1112 (Unigy II I & O) - East Penn Manufacturing
Contents
1. Cell Voltage Although the charger must maintain the system voltage within 0 5 individual battery cell voltages may vary by 0 05 volts per cell of the average cell float voltage Equalizing Upon installation of the battery system an optional charge of 14 40V per battery 0 06 77 F 25 C 2 40 vpc 0 01 77 F 25 for 24 hours not to exceed 24 hours can be applied Note Verify that the higher battery voltage will not adversely affect any other connected equipment If this is done be sure to reset the charging equipment to the proper float voltage RECORD KEEPING Voltages Temperatures amp Ohmic Readings Record keeping is an important part of stationary battery maintenance 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 C Battery Maintenance Report Voltages Temperatures amp Ohmic Readings con t While it is acceptable to operate at temperatures less than 77 F 25 it will require longer charging time to become fully recharged Also the capacity will be less at operating temperatures below 77 25 After installation and when the batteries have been on float charge for one week the following data should be recorded 1 Battery terminal voltage Charger voltage Individual cell float voltages Individual cell ohmic readings On a 4 post cell pla2. 9 6 Each battery is shipped with its own schematic Make sure the polarity on the batteries match the drawings ND A OT ELECTRICAL CONNECTION Connector Assembly 1 The contact surfaces of each individual post on every cell have been cleaned and coated with a thin film of no ox ID A grease at the factory Assure the contact surfaces are free of dust or dirt prior to assembly Connector Assembly con t 2 The Interlock and Non Interlock battery 45 75 6 95 AH are supplied with connector package 1CU requiring one connector per post Install the connectors loosely to allow for final alignment then torque to 125 x 5 inch pounds 14 1 5 Nm The installation and direction of the post bolts is important Refer to Fig 4 1 4 2 and 4 3 pg 11 and 12 Fig 4 4 pg 4 For proper direction when inserting into posts The 125 AH battery is supplied with a 2CU connector package as standard Refer to Fig 5 1A pg 13 for special connector orientation for side terminal amp stack to stack connections Batteries used in high rate discharge applications require multiple connectors per connection Refer to optional connector packages in Fig 4 5 pg 4 CD Connector Packages Standard Package 45 75 amp 95 AH 1CU 1 connector post 250 amps 480 wpc 5 15 plate 450 amps 720 wpc 17 27 plate 550 amps 880 wpc 29 33 plate 2CU 2 connectors post Standard on 12
3. DETAIL SIDE TERMINAL PLATE TERMINAL y 3 8 16 X 41 2 LONG BOLT FLAT WASHER gt FLAT WASHER 7 g LOCK WASHER SIDE TERMINAL CONNECTOR STEP 1 pex NUT _ _ BOLT ASSEMBLE AFTER MOUNTING BRACKET AND TERMINAL PLT SUPPORT SLOT IN LOWER ARM OF MOUNTING BRACKET SLIPS OVER TAB IN MOUNTING SUPPORT 3 8 FLAT WASHER LOCK WASHER HEX NUT MOUNTING BRACKET 3 8 16 X 4 1 2 LONG BOLT FLAT WASHER SPACER NEEDED FOR BOTTOM SIDE MOUNT ONLY SPACER IS PLACED BETWEEN MODULE AND UPPER ARM OF MOUNTING BRACKET Fig 5 2A 14 8 8 16 X 1 1 4 BOLT SHIELD ASSEMBLY SLIDES LOCK WASHER ONTO TERMINAL BRACKET FLAT WASHER SLIDE CLIP INTO TOP CHANNEL FROM CUT OUT ON BACK OF CHANNEL APPLY CLIPS AT BOTH ENDS OF CHANNEL FLAT WASHER LOCK WASHER HEX NUT FRONT amp BACK TERMINAL SHIELDS FINAL ASSEMBLY SLIDE INTO SHIELD JOINT JTPR0600 TERMINAL 1 4 20 X 1 1 2 PLATE FOR 21 THRU 33 PLATE APPLICATION FLAT WASHER 3 TERMINAL CONNECTOR JMP3129 FOR 29 33 PLATE APPLICATION FLAT WASHER LOCK WASHER HEX NUT Fig 5 3 45 75 amp 95 AH 3 8 16 X 1 1 4 BOLT TAE r BO SHIELD ASSEMBLY SLIDES LOCK WASHER ONTO TERMINAL BRACKET FLAT WASHER SLIDE CLIP INTO TOP CHANNEL FROM CUT OUT ON BACK OF CHANNEL APPLY CLIPS AT BOTH ENDS OF CHANNEL FLAT WASHER FLAT WASHER w LOCK WASHER 1 4 20 X 1 BOLT FRO
