EN 62485-3 and EN 50110-1.
• Keep batteries out of reach of children! 🙅
• No smoking! 🚬
• Do not expose batteries to open flames, incandescent embers, or sparks, as they can cause battery explosion.
• Avoid sparks from cables or electrical equipment, and electrostatic discharges.
• If acid contacts eyes or skin, wash immediately with plenty of clean water. Seek immediate medical attention after thorough rinsing.
• Acid-contaminated clothing must be washed in water.
• Explosion and fire hazard! 🔥
• Avoid short circuits: do not use uninsulated tools, do not place or drop metal objects on the battery. Remove rings, watches, and clothing with metal parts that can contact battery terminals. ⚡

Safety and Commissioning

Safety Measures (cont.)

• The electrolyte is highly corrosive.
• Do not tip the battery.
• Batteries and monoblocs are heavy. Ensure safe installation! Use only appropriate handling equipment. Lifting hooks must not damage blocks, connectors, or cables.
• Do not expose batteries to direct sunlight without protection.
• Discharged batteries can freeze. Therefore, always store them in a frost-free area.
• Dangerous electrical voltage!
• Be aware of hazards that can be generated by batteries.

Non-compliance with usage instructions and repair with non-original parts will void the warranty.

All battery, charger, or any other accessory malfunctions must be immediately reported to After-Sales Service.

DESCRIPTION: Powerbloc™ traction batteries are suitable for equipping all types of reduced traction equipment.

Commissioning

The battery must be inspected to ensure it is in perfect physical condition.

Check:

• Battery cleanliness. Before mounting, the battery compartment must be cleaned.
• Battery terminal cables have good contact with the terminals and the polarity is correct; otherwise, the battery, vehicle, or charger may be destroyed.
• Electrolyte level and presence of plugs.
• In case of a water topping-up system option, check the presence of specific plugs and 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 Equalization Charging section) before commissioning. Only blocks with the same discharge state (same voltage and tolerance as in the following table) should be connected.

After connection, the terminals must be covered with grease as protection against external corrosion. The tightening torques for cable bolts/screws and end terminals are: DIN conical pin 8 ± 1 Nm.

Operation and Charging

Operation

The applicable standard is EN 62485-3 "Traction batteries for industrial forklifts". The nominal operating temperature of the battery is 30°C. Higher temperatures shorten battery life; lower temperatures reduce available capacity. The upper temperature limit is 55°C and is not acceptable as an operating temperature. Battery capacity changes with temperature and decreases considerably below 0°C. Optimal battery life depends on operating conditions (moderate temperature and discharges equal to or less than 80% of the nominal C₅ capacity). The battery will reach maximum capacity after approximately 10 charge-discharge cycles.

Discharge

The battery vent plugs must not be sealed or covered. Electrical connections (e.g., sockets) must only be made or broken when there is an open circuit. To achieve optimal battery life, discharges during work exceeding 80% of the nominal capacity (deep discharge) must be avoided. At the end of discharge, a minimum electrolyte density of 1.13 kg/l must be checked. Discharged batteries must be recharged immediately and should never be left discharged:

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

Charging

Powerbloc™ batteries can be recharged with a 50 Hz or HF charger. If you wish to use an existing charger with a Wa, WoWa, IUla, WUIa profile, you must verify if the profile is approved by our technical department. Only direct current should be used for charging. Connect the battery only to the correctly assigned charger, suitable for the battery size, to avoid overloading electrical cables and contacts, electrolyte overflow, and unacceptable cell gassing. During gassing, current limits must not be exceeded according to EN 62485-3.

Before starting charging, ensure:

• Presence of plugs.
• In case of a water topping-up system, check the proper condition of the topping-up circuit and specific plugs, the water tube connection for the filling device (quick connection between battery and water supply system).

During charging, appropriate measures must be taken for gas emission removal. Battery casing covers and battery compartment access covers must be opened or removed. Keep vent plugs closed.

The battery will be connected to the charger with the charger off, ensuring correct polarity (positive to positive, negative to negative). Then turn on the charger. In case of automatic filling with manual command, press the button on the solenoid valve box to release demineralized water supply at the end of charging.

During charging, the battery temperature increases by approximately 10°C; therefore, charging should only begin if the electrolyte temperature is below 45°C. The battery electrolyte temperature must be at least +10°C before charging; otherwise, full charging may not be achieved without specific charger settings.

Charging is considered complete when the electrolyte specific gravity and battery voltage remain constant for 2 hours. During charging, the cells emit hydrogen and oxygen gas. Room ventilation must be ensured, especially during charging. All installations must comply with the regulations in force in the country of use.

Charging

Normal Charging

Applies after a "normal" discharge of the battery (up to 80% of C₅), not interrupted until the charger display indicates the end of charging.

Immediate recharge of the battery is not necessary if, after a usage cycle, the residual capacity is still greater than or equal to 60% of its capacity. In this case, recharging is required by the next day at the latest.

