Safety, Storage, Operating and Maintenance Manual
Contents
1. 14 6A General tek ee eae Ska eth Adee a ne wkd ae 14 0 2 ACCESSONCS en oe tee hoe RE 14 6 3 Recommended Installation Equipment and 15 7 0 INITIAL and or FRESHENING 16 80 55 2 22 dene Deb ea Keke pees eR AR TESS Res eee ae oes 17 Bice 17 8 1 1 Determining the 51 1 17 8 2 Float Operation Eee ee ee eR ae 18 8 2 1 Float Charge 19 8 3 Equalizing Charge sroine eee eee 20 8 3 1 Equalizing Charge 1 45 007 21 Publication No US VR OM 002 2008 www enersys com En er Power Full Solutions 9 0 BATTERY TAPS 25 0 asc eva OS POPE es pee ee A 22 10 0 252222 22 4 2 or tee ve eae ee re eee ak 22 110 22 25 52 Gas bee Sed ey 22 11 1 Battery Cleaning 22. 3 8 Drive Rachet Wrench with Minimum 3 Extension With 3 8 thru 11 16 and M6 M8 and M10 Sockets Box Wrenches 3 8 to 11 16 and M6 M8 and M10 Screwdrivers Wipes Paper or Cloth Stiff Bristle Nonmetallic Brush Pad Tape Measure Nonmetallic Safety Equipment and Clothing Small Paintbrush Standard Allen Wrench Set NO OX ID Grease CAUTION Be sure you have all the proper protective clothing and safety tools and equipment on hand before starting the installation Publication No US VR OM 002 March 2008 www enersys com 15 Neroys Power Full Solutions 7 0 INITIAL and or FRESHENING CHARGE Batteries lose some initial charge during shipment and storage Depending on storage time a battery may require a freshening charge See Section 4 0 for battery storage times Constant voltage is the ONLY charging method allowed Confirm that your charger bus is a constant voltage type Most modern chargers are the constant voltage type 1 Determine the maximum voltage that may be applied to the system equipment or maximum charger voltage if load is not yet connected Refer to the recommendations of the manufacturer supplier of system equipment connected to DC bus Divide the maximum total system voltage by the number of cells not units connected in series This is the maximum volts per cell that may be used for the initial charge Do NOT exceed 2 35 vo
3. r T g slabs 8 JE 5 JHE peua 9242351594 195 03 182 ANVdINOS 1 10 OS pue JONVNALNIVIN Enersys Solutions 12 0 TEMPORARY NON USE EXTENDED OUTAGE 12 1 Installed Out of Service System If an INSTALLED battery is expected to STAND IDLE longer than the storage period recommended for the storage temperature see Table 4 1 on page 9 treat as follows 1 Before taking the battery out of service give it an equalizing charge according to Section 8 3 1 2 After the charge open the connections at the battery terminals to remove load from the battery 3 Throughout the extended non use period give the battery an equalizing charge before the end of the recommended storage intervals noted in Table 4 1 Disconnect the battery from the charger between equalizing charges 12 2 Return to Service To return the battery to normal service 1 Reconnect the battery the load and charger 2 Give the battery an equalizing charge as described in Section 8 3 1 3 Return the battery to float operation Publication No US VR OM 002 29 March 2008 www enersys com Full Solutions 5 30 Publication No US VR OM 002 www enersys com March 2008 PRECAUTIONS 1 Do not bring
4. 2 3 Precautions ee gates Sead tee kee Sree tee oes 4 2 3 1 Sulfuric Acid Burns 2 225 ee 4 232 IEXPIOSIVE GASES 5 2 3 3 Electrical Shocks and 1 5 3 0 INSPECTING THE BATTERY SHIPMENT 7 7 3 2 Visible External eee 7 3 3 Concealed 0 5555 5 554 ene ees eee eee 8 4 0 BATTERY STORAGE BEFORE INSTALLATION 9 41 General ii evens eae Medes eae PR ae ee eRe ates 9 4 2 Localo 55255 5 eee ee ee ea SER ees 9 4 3 26 eee ao 10 5 0 INSTALLATION CONSIDERATIONS 11 5 General eae odes cede Seca a 11 5 2 Considerations for Connecting the Battery System to Operating Equipment 12 5 3 Considerations for Parallel Installation 13 6 0 UNPACKING AND HANDLING FOR INSTALLATION