4. acid electrolyte Class C fire extinguisher Acid neutralizing agent Adequately insulated tools Lifting devices of adequate capacity when required T O C1 Procedures The following safety procedures should be followed during installation Always wear safety glasses or face shield when working on or near batteries Refer to Figure 1 1 These batteries are sealed and contain no free electrolyte Under normal operating conditions they do not present any sulfuric acid danger However if the battery jar or cover is damaged sulfuric 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 SDS for additional precautions and first aid measures SDS sheets can be obtained at www eastpennmanufacturing com 2 Prohibit smoking and open flames and avoid arcing in the immediate vicinity of the battery 3 Do not wear metallic objects such as jewelry key chains while working on batteries Do not store un insulated tools in pockets or tool belt while working in vicinity of battery 4 Keep the top of the battery dry and clear of tools and other foreign objects 5 Provide adequate ventilation per IEEE standard 1187 and or Federal State amp Local codes and follow recommended charging voltages 6 Never remove or tamper with the pressure relief valves unless for cell removal Warranty void if vent
5. affected by dis charges and recharges these readings must be taken when batteries have been on continuous uninterrupted float for at lease one month Cells should be within 0 05 volts of the average cell float voltage Record the ambient temperatures Record individual cell ohmic readings Record all interunit and terminal connection resistances Micro ohm readings should be taken during this inspection If any reading differs by more than 20 from initial readings taken retorque the connection Recheck the micro ohm reading If the reading remains high clean the contact surface according to installation portion of this manual Other Maintenance Inspection intervals follow IEEE 1188 gt OM 3 Rectifier Ripple Voltage FREQUENGY Ripple that has a frequency greater 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 0 596 peak to peak of the manufacturer s recommended string voltage Failure to comply can void the warranty Battery Cleaning Batteries cabinets racks and modules should be cleaned with clear water a mixture of baking soda and water or East Penn Mfg supplied battery cleaner part 00321 Never use solvents to clean the battery Capacity Testing Per IEEE 118
6. 1 THREAD POLYPROPYLENE ROPE THROUGH TWO TERMINALS AS SHOWN AND KNOT 2 PULL CELL FROM MODULE ACROSS LIFT TRUCK AS SHOWN POLYPROPYLENE ACID RESISTANT GLOVE STEP 4 CELL REPLACEMENT 1 CHECK POLARITY ORIENTATION PUSH CELL BACK INTO MODULE 2 REMOVE ROPE IF USED 3 REPLACE RETAINER BARS 4 REPLACE CONNECTORS 5 REPLACE MODULE FRONT SHIELD 6 RECONNECT SYSTEM GROUND CONNECTION 7 RECONNECT CHARGER Fig 8 4 PALLET FRONT PROTECTIVE WAFFLE BOARD MOUNTING PLATE amp 3 8 X 1 3 4 GRADE 5 BOLT ASSEMBLY REMOVE AND DISCARD MODULES STACK 4 HIGH MAX MODULES ARE STACKED IN SHIPPING BOX TOP TERMINAL BRACKET SUPPORT CHANNEL ACCESSORY PACKAGE SEE PARTS LIST FOR COMPONENTS CLEAR FRONT SHIELD PACKAGE SHIPPING BOX REVERSE ORDER FROM LAYOUT REMOVE ONE MODULE AT A TIME Fig 2 1 2 REQUIRED FOR LIFTING DETAIL OF STRAP ASSEMBLY Interlock System Leveling When leveling Unigy II Interlock battery systems that are installed with a 1 piece base support it is critical to note that the back channel is 3 16 shorter than the front channel If a level is placed across the front and rear channels a 3 16 shim should be placed on top of the rear channel in order to level properly INCORRECT LIFT STRAP LOCK WASHER 4 3 8 16 X 1 1 4 BOLT E p S Ee c IR MOUNTING SUPPORT 3 16 SHIM CORRECT Fig 3 1A TO