Equalization Charging

Equalization charges are used to protect the battery's service life and maintain its capacity. They are necessary after deep discharges and after repeated incomplete charges. They allow for the homogenization of the electrolyte specific gravity:

• To compensate for self-discharge caused by the storage period.
• To compensate for any lack of charging with normal charges.
• For rapid homogenization of the electrolyte, after adding distilled or demineralized water.
• To compensate for stratification, after partial charges without electrolyte mixing (not recommended).

Perform after a normal charge when a variation (differences of over 10 grams per liter) in specific gravity is registered. It is performed using a constant current with a low value, around C₅/30 (C₅/20 max), and after a normal battery charge (end of charge, see Charging section). The recommended duration is 8 hours. Equalization charging can be interrupted if specific gravities are homogenized. When the nominal electrolyte specific gravity is not achieved after an equalization charge, and this low specific gravity is not a consequence of electrolyte spillage, a recharge can be performed after completing the equalization charge. This must be done with constant current, around C₅/60 A, and after a full charge for 72 hours. Pay attention to temperature and sufficient ventilation!

Desulfurization Charging

Must be performed after a very deep discharge of the battery (> 80% C₅) when the charger does not start recharging due to excessive battery discharge. This must be performed with constant current, around C₅/60, for a minimum of 2 hours. Follow with a normal charge and an equalization charge (desulfurization if necessary). The best result is obtained with the lowest current value. In any case, stop charging if the electrolyte temperature reaches 45°C.

Maintenance

Electrolyte

The nominal electrolyte specific gravity is 1.29 kg/l at 30°C in a fully charged state. Depending on the temperature, apply the specific gravity correction at 30°C:

Example: Specific gravity reading 1.285 at 36°C: 1.285 + (0.0007 X 6) = 1.289 at 30°C.

Electrolyte purity must comply with IEC 62877-2: 2016.

Battery Verification

After a normal charge, measure:

• Total voltage
• Cell voltage
• Electrolyte specific gravity in multiple cells or the entire battery.

NOTE: Measure at a constant current of I=0.033 C₅ or, if the charger can do so, at "equalization charging". Voltages for a new battery will be greater than or equal to 2.65 V per cell under I=0.033C₅.

Maintenance Schedule

Daily:

• Keep the battery clean and dry to prevent self-discharge and current leakage.
• Check the condition of plugs and cables, and verify that all insulating covers are in place and in good condition.

Weekly:

If necessary, adjust the electrolyte level of each cell and use only demineralized or distilled water. The level must never be below the minimum level; in other words, always above the plates. This is done:

• At the end of charging and without exceeding the maximum level if the battery is equipped with standard filling plugs.
• By connecting to the water circuit if the battery is equipped with automatic filling. The pressure must be between 0.2 and 0.6 bar.

VERY IMPORTANT: In difficult conditions, high room temperature - for example, electrolyte level - must be checked as often as necessary. If there are signs of electrolyte spillage - generally lead sulfate traces - wash the battery with clean water at low pressure, with the cell vent plugs fitted and closed.

Monthly or Quarterly:

Perform the final charge check: measure and record the voltages of all blocks with the charger on. Measure and record the electrolyte specific gravity of all blocks. If you observe significant variations from previous measurements or large variations between blocks or cells, please contact our service department. If battery autonomy is insufficient, check if the necessary work is compatible with the battery capacity, battery condition (specific gravity at the end of charging), and charger settings.

Annually:

Battery: for screw connectors, check the tightening torques of terminal bolts/screws and ensure the terminals are covered with grease as protection against external corrosion. Charger: remove internal dust, check all connections (plugs, cables, and contacts) and charging parameters. According to EN 1175-1, the insulation resistance of the forklift and battery must be checked at least once a year by a qualified electrician. Battery insulation resistance tests must be performed in accordance with EN 1987-1. The average battery insulation resistance must not be less than 50 Ω per volt of nominal voltage (EN 62485-3). For batteries with a nominal voltage of maximum 20 V, the minimum value is 1000 Ω.

Storage and Transport

Batteries must always be stored and transported vertically to prevent electrolyte leakage. Store fully charged batteries in a dry, clean, and frost-free location. Always disconnect the battery from the electric vehicle before storage. For easy recharging of batteries, it is recommended not to store them without recharging for more than 3 months at 20°C and 2 months at 30°C.

Storage duration must be taken into account within the battery's expected service life. To ensure the battery is always ready for use, you can choose from several charging methods:

• A monthly equalization charge, according to the Equalization Charge section.
• A maintenance charge of 2.27 V x number of cells.

[Environmental Hazard Symbol] Risk of lead pollution. Return to manufacturer! Batteries marked with this symbol must be recycled. Batteries not returned for recycling must be disposed of as hazardous waste!

[Lead Symbol] Pb

[Recycling Symbol]

When using traction batteries and chargers, the operator must comply with the standards, laws, rules, and regulations in force in the country of use!