5. To perform the heavy corrosion cleaning follow the procedure below 1 Unbolt and remove connectors 2 Apply a solution of bicarbonate of soda and water to the cell posts and connectors to neutralize the corrosion as described in Section 11 1 2 3 Clean the contact surfaces by rubbing the surface of post or terminal and lead plated contact surfaces with a stiff bristle nonmetallic brush pad Lightly brush tin plated connectors Exercise care so you do NOT remove the plating on the connectors terminal plates or lugs exposing copper 4 Bolt all intercell connectors WARNING Stamped flat washers may sharp edge Install the Install as follows washer with the sharp edge away from the lead plated copper a Intercell Connector Lock Washer intercell connector to avoid damaging the lead plating b Flat Washer d Bolt REFER TO APPROPRIATE INSTALLATION MANUAL FOR ADDITIONAL INFORMATION 5 Install all connections finger tight to allow for some adjustment of position 6 After all connections are completed torque to original installation specifications 7 Recoat the contact surfaces with a thin application of the NO OX ID grease heated to a liquid form and applied with a small paintbrush Publication No US VR OM 002 23 March 2008 www enersys com Power Full Solutions 11 2 TEST PROCEDURES 11 2 1 Procedure for Battery Capacity Tests Use the following test procedure or use the test procedur
6. and fire Installation and servicing of batteries should be performed by WARNING Personnel knowledgeable about batteries and the required precautions Keep unauthorized personnel away from the batteries Proper maintenace to the battery system of this unit must be done WARNING by a qualified service technician This is essential to the safety and reliability of your Uninterruptible Power Supply UPS system gt Publication No US VR OM 002 iii March 2008 www enersys com When working with EnerSys Modular Battery System be sure to refer to the Installation Manual specified for that system and Rack Assembly Instructions included in the rack shipment Publication No US VR OM 002 www enersys com March 2008 er Power Full Solutions TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS i 1 0 GENERAL INFORMATION 1 1 1 2 erio cka A rk wa lee 1 1 a er E E i E 2 2 0 SAFETY ien a E ata 3 2A General isc on Geen bY ae Mia 3 2 2 Safety Equipment and Clothing 4 3
7. any heat or flame source near battery 2 Do not remove pressure relief valves DO NOT PUSH ON CENTER USE EDGE OF MODULE TO POSITIONIBATTERY WHEN POSITIONING BATTERY Do not lift any cells by the terminal posts Do not tamper with seal nuts on the cell post Do not remove lead coating from post or connectors and expose any bare copper Do not allow cell temperature to exceed 105 during charging Do not clean cell with anything other than water bicarbonate of soda Do not over torque connections Do not store VRLA type batteries for over six months without charge at normal temperatures These are only a few of the precautions Please read all accompanying literature thoroughly for specific safety and installation information lt 5 When ordering new batteries also remember to properly recycle your old lead batteries Federal and state regulations require lead acid batteries be recycled 5 gt EnerSys nationwide service organization can arrange pickup transportation to and 9000 recycling at any one of our company affiliated smelters Call 1 800 972 7372 for RECYCLE more information Please visit www enersys com for literature updates EnerSys EnerSys EMEA Represented by PO Box 14145 Brussels Belgium ner 4 Reading PA 19612 4145 32 0 2 247 94 47 USA EnerSys Asia Power Full Solutions Tel 1 610 208 1991 Guangdong China 1 800 538 3627 Tel 86 755 2689 36
8. 2 11 1 1 Standard ses dye ere be ey 22 11 1 2 Corrosion Cleaning o Be glee 23 11 1 3 Heavy Corrosion 0 0 23 1 2 WEST Procedi ESSren ra AEAEE asd E mate cig eae ae 24 11 2 1 Procedure for Battery Capacity Tests 24 11 3 Maintenance 5 25 255 55255 ye Ey EE EE AA 26 12 0 TEMPORARY NON USE EXTENDED OUTAGE 29 12 1 29 12 2 os sage eee ea ERNE SNES Peed ey aed 29 vi Publication No US VR OM 002 March 2008 www enersys com En er Power Full Solutions 1 0 GENERAL INFORMATION 1 1 Introduction EnerSys modular valve regulated lead acid VRLA batteries have unique features that make them easy to install and maintain These batteries are composed of absorbed glass mat AGM separators with flat plates and or gelled electrolyte with tubular positive plates The AGM retains the acid between the plates to ensure long float service In the case of gelled acid the acid is retained in a gel medium thus maximum contact with the plates ensures long float service in