7. 5 AH 1000 amps 1600 wpc 9 33 plate ACU 4 connectors post 2000 amps 3200 wpc 13 33 plate 6CU 6 connectors post 3000 amps 4800 wpc 25 33 plate 1CU 4 20 x 1 long JMP1428 2CU 4 20 x 1 long JMP1407 ACU 4 20 x 1 long JMP1435 6CU 4 20 x 2 long JMP1409 Fig 4 5 Terminal Assembly 1 Attach the terminal mounting bracket to the module frame See Fig 5 1 pg 13 for Interlock and Fig 5 2 and 5 2A for Non Interlock pg 14 for Side Terminal oee Fig 5 3 and Fig 5 3A pg 15 for Top Terminal 2 Attach the terminal plates or the terminal connectors to the battery posts and then torque to 125 5 inch pounds 14 1 5 Nm See Fig 5 3 and Fig 5 3A pg 15 for 95 AH vs 125 AH 3 For cable connection assembly See Fig 7 1 pg 16 and Fig 7 1A pg 17 Final Assembly Check Procedure 1 For future identification of all cells number individual cells in sequence beginning with number one 1 at the positive end of the battery The last cell of the battery is located at the negative output terminal 2 Read and record the voltages of the individual cells to assure that they are connected properly The total battery voltage should be approximately equal to the number of cells connected in series multiplied by the measured voltage of one cell If the measurement is less recheck the connections for proper polarity Verify that all cell and battery connections ha
8. 8 Capacity testing is used to trend battery aging The result of a capacity test is a calculation of the capacity of the battery The calculated capacity is also used to determine if the battery requires replacement Do not discharge the battery beyond the specified final voltage When discharging at higher rates extra connectors may need to be added to prevent excessive voltage drop and or excessive temperature rise When performing capacity testing and recording data use IEEE 1188 instructions Should it be determined that any individual battery ies cell s need to be replaced contact East Penn CELL REMOVAL PROCEDURE 1 Before removing cells review Safety Precautions on pg 3 of this manual Contact East Penn Manufacturing Company Inc with specific questions or concerns 2 Refer to Fig 8 1 through 8 4 below for specific instructions STEP 1 HARDWARE REMOVAL 1 DISCONNECT CHARGER 2 DISCONNECT THE SYSTEM GROUND CONNECTION 3 REMOVE MODULE FRONT SHIELD ASSEMBLY REMOVE THE CELL RETAINER BAR 4 DISCONNECT THE CELL FROM OTHER CELLS IN SERIES 1 4 20 X 1 LG THREAD CUTTING SCREW INTERLOCK 1 4 20 HEX NUT STANDARD Fig 8 1 STEP 2 PRESSURE RELIEF 1 PRY VENT SHROUD OFF 2 REMOVE FLAME ARRESTOR 3 UNSCREW VALVE WITH 17mm HEX KEY PRESSURE WILL RELEASE 4 RETORQUE VALVE IMMEDIATELY TO 12 14 in lbs WITH 17mm HEX KEY CATALYST VALVE FLAME ARRESTOR SHROUD STEP 3 CELL REMOVAL
9. Be ULE SPACESAVER SYSTEMS Interlock 45 75 95 amp 125 AH Non Interlock 45 75 amp 95 AH Installation and Operation Manual Batteries battery posts terminals and related accessories California Proposition 65 contain lead and lead compounds and other chemicals known p the state of California to cause cancer and birth defects or Warning other reproductive harm Wash hands after handling TABLE OF CONTENTS Safety Precautions Record Keeping Protective Equipment Voltages Temperatures Procedures amp Ohmic Readings Receiving amp Storage Maintenance Receiving Inspection Annual Inspection Unpacking Rectifier Ripple Voltage Storage Battery Cleaning Capacity Testing General Cell Removal Procedure Grounding FIGURES Electric Code for Maintenance Access APPENDIX A Floor Anchoring amp Module Arrangements Recharge Interval Chart Module Installations APPENDIX B Electrical Connection Voltage Compensation Chart Connector Assembly 9 P Terminal Assembly APPENDIX C Final Assembly Check Procedure Battery Maintenance Report Parallel Strings APPENDIX D Module Front Shield Assembly UNIGY II SPACESAVER System Top Protective Shield Assembly Acid Volumes amp Weights Terminal Plate Shield Assembly Installation System Operations Charger Voltage Operating Temperatures Cell Voltage Equalizing BATTERIES AND RELATED PARTS LE P gt CONTAIN LEAD DANGER Lead Acid Battery Contains
