Exide motive power Gebrauchsanweisung Seite 16

1. Design
The EXIDE Aquamatic/BFS battery water refilling systems are used for automati-
cally adjusting the nominal electrolyte level. Venting holes are provided for letting
off the gases which arise during charging. In addition to the optical level indicator,
the plug systems also have a diagnostics hole for measuring the temperature and
the electrolyte density. All EXIDE battery cells of the design series EPzS; EPzB;
CSM and CSM can be equipped with the EXIDE Aquamatic/BFS filling systems.
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The water can be refilled by means of a central sealing coupler through the hose
connections in the individual EXIDE Aquamatic/BFS plugs.
2. Application
The EXIDE Aquamatic/BFS battery water refilling system is used in traction batte-
ries for forklift trucks. The water refilling system is provided with a central water
connection for the water supply. Soft PVC hose is used for this connection and for
the hose connections for the individual plugs. The hose ends are put onto the
hose connection sleeves located on the T or < pieces.
3. Function
The quantity of water required in the refilling process is controlled by the valve
located in the plug in combination with the float and the float rods. In the EXIDE
Aquamatic System the existing water pressure at the valve turns off the water
supply and ensures that the valve closes securely.
When the maximum filling level is reached in the EXIDE BFS system, the float
and the float rods through a lever system close the valve with five times the
buoyant force and consequently interrupt the water supply reliably.
4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the
battery charging comes to an end; this ensures that the refilled water quantity is
mixed with the electrolyte. In normal operation it is usually sufficient to fill once a
week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in
the water pipe is between 0.3 bars and 1.8 bars. The EXIDE Aquamatic System
has an operating pressure range of between 0.2 bars and 0.6 bars.
The EXIDE BFS system has an operating pressure range of 0.3 bars to 1.8 bars.
Deviations from the pressure ranges impair the system's functional reliability. This
wide pressure range permits three types of filling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used.
For the EXIDE Aquamatic System the installation height is 2 m to 6 m and for the
EXIDE BFS system the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the EXIDE Aquamatic System is set from 0.2 bars
to 0.6 bars and from 0.3 bars to 1.8 bars in the EXIDE BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the neces-
sary filling pressure. No difference in height is permitted between the standing
level of the ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under
which the battery is used, the ambient temperatures and the type of filling and/or
the filling pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is
manual, the water feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to
fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any
kind of dirt which could impair the functional reliability of the EXIDE
Aquamatic/BFS plug. For safety reasons it is recommendable to insert a filter ele-
ment (optional) with a max. passage opening of 100 to 300 µm into the battery's
main supply pipe.
We reserve the right make technical modification.
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8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric
circuit. No changes may be made.
9. Operating temperature
The temperature limit for battery operation is set at 55° C.
Exceeding this temperature damages the batteries. The EXIDE battery filling
systems may be operated within a temperature range of > 0° C to a maximum of
55° C.
CAUTION:
Batteries with automatic EXIDE water refilling systems may only be oper-
ated in rooms with temperatures > 0° C (as there is otherwise a danger that
the systems may freeze).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling
systems must have a diagnostics hole with a 6.5 mm-diameter (EXIDE Aquamatic
plugs) or a 7.5 mm-diameter (EXIDE BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water.
No parts of the plugs may come in contact with soap or fabrics which contain
solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed
pipe on the battery side. During the filling process, the paddlewheel is turned by
the flowing water. When the filling process ends, the wheel stops and this indi-
cates the end of the filling process. (ident no.: 7305125).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug
systems (EXIDE plug lifter). The greatest of care must be employed when prising
out the plug to prevent any damage to the plug systems.
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact
pressure of the hose connection on the plugs' hose couplings and to loosen it
again.
10.3 Filter element
For safety reasons a filter element (ident no.: 73051070) can be fitted into the bat-
tery's main supply pipe for supplying battery water. This filter element has a maxi-
mum passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the EXIDE water refilling systems (Aquamatic/BFS)
through a central supply pipe. This is connected to the water supply system at the
battery charging station by means of a sealing coupler system.
On the battery side a closing nipple (ident no.: 73051077) is mounted and the
customer must place a sealing coupler construction on the water supply side
(obtainable under ident. no.: 73051079).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is
at 0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system