9. 39 www enersys com 2008 EnerSys All rights reserved Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted Publication No US VR OM 002 March 2008 Subject to revisions without prior notice E amp O E
10. ATTERY LOCATION and or NUMBER No of CELLS TYPE DATE NEW jf DATE INSTALLED SERIAL SYSTEM VOLTAGE TEMPERATURE CHARGER VOLTAGE 20 CHARGER CURRENT Terminal Terminal Cell to Cell Cell to Cell Terminal Cell to Cell Cell to Cell Volts Connection Connection Volts Connection Resistance Resistance Resistance Resistance Resistance Resistance ey a a oe 1 2 2 So T eee 1 E ee ia SS gt r _ L ee ee ee 22 ae ee ee a SS eS T 8 ee 0 1 ees a 1 ee 2 ee ee eee ee U a l l e ee Le 1 eee ee a Se 27 82 61 eoue sisoy 195 03 180 2 jeujuuaL 5 03 18D 921233159 03
11. BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM Publication No US VR OM 002 1 March 2008 www enersys com Power Full Solutions 1 3 Service Should you require installation supervision service parts accessories or maintenance EnerSys has a nationwide service organization to assist with your new battery purchase Please call your nearest EnerSys sales service representative for more information or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service 2 Publication No US VR OM 002 www enersys com March 2008 En er Powers Full Solutions SAFETY FIRST DON T TAKE 2 0 SAFETY CHANCES 2 1 General PowerSafe valve regulated lead acid batteries are reduced maintenance batteries that oper ate on recombinant principles and are safer than conventional wet cell lead acid batteries Under NORMAL operating conditions and use their design features minimize hydrogen gas release e virtually eliminate acid misting e essentially eliminate leakage Under ABNORMAL operating conditions or as a result of damage abuse and or misuse the potentially hazardous conditions of hydrogen gassing acid misting and leakage may occur YOU SHOULD BE TRAINED IN HANDLING INSTALLING OPERATING AND MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM You MUST understand the risk of working with batteries and BE PREPARED and EQUIPPED to take the necessary safety p
12. Consult with the system equipment supplier to determine these parameters because battery performance is based on these values which are measured at the battery terminals Therefore ensure that the load cables e between the battery and its load are the shortest routing possible to the terminal allowing sufficient additional cable about 6 15 cm for connect disconnect e are the proper size to minimize the voltage drop between the battery output terminals and the load connected to the terminal plate NEVER connect the load cable s directly to the battery terminal 12 Publication No US VR OM 002 www enersys com March 2008 Ener 3 Solutions To select the proper cable size 1 Determine the cable size necessary to carry the design load 2 Calculate the voltage drop of the cable between the battery terminal plate and the operating equipment 3 Increase cable size to achieve the allowable voltage drop Cable selection should provide no greater voltage drop than required between the battery system and the operating equipment as determined by the equipment system supplier Excessive voltage drop will reduce the desired support time of the battery system 5 3 Considerations for Parallel Installation If it is necessary to connect the battery system in parallel to obtain sufficient capacity cable connections to each of the parallel strings are important If parallel connection is required do N
