Document Purpose
This document provides detailed instructions and a structured report format for commissioning EnerSys Perfect Plus™ PzS and PzB dry pre-charged traction batteries. It is designed to complement the official Owner's Manual, ensuring proper setup and initial operation.
Critical Safety Guidelines
- All battery handling and commissioning must be performed by qualified personnel.
- Mandatory use of protective eyewear and clothing is required.
- Strictly avoid short circuits and the placement of conductive materials on battery terminals.
- Handle electrolyte with extreme caution due to its corrosive nature; immediate washing of skin contact is essential.
- Ensure batteries are securely installed, utilizing appropriate lifting equipment for their weight.
- Be aware of and respect the presence of dangerous electrical voltage.
Commissioning Procedure Summary
The commissioning process involves several key stages:
- Initial Inspection: Verify the mechanical condition of the battery installation and charging equipment. Ensure all cable connections are secure, correctly polarized, and tightened to specified torque values.
- Cell Filling: Fill each cell with electrolyte to the designated level, typically up to the anti-surge baffle or separator top. Adhere to specified electrolyte specific gravity (S.G.) standards (e.g., DIN 43530-2).
- Rest Period: Allow the battery a minimum 2-hour rest period post-filling for plate impregnation.
- First Charge: Execute the initial charge cycle completely and without interruption. Monitor electrolyte temperature, ensuring it does not exceed 55°C.
- Post-Commissioning Measurements: Record critical parameters including cell voltage, electrolyte temperature, and specific gravity for all cells after the commissioning charge is finalized.
Reporting Requirements
The document includes a comprehensive report section for documenting battery details, specific gravity of filling acid, commissioning execution points, dates, times, and detailed measurements for pilot cells and all cells. Completed reports should be submitted to the battery manufacturer.
Important Considerations
Warranty is voided by ignoring instructions, using non-original parts, or adding unauthorized electrolyte additives. Compliance with relevant directives, such as ATEX (94/9 EC), and national installation/ventilation standards (e.g., DIN EN 50272-3) is mandatory. Specific connectors may be required for dry-charged batteries.
