8A 8G I&O Manual - East Penn Manufacturing
Contents
1. 8A amp 8G BATTERY INSTALLATION AND OPERATING INSTRUCTIONS This manual is intended to be a guide to optimize battery performance for multiple cyclic amp float applications Consult applicable User Manuals for additional parameters for specific systems This manual is not intended for SLI or Vehicle related applications Vehicle Equipment Owner s Manual should be followed for SLI amp Vehicle related applications A Maela wo Oig l Diaan EYES y NO UNINSULATED EXPLOSIVE GASES SPARKS CAN ee BLINDNESS g FLAMES CONNECTORS OR INJU I e SMOKING BATTERIES AND OTHER RELATED PARTS CONTAIN LEAD FLUSH EYES IMMEDIATELY l WITH vA SULFURIC I ACID ie CAN CAUSE Ha BLINDNESS OR q sz SEVERE BURNS FAST HIGH VOLTAGE RISK OF SHOCK DO NOT TOUCH DO NOT REMOVE VENT VALVE VENTILATE WELL WHEN IN AN ENCLOSED WARRANTY VOID IF VENT VALVE IS REMOVED SPACE AND WHEN CHARGING SEE INSTALLATION MAINTENANCE AND OPERATION REPAIR SHOULD BE PERFORMED ONLY INSTRUCTIONS FOR IMPORTANT SAFETY PRECAUTIONS BY A QUALIFIED SERVICE TECHNICIAN California Proposition 65 Warning SAFETY PRECAUTIONS Although all valve regulated batteries have the elec trolyte immobilized within the cell the electrical hazard associated with batteries still exists Work performed on these batteries should be done with the tools and the protective equipment listed below2. 35 35 35 35 36 36 36 36 37 37 37 37 38 38 38 38 39 39 39 39 40 40 40 40 Avg Voltage Avg Voltage Avg Voltage Avg Voltage Readings Taken By Remarks Recommendations Readings should be taken at installation and annually thereafter POWERED FOR PERFORMANCE EAST PENN manufacturing co ine Lyon Station PA 19536 0147 e Phone 610 682 6361 Fax 610 682 4781 Order Department Hotline 610 682 4231 www eastpennunigy com E mail sales eastpennunigy com E P M Form No 1833 2012 by EPM Printed in U S A DISTRIBUTED BY All data subject to change without notice No part of this document may be copied or reproduced electronically or mechanically without written permission from the company
3. Valve regulated battery installations should be supervised by personnel familiar with batteries and battery safety precautions WARNING Risk of fire explosion or burns Do not disassemble heat above 40 C or incinerate Protective Equipment Although VRLA batteries can vent or leak small amounts of electrolyte electrical safety is the principle but not the only concern for safe handling Per IEEE 1188 recom mendations the following minimum set of equipment for safe handling of the battery and protection of personnel shall be available Safety glasses with side shields or goggles or face shields as appropriate Consult application specific requirements Electrically insulated gloves appropriate for the installation Protective aprons and safety shoes Portable or stationary water facilities in the battery vicinity for rinsing eyes and skin in case of contact with acid electrolyte Class C fire extinguisher Acid neutralizing agent Adequately insulated tools Lifting devices of adequate capacity when required Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the state of California to cause cancer and birth defects or other reproductive harm Wash hands after handling WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Ba
4. to ensure the individual batteries are connected correctly The total voltage should be approximately equal to the number of batteries times the measured voltage of one battery when connected in series If the measurement is less recheck the connections for proper voltage and polarity 5 Read and record connection resistance and note the method of measurement This helps determine a satis factory initial installation and can be used as a reference for future maintenance requirements See Appendix B recording forms in the back of the manual Clean remake and remeasure any connection having a resistance measurement greater than 10 of the average of all the same type of connections 6 Battery performance is based on the output at the battery terminals Therefore the shortest electrical connections between the battery system and the operating equipment results in maximum total system performance Cable size selection should be determined by current carrying requirements as well as providing a minimum voltage drop between battery system and operation equipment Proper techniques should be applied per electrical standards such as NEC and or local codes Note Excess voltage drop will reduce the support time of the battery system SYSTEM OPERATION State of Charge Battery state of charge can be determined by measuring the open circuit voltage Consult the below table State of Charge vs Open Circuit Voltage 100 12 85 or highe
5. AU1 8GU1 B 8G40 C 8A22NF 8G 2NF 30 0 D 8634 H E 8A24 8G 24 25 0 F 8A27 8627 G H 8G58 HP I 8A4D 8G4D 8GTE35 20 0 F J 8A 8D 8G8D E K 8AGC2 8GGC2 15 0 D ae 10 0 as A 5 0 0 0 4 6 8 10 12 14 16 18 20 Time HR Above values are to 90 SOC State of Charge based on C100 Ah capacity 13 00 12 50 200 DISCHARGE Ci 5 11 50 C20 11 00 10 50 0 10 20 30 40 50 60 70 80 90 100 DISCHARGED 6 APPENDIX B Beka BATTERY MAINTENANCE REPORT Inspection Date No of Units String Company Type Address Date New Battery location and or number Date Installed Individual Charger Output Amp Air Temperature F Batter y Readings Total Battery String Voltage Panel Meter Volts Year Year Year Year Unit Ohms or Unit Ohms or Unit Ohms or Unit Ohms or Number Volts Mhos Number Volts Mhos Number Volts Mhos Number Volts Mhos 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 8 8 8 8 9 9 9 9 10 10 10 10 11 11 11 11 12 12 12 12 13 13 13 13 14 14 14 14 15 15 15 15 16 16 16 16 17 17 17 17 18 18 18 18 19 19 19 19 20 20 20 20 21 21 21 21 22 22 22 22 23 23 23 23 24 24 24 24 25 25 25 25 26 26 26 26 27 27 27 27 28 28 28 28 29 29 29 29 30 30 30 30 31 31 31 31 32 32 32 32 33 33 33 33 34 34 34 34