13. OT exceed five strings in parallel To obtain proper load sharing on the discharge satisfactory recharge and the same float volt age for each string cables from the batteries to the load must be e as short as possible equal to the longest intercell connector of equal lengths to the load e of sufficient ampacity cable ampacity should not be exceeded Publication No US VR OM 002 13 March 2008 www enersys com En er Power Full Solutions 6 0 UNPACKING AND HANDLING FOR INSTALLATION 6 1 General Battery modules are shipped upright on pallets All accessories for installation and use are supplied as optional prepackaged kits and are shipped on separate pallet s and or in box es Cells may be packed in wooden boxes which must be opened completely and carefully The cells must then be handled as described in the appropriate Installation Manual DO NOT lift any cell by the terminal posts as this will void the warranty When lifting large cells units with crane hoist or similar device use lifting belt s and protective styrofoam shipping cover s provided when applicable DO NOT attempt to remove the pressure relief valves or vent covers as this will void the warranty Attempted removal may also damage the vent and prevent proper functioning of the battery 6 2 Accessories CHECK accessory package with Packing List Bill of Material to ensure completeness VERIFY QUANTITY OF ITEMS WITH THE PACKING LIST DO NOT proceed wi
14. R OM 002 www enersys com March 2008 Ener Power Full Solutions K TABLE TABLE 11 1 Initial Temperature Publication No US VR OM 002 25 March 2008 www enersys com En er Power Full Solutions 11 3 Maintenance Records A complete recorded history of the battery operation is essential for obtaining satisfactory performance Good records will show when corrective action may be required to eliminate possible charging maintenance or environmental problems Should you have ANY questions concerning how to perform the required maintenance contact your nearest EnerSys sales service representative or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service Accumulate and permanently record the following data for review by supervisory personnel so that any necessary remedial action may be taken 1 Upon completion of the initial charge and with the battery on float charge at the proper voltage for one 1 week read and record the following e individual cell or unit voltages volts e cell to cell connection resistance ohms terminal connection resistance ohms ambient temperature in the immediate battery environment or C Some internal failure modes of cell types DDm mSeries DDS DDV and DGX cannot be detected by cell or unit voltage measurements IEEE 1188 1996 recommends taking an internal ohmic measurement of the cell unit at quarterly intervals These in
15. T WITH CLOTHING OR MATERIAL IMMEDIATELY 1 REMOVE CONTAMINATED CLOTHING 2 Apply a solution of sodium bicarbonate solution 1 0lb 1 Ogal or 0 5 kg 5 0 liters of water on the clothing or material 3 Apply the solution until bubbling stops then rinse with clean water NOTE case of a sulfuric acid SPILL bicarbonate of soda or an emergency spill kit should be within the battery room in accordance with OSHA regulations 1910 17802 4 Publication No US VR OM 002 www enersys com March 2008 Enersys 2 3 2 Explosive Gases Batteries can generate gases which when released can explode causing blindness and other serious personal injury Always wear protective clothing and use the correct safety tools Eliminate any potential of sparks flames or arcing 22 IN CASE OF FIRE To extinguish fire a battery room containing lead acid batteries use foam or dry chemical extinguishing medium Do NOT discharge the extinguisher directly onto the battery The resulting thermal shock may cause cracking of the battery case cover SPECIAL PROCEDURES If batteries are on charge shut off power Use positive pressure self contained breathing apparatus Wear acid resistant clothing Water applied to electrolyte generates heat and causes it to splatter TOXIC FUMES Burning plastic may cause toxic fumes Leave area as soon as possible if toxic fumes are present Wear breathing apparatus if req