10. Lead Sulfuric Acid Electrolyte Lead Compounds Harmful if swallowed inhaled or in contact with skin Wear protective gloves protective clothing eye protection face protection Acid causes severe skin burns and eye damage Use only outdoors or in a well ventilated area May damage fertility or the unborn child if ingested or inhaled Avoid contact with internal acid May cause harm to breast fed children Do not breathe dust fume gas mist vapors spray W May cause cancer if ingested or inhaled Keep away from heat sparks open flames hot surfaces No smoking UL Recognized AS H HAN DS Causes skin irritation serious eye damage IF SWALLOWED OR CONSUMED rinse mouth Do NOT induce vomiting ITO AFT E R HAN D LI N G Contact with internal components may cause irritation or severe burns Call a poison center doctor if you feel unwell CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related Causes damage to central nervous system blood and kidneys IF ON CLOTHING OR SKIN or hair Remove Take off immediately all accessories contain lead and lead compounds and through prolonged or repeated exposure if ingested or inhaled contaminated clothing and wash it before reuse Rinse skin with other chemicals known to the state of California to cause Irritating to eyes respiratory system and skin water shower cancer and birth defects or other reproductive harm Ma form ex losive as mixture durin char ing IF INHALED Remov
11. NT amp BACK TERMINAL SHIELDS SLIDE INTO SHIELD JOINT SHIELD ASSEMBLY JTSR0033 FOR 29 33 1 4 20 X 1 1 2 PLATE APPLICATION JTPR2975 TERMINAL PLATE FOR FLAT WASHER 29 33 PLATE APPLICATION FLAT WASHER LOCK WASHER HEX NUT Fig 5 3A 125 AH 15 CUT OUT TOP PROTECTIVE SHIELD FOR TERMINAL LOCATION SHIELD SLIDES INTO AND SNAPS ONTO THE CLIP INSERT CLIP END INTO HOLES ON MODULE SLIDE TOP PROTECTIVE SHIELD ONTO FRONT SHIELD ON TOP MODULES ONLY DETAIL OF ASSEMBLED SHIELD 2 END CLIPS AND 1 FRONT SHIELD PER ASSEMBLY Fig 5 4 560 HOLE TYPE 56 X 1 19 LG SLOT TYPE 17 AND 19 PLATE POST 34 X 1 00 LG SLOT TYPE HOLES amp SLOTS 21 THROUGH 33 PLATE POST 29 THROUGH 33 PLATE POST 125 AH PRODUCT LINE ONLY NOTES 56 DIAMETER HOLES AND 1 19 LONG SLOT USED TOP TERMINATION FOR CABLE MOUNTING TO FIT 50 DIAMETER BOLTD Fig 7 1 16 z lt LLI H LLI o Fig 7 1A 17 APPENDIX A Recharge Interval Chart NENNEN Ni N Temp CF Time Months m 18 APPENDIX B Voltage Compensation Chart op Float Voltage Per Cell F gt 35 gt 95 34 93 2 33 91 4 32 89 6 31 87 8 30 86 0 29 84 2 28 82 4 27 80 6 26 78 8 25 2250 70 24 75 2 23 73 4 22 71 6 21 69 8 20 68 0 19 66 2 18 64 4 17 62 6 16 60 8 15 59 0 14 S 13 55 4 12 53 6 11 51 8 210 2 280 50 2mV per C APPENDIX C BATTERY MAINTENANCE REPOR
12. P1451 5 amp 7 PLATE CELLS ONLY SPACER REQUIRED FOR 5 amp 7 PLATE CELLS ONLY Fig 4 2 RECOMMENDED BOLT DIRECTION T RT ATT JU FEE LE 5 15 PLATE 17 27 PLATE 29 33 PLATE NOTES INSULATED TORQUE WRENCH SHOULD BE PLACED ON BOLT HEAD TO ENSURE MAXIMUM CLEARANCE Fig 4 3 12 MOUNTING BRACKET DETAIL A sm v CLEAR TERMINAL 3 8 16 X 2 1 2 LG BOLT L 1 4 20 X 1 LG BOLT FLAT WASHER FLAT WASHER L 2 2 FINAL ASSEMBLY SIDE TERMINAL CONNECTOR SLOTS amp HOLES TO ASSEMBLE AFTER LOCK WASHER FIT 1 2 DIAMETER BRKT amp TERM PLT FINAL ASSEMBLY DOUBLE SIDE TERMINAL CONNECTOR DETAIL A SIDE TERMINAL PLATE 1 4 20 X 1 LG BOLT LOCK WASHER FLAT WASHER FLAT WASHER BOLT THROUGH TERMINAL CONNECTOR INTO TERMINAL AS SHOWN TO CLEAR SHIELD CLIP TETEN 3 u z wv A DETAIL A SCALE 0 30 1 DOUBLE STACK CONNECTOR ON ONE SIDE NOTES OF TERMINAL TO CLEAR SHIELD CLIP BOLT 1 REFERENCE amp O MANUAL FOR THROUGH COPPER CONNECTOR INTO COMPLETE CONNECTOR ASSEMBLY TERMINAL AS SHOWN 2 2CU PACKAGE ONLY 3 BATTERY SYSTEM RATED TO 2 HOUR DISCHARGE 695 AMPS TO 1 75 END DETAIL B VOLTAGE SCALE 0 30 1 Fig 5 1A 13 STEP 2 CLEAR TERMINAL SIDE SHIELD ce sp 00 0 58 FLAT WASHER 0 94 0 88 034 1 19 gt LOCK WASHER 0 75 d HEX NUT MOUNTING BRACKET
13. RQUE TO 50 in Ibs 5 6 Nm TOP MODULE SLIDES INTO CUT OUTS OF BOTTOM MODULE NO BOLTING NEEDED JOINING PLATE TOP MODULE ONLY BOTTOM MODULE 3 8 16 X 1 1 4 BOLT FLAT WASHER LOCK WASHER MODULE SUPPORT HEX NUT amp LOCK WASHER FLAT WASHER FLAT WASHER 3 8 16 X 1 BOLT A SD X 3 8 16 X 1 1 4 BOLT UN FLAT WASHER LOWER MODULE NESTS LOCK WASHER INTO UPPER MODULE FASTENED WITH 3 8 TORQUE TO 50 in Ibs HARDWARE 5 6 Nm NOTES 1 HARDWARE REQUIRED TO MEET ZONE 4 CERTIFICATION 45 75 8 95AH INTERLOCKTM 2 TORQUE REQUIREMENT 50 FT LBS 67 8 Nm ZONE 4 ONE PIECE MOUNTING SUPPORT 3 amp 6 GELL MODULES 2 amp 4 CELL MODULES 3 amp 6 GELL MODULES 2 amp 4 CELL MODULES 75 95 75 A H 95 A H V X V X V 812 FLOOR MOUNTING HOLES 1 00 TYP Fig 3 5 TORQUE TO 125 5 in Ibs 14 1 5 Nm FLAT WASHER 1 4 20 BOLT ADDITIONAL CONNECTIONS LOCK WASHER FLAT WASHER BOLT ASSEMBLY CONFIGURATION WITH THE ADDITION OF MULTIPLE CONNECTOR PACKAGES IT IS RECOMMENDED TO ALTERNATE CONNECTORS EVENLY USING OPPOSITE SIDE OF TERMINAL Fig 4 1 11 SHORT L CONNECTOR JMPL1719 17 19 PLT JMPL2127 21 27 PLT JMPL2933 29 33 PLT BOLT ASSEMBLY JM
14. T Date Company Address Battery Location and or Number No of Cells Type Date Mfg Date Installed Ambient Air Temperature _ oF Total Battery Voltage Panel Meter Volts Installer Cell Cell Cell Ohmic Ohmic Ohmic Ohmic Ohmic Ohmic Value Value Value Value Value Value Readings Taken By Readings should be taken at installation and at least annually thereafter Notation This form must be completed and submitted with any product warranty claim 20 APPENDIX D Unigy SPACESAVER System Acid Volumes amp Weights Cell Acid Vol Acid Vol Size CC gal 1 814 1 395 2 542 1 955 3 276 2 520 45 11 4 004 3 080 4513 4732 3640 096 957 4780 3635 096 58 82 Data subject to change 4 258 3 275 21 NOTES 22 NOTES 23 gt EASTPENN East Penn Manufacturing Go Lyon Station PA 19536 0147 610 682 3263 Fax 610 682 4781 e mail reservepowersalesQdekabatteries com Form No 1112 Rev 7 15 2015 by EPM Printed in U S A 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
15. ce meter leads on the left positive left negative posts or right positive right negative posts For 6 post cells measure from center positive center negative posts Do not measure diagonally from positive to negative posts See Fig 6 1 pg 6 Ambient temperatures Terminal connections should be checked to verify that the installer did torque all connections properly 125 5 in Ibs Micro ohm readings should be taken across every connection Refer to Fig 6 2 pg 6 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 connection to 125 5 inch pounds If the reading still remains high clean contact surfaces according to Step 2 under Connector Assembly R O OT Fig 6 2 Failure to maintain proper records including information as detailed above may result in voiding any applicable warranty MAINTENANCE Always wear eye protection when working on or near batteries Keep sparks and open flames away from batteries at all times See Safety Precautions on pg 3 Annual Inspection Conduct a visual inspection of each cell Record the battery string voltage Record the charger voltage Record the individual cell voltages The accuracy of the DMM Digital Multimeter must be 05 on dc scale or better The DMM must be calibrated to NIST traceable standards Because float readings are
16. desired float voltage varies with temperature according to the table in the next column Temperature Compensation Battery voltage should be adjusted for ambient temperature variations 2mV per C 1 8 F per cell Consult Voltage Compensation Ghart in Appendix B for temperature compensation voltage maximum and minimum limits Battery Operation Battery operating temperature will affect battery capacity and operating life Operation at temperatures greater than 77 F 25 C will reduce the operating life of the battery For every 13 F 7 C increase in operating temperature above 77 F 25 C the warranty period will be proportionally reduced by 50 as shown below Operating Temp Proportional of Life 100 81 F 27 C 80 87 F 30 C 60 90 F 32 C 50 The average cell 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 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 Cells must not be operated below 50 F 10 C If operating temperatures are expected to be less than 50 F 10 C contact East Penn for recommendations Batteries must be located in a manner that the individual cells do not vary by more than 5 F 2 8 C between the lowest and highest individual cell temperatures
17. e person to fresh air and keep comfortable for California Proposition 65 Workplace Warning Sign y 9 re breathing Immediately call POISON CENTER or doctor physician Must be posted in workplace near batteries IF IN EYES Rinse cautiously with water for several minutes Remove contact lenses if present and easy to do Continue rinsing If exposed concerned or if you feel unwell seek medical attention advice Store locked up in a well ventilated area in accordance with local and lo v 9 9 88 88 1 Extremely flammable gas hydrogen Explosive fire blast or projection hazard Obtain special instructions before use Do not handle until all safety precautions have been read and understood national regulation Wash thoroughly after handling gt gt m Dispose of contents container in accordance with local and national Do not eat drink or smoke when using this product regulation Avoid contact during pregnancy while nursing Keep out of reach of children PROPOSITION 65 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 Batteries also contain other chemicals known to the State of California to cause cancer WASH HANDS AFTER HANDLING WARNING Risk of fire explosion or burns Do not disassemble or incinerate Not recommended for inverted use F
18. eduled interval Record dates and conditions for all charges during storage 3 If a boost charge is required the recommended charge is 24 hours at a constant voltage equal to 2 40 volts per cell 4 Do not store beyond 12 months 5 Store in horizontal position only INSTALLATION 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 or 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 applications Two 201 diameter x 50 center holes are provided in back of each module to accept a 6 x 50 center compression grounding lug The holes must be tapped for a 1 4 20UNC thread and paint must be removed for a proper grounding pad location Electric Code for Maintenance Access Refer to ANSI NFPA 70 National Electric Code for access and working space requirements around the battery A minimum of 36 aisle space is recommended in front of the battery for service and inspection N
19. 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 packages 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 9 When lifting batteries the proper equipment is needed such as a forklift or a portable crane Always check the lifting capacities of the equipment being used and never lift more than one module and or cell at a time Storage 1 Cells should be stored indoors in a clean level dry cool location Recommended storage temperature is to 90 F 18 C to 32 C 2 otored lead acid batteries self discharge and must be given a boost charge to prevent permanent performance degradation to 77 F 18 C to 25 C storage Batteries should be recharged six months from date of manufacture gt 77 F 25 C storage Use the chart in Appendix A for recharge intervals Voltage readings should be taken on a monthly basis Cells that reach 2 10 volts per cell should be recharged regardless of sch
20. ollow product charging instructions High Voltage Risk of shock Do not touch uninsulated terminals or connectors Do Not Remove Vent Valve Manufactured by East Penn Manufacturing Co 102 Deka Road Lyon Station PA 19536 USA 610 682 6361 Lead Acid Battery Electrolyte Sulfuric Acid SAFETY PRECAUTIONS VRLA Valve Regulated Lead Acid batteries have the electrolyte immobilized within the cell however electrical hazard associated with batteries still exists Work performed on these batteries should be done with the tools and the protective equipment listed below VRLA 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 recommendations the following minimum set of equipment for safe handling of the battery and protection of personnel shall be available 1 Safety glasses with side shields or goggles or face shields as appropriate Consult application specific requirements 2 Electrically insulated gloves appropriate for the installation 3 Protective aprons and safety shoes Portable or stationary water facilities in the battery vicinity for rinsing eyes and skin in case of contact with
21. oss of performance capabilities of that string will result in higher loads in the other parallel string s which may exceed the ratings of the battery connections This can damage the battery system and dramatically shorten battery life Module Front Shield Assembly 1 Attach one black clip to each end of the clear shield See Fig 5 4 pg 16 and 5 5 pg 5 2 Install the fully assembled shield into the tabs on the module See Fig 5 6 pg 5 amp Fig 5 4 pg 16 Top Protective Shield Assembly For side terminal assembly attach the black top protective cover to the highest front shield For top terminal assembly cut the black protective cover to fit between the terminals and then attach to the front shield See Fig 5 4 pg 16 Terminal Plate Shield Assembly For side terminal shield assembly Refer to Fig 5 1 pg 13 for Interlock and Fig 5 2 and 5 2A for Non Interlock pg 14 and Fig 5 7 pg 5 For top terminal shield assembly Refer to Fig 5 3 pg 15 and Fig 5 8 pg 5 5 mimm r SYSTEM OPERATIONS Charger Voltage These batteries are designed for continuous float applications Float Standby 2 25 vpc 0 01 77 F 25 C When setting the float voltage on the charger the system should be set to float at the nominal cell float voltage times the number of cells per string The charger must be able to maintain the system voltage within 0 5 of the desired level at all times The
22. ote Battery system and or individual module grounding if required is the installers responsibility Floor Anchoring amp Module Arrangements See East Penn Mfg Co s schematic diagram illustration One is supplied with each shipment If it cannot be located contact East Penn Mfg Co for a copy Refer to your delivery number located on the packing slip This will aid in obtaining the proper drawing Module Installations Assemble modules per the following details CAUTION Never lift more than one module at a time with the lifting slings See Fig 3 2 pg 9 UBC Zone 4 hardware included for Interlock module assembly 45 75 amp 95 AH See Fig 3 4 pg 10 Unbolt the floor mounting channel from the top of the battery Use the two slings provided to lift modules Note For Interlock module lift the top module slightly and slide front This will release the interlock tabs and will free itself from the remaining stack See Fig 3 2 pg 9 For the Non Interlock modules reference figure 3 5 pg 11 for marking hole locations to mount base supports to floor For the Interlock modules use 1 piece base for marking floor hole location See local building codes for anchor bolt requirements anchor bolts not included Remove the next module in the same manner as the first Place in position Note For Interlock module slide back allowing the tabs to lock in place No rear bolts required See Fig 3 2 pg
23. valve is removed 7 Inspect all flooring and lifting equipment for functional adequacy 0 Adequately secure battery modules racks or cabinets to the floor 9 Connect support structures to ground system in accordance with applicable codes 10 The below IEEE Standards contain additional information Other standards may be relevant to your specific application IEEE 1187 Recommended Practice for Installation Design of VRLA Batteries IEEE 1188 Recommended Practice for Maintenance Testing of VRLA Batteries IEEE 1189 Selection of VRLA Batteries for Stationary Applications A DANGER HIGH VOLTAGE SHIELD RISK OF SHOCK Wy EYES DO NOT TOUCH EXPLOSIVE Sr GASES CAN CAUSE BLINDNESS OR INJURY CONNECTORS s FLUSH EYES IMMEDIATELY WITH WATER SEE INSTALLATION MAINTENANCE AND OPERATION INSTRUCTIONS FOR IMPORTANT SAFETY PRECAUTIONS VENTILATE WELL WHEN IN AN ENCLOSED SPACE AND WHEN CHARGING DO NOT REMOVE VENT VALVE WARRANTY VOID IF VENT VALVE IS REMOVED Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known California Proposition 65 to the state of California to cause cancer and birth defects or Warning other reproductive harm Wash hands after handling Fig 1 1 RECEIVING amp STORAGE Receiving Inspection Upon receipt and at the time of actual unloading each package should be visually inspected for any possible damage or
24. ve been properly torqued 3 Measure and record the intercell connection resistance using a micro ohms meter This helps determine the adequacy of initial connection installation and can be used as a reference for future maintenance requirements Refer to the recording forms in Appendix C of this manual Review the records of each connection and detail resistance measurements Clean remake and remeasure any connection that has a resistance measurement greater than 10 of the average of all the same type connections i e intercell intermodule etc 4 Battery performance is based on the output at the battery terminals Therefore the shortest electrical connection between the battery system and the operating equipment results in maximum total system performance Select cable size based on current carrying capability and voltage drop Cable size should not provide a greater voltage drop between the battery system and operating equipment than specified Excessive voltage drop in cables will reduce the desired reserve time and power from the battery system Parallel Strings When paralleling valve regulated batteries the capacity arrangement and external circuit length should be identical for each battery Wide variation in the battery circuit resistance can result in unbalanced charging i e excessive charging currents in some batteries and undercharging in others As a result cell failures in one battery string and subsequent l
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