6. ant voltage of 13 80V 6 90V for 6V battery for 24 hours at 77 F 25 C 4 Do not store beyond 12 months INSTALLATIONS General Caution should be taken when installing batteries to insure no damage occurs The battery cabinet tray rack etc shall be inspected for sharp edges that could cause damage to the battery casing Batteries shall not be dropped slid placed on rough or uneven surfaces such as tray lips or grated flooring Mishandling of batteries could result in equipment damage or human injury East Penn will not be liable for damage or injury as a result of mishandling or misuse of the product Grounding When grounding the battery system proper techniques should be applied per electrical standards such as NEC and or local codes as well as User Manual of specific application BATTERY ASSEMBLY Always wear eye protection 1 Set up the batteries so that the positive post of one battery is connected to the negative post of the next battery for all series connections 2 All battery electrical contact surfaces shall be cleaned by rubbing gently with a non metallic brush or pad before installing connectors No Ox ID grease can be used but is not required BATTERY ASSEMBLY con t 3 Install all electrical connectors cables and bolting hard ware loosely to allow for final alignment of batteries Torque to manufacturer recommendations 4 After torquing read the voltage of the battery string
7. ater than 667Hz duration less than 1 5ms is acceptable unless it is causing additional battery heating Ripple that has a frequency less than 667Hz duration greater than1 5ms must meet the following voltage specification to be acceptable VOLTAGE Ripple voltage shall be less than 5 peak to peak of the manufacturer s recommended string voltage Battery Cleaning Batteries cabinets racks and modules should be cleaned with clean water If neutralizing is required use a mixture of baking soda and water Use clean water to remove baking soda residue Never use solvents to clean the battery ies Capacity Testing Capacity tests should not be run unless the battery s operation is questionable Do not discharge the battery ies beyond the specified final voltage When discharging at higher rates extra connectors may be required to prevent excessive voltage drop When performing capacity testing and recording data use applicable standard and or User Manual Should it be determined any individual battery ies or cell s need to be replaced contact your nearest East Penn agent or East Penn Mfg Co APPENDIX A Boe Kar Voltage Compensation Chart Note 1 Above values based on 12 volt battery 2 Divide above values in half for 6 volt battery Pe Kar APPENDIX A Current A VOLTAGE CHARGING CURRENT VS CHARGING TIME 50 0 K 45 0 J gt 40 0 BATTERY TYPE 35 0 A 8
8. ppendix A for temperature compensation voltage maximum and minimum limits The average battery operating temperature should not exceed 95 F 35 C and should never exceed 105 F 40 5 C for more than an eight hour period Operating at temperatures greater than 77 F 25 C will reduce the operating life of the battery If operating temperatures are expected to be in excess of 95 F 35 C contact East Penn for recommendations Discharging at temperatures less than 77 F 25 C will reduce the capacity of the battery Charge Current To properly determine the amount of charge current required the following variables are to be considered DoD Depth of Discharge Temperature Size amp efficiency of the charger Age and condition of battery ies Maximum charge current should be limited to 30 of the C20 Ah rate for the battery ies being used in the system Example 8G24 C20 rate 73 6Ah Max recharge rate 73 6Ah x 0 3 22 1A Consult Charging Current vs Charging Time chart in Appendix A as a guide line to determine recharge time from 0 to 90 state of charge at an initial charge current Discharge Voltage Curve To estimate battery voltage during a constant current discharge at various DoD Depth of Discharge consult chart Discharge Voltage Curve in Appendix A NOTE Battery voltage can vary depending on temperature age and condition of battery RECORD KEEPING Voltages Temperatures amp Ohmic Readings Consult Use
9. pressure relief valves Warranty void if vent valve is removed Inspect all flooring and lifting equipment for functional adequacy Leker RECEIVING AND STORAGE Receiving Inspection Upon receipt and at the time of actual unloading each package should be visually inspected for any possible damage or electrolyte leakage If either is evident a more detailed inspection of the entire shipment should be conducted and noted on the bill of lading Record receipt date inspection data and notify carrier of any damage Unpacking 1 Always wear eye protection 2 Check all batteries for visible defects such as cracked containers loose terminal posts or other unrepairable problems Batteries with these defects must be replaced 3 Check the contents of the package against the packaging list Report any missing parts or shipping damage to your East Penn agent or East Penn Mfg Co immediately 4 Never lift batteries by the terminal posts 5 Always lift batteries by the bottom or use the lifting handles Storage 1 Batteries should be stored indoors in a clean level dry and cool location Recommended storage temperature is 0 F to 90 F 18 C to 32 C 2 Stored lead acid batteries self discharge and must be given a charge six months from date of manufacture to prevent permanent performance degradation Record dates and conditions for all charges during storage 3 Recommended charge during storage is at a const
10. r 12 80 or higher 75 12 65 12 60 50 12 35 12 30 25 12 00 12 00 0 11 80 11 80 NOTE Divide values in half for 6 volt battery ies The true O C V of a battery can only be determined after the battery has been removed from the load charge discharge for 24 hours Charging Consult Charger User Manual of specific application for Safety and Operating requirements For cyclic applications it is important that the battery ies be charged fully after each discharge It is recommended that 108 to 115 of the Ah Amp Hour capacity removed from the battery ies be replaced after each discharge This additional Ah is to compensate for any efficiency losses between the battery charger and the battery ies Keka SYSTEM OPERATION con t Charge Voltage For both 8A amp 8G batteries the following voltage settings should be followed Charge Absorption Equalize 13 80V to 14 60V 77 F 25 C Float Standby 13 50V 01 77 F 25 C The charger must be able to maintain the system voltage within 0 5 of the desired level at all times Note Divide values in half for 6 volt battery ies Temperature Compensation Battery voltage should be adjusted for ambient temperature variations 3mV per C 1 8 F per cell 18mV per 12V battery 9mV per 6V battery For temperatures above 77 F 25 C subtract and for temperatures below 77 F 25 C add Consult Voltage Compensation Chart in A
11. r Manual of specific application for additional Safety amp Operating requirements Record keeping is an important part of battery mainte nance and warranty coverage This information will help in establishing a life history of the battery and inform the user if and when corrective action needs to be taken Refer to Appendix B Battery Maintenance Report After installation and the batteries are at a fully charged condition the following data should be recorded Depending on application some of the following recommendations may not apply e Battery and or string terminal voltage e Charger voltage e Individual battery float charge voltages e Individual battery ohmic readings e Ambient temperatures e Terminal connections should be checked to verify all connections are properly torques Micro ohm readings should be taken across every connection Refer to meter manufacturer s instructions for proper placement of probes If any reading differs by more than 20 from its initial installation value re torque the connections If the reading still remains high clean contact surfaces according to installation portion of this manual Note To provide accurate consistent values battery ies must be fully charged at same temperature and probes placed at same location each time readings are taken Leker MAINTENANCE Always wear eye protection when working on or near batteries Keep sparks and open flames away from ba
12. tteries also contain other chemicals known to the State of California to cause cancer WASH HANDS AFTER HANDLING SAFETY PRECAUTIONS con t Procedures O Consult User Manual of specific application for additional Safety amp Operating requirements The following safety procedures should be followed during installation Always wear safety glasses or face shield These batteries are sealed and contain no free elec trolyte Under normal operating conditions they do not present any acid danger However if the battery jar or cover is damaged acid could be present Sulfuric acid is harmful to the skin and eyes Flush affected area with water immediately and consult a physician if splashed in the eyes Consult MSDS for additional precautions and first aid measures Prohibit smoking and open flames and avoid arcing in the immediate vicinity of the battery Do not wear metallic objects such as jewelry while working on batteries Do not store un insulated tools in pockets or tool belt while working in vicinity of battery Keep the top of the battery dry and clear of all tools and other foreign objects Provide adequate ventilation as regulated by Federal State and Local codes and follow recommended charging voltages Extinguishing media Class ABC extinguisher Note CO may be used but not directly on the cells due to thermal shock and potential cracking of cases Never remove or tamper with
13. tteries at all times Consult User Manual of specific application for additional Safety amp Operating requirements Annual Inspection Depending on the application some of the following recommendations may not apply 1 Conduct a visual inspection of the battery ies 2 Record battery and or string voltage The accuracy of the DMM Digital Multimeter must be 0 05 on dc scale or better The DMM must be calibrated to NIST traceable standards Because voltage readings are affected by discharge and recharges for cyclic applica tions the battery ies must be in a fully charged condition prior to taking readings Batteries should be within 0 30 volts 0 15 volts for 6V of the average battery float voltage Record charger voltage Record the ambient temperature Record individual battery ohmic readings ook Ww tion If any reading is greater than 20 from initial readings retorque the connection Recheck the micro ohm reading If the reading remains high clean contact surface according to installation portion of this manual Note To provide accurate consistent values battery ies must be fully charged at same temper ature and probes placed at same location each time readings are taken Record all interunit and terminal connection resistances Micro ohm readings should be taken during this inspec MAINTENANCE con t Rectifier Ripple Voltage FREQUENCY Ripple that has a frequency gre
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