16. amage Check material quantities received against the Bill of Lading including the number of battery pallets and the number of accessory boxes Note any damage to packing material e wetness or stains indicating electrolyte leakage If damage is noted 1 Make a descriptive notation on the delivery receipt before signing 2 Request an inspection by the carrier 3 File a damage report Publication No US VR OM 002 7 March 2008 www enersys com SSS En er Power Full Solutions 3 3 Concealed Damage Within 15 days of receipt unpack the cells batteries and check for concealed damage Remember you are handling a LIVE battery Take precaution against a shock hazard Follow all safety precautions as noted in Section 2 0 Note any e damage to packing material e wetness or stains indicating electrolyte leakage If damage is noted 1 Request an inspection by the carrier 2 File a concealed damage claim Check the received materials against the detailed packing list to verify receipt of all materials in the quantities specified For export the cells may be packed in wooden boxes which must be opened completely and carefully and the cells then handled as described hereafter See Section 6 for unpacking and handling DELAY IN NOTIFYING THE CARRIER MAY RESULT IN LOSS OF YOUR RIGHT TO REIMBURSEMENT FOR DAMAGES Refer to the Bill of Lading if when performing the parts inventory you are unsure about the appear
17. ance of a part If you have any questions concerning potential damages contact your nearest EnerSys sales service representative or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service 8 Publication No US VR OM 002 www enersys com March 2008 Solutions 4 0 BATTERY STORAGE BEFORE INSTALLATION 4 1 General Batteries should be unpacked installed and charged as soon as possible after receipt However if this is impractical follow the instructions below for storing the battery before installation 4 2 Storage Location 1 Store batteries indoors in a clean dry and cool location Storage at higher temperatures will result in accelerated rates of self discharge and possible deterioration of battery performance and life 2 Do NOT stack pallets DAMAGE MAY OCCUR AND THE WARRANTY MAY BE VOIDED 3 The maximum storage time from shipment to initial charge is six months for batteries stored at ambient temperatures no warmer than 77 F 25 C For storage temperatures greater than 77 F 25 C the battery must be recharged one 1 month sooner for every 3 C increase above 77 F 25 C See Table 4 1 TABLE 4 1 STORAGE TEMPERATURE STORAGE TIME 32 F 0 C to 50 F 10 C 9 months 51 F 11 C to 77 F 25 C 6 months 78 F 26 C to 92 F 33 C 3 months If storage time exceeds the storage time recommended Tab
18. ating life Lower temperatures reduce battery performance Minimize temperature variations between the cells To avoid temperature variation between the cells do NOT locate the battery near HVAC ducts or exhausts heats sources i e equipment that generates heat or direct sunlight Publication No US VR OM 002 March 2008 www enersys com Ener Solutions TABLE 5 1 continued CONSIDERATION RECOMMENDATION Ventilation No special battery room or ventilation is required However do NOT install in an airtight enclosure Grounding It is recommended that the modules or racks be grounded in accordance with NEC and or local codes Reasonably level Shimming up to 1 4 6mm maximum to level battery front to rear and side to side Capable of supporting the weight of the battery as well as any auxiliary equipment Anchoring All installations should be floor anchored Anchoring should meet all local state federal codes and industry standards Floor anchoring and its design are the responsibility of the installer Ensure seismic requirements are considered Proximity to PowerSafe VRLA batteries may be installed next to electronic Electronic Equipment equipment unless it generates heat 5 2 Considerations for Connecting the Battery System to Operating Equipment The battery has been sized based on a specific load amps or KW for a specific run time to a specific end voltage
19. cells may result from e low float voltage due to improper adjustment of the charger apanel voltmeter that reads high resulting in a low charger output voltage e selection of too low a float voltage e variations in cell temperatures in the series at a given time due to environmental conditions or module arrangement The maximum cell to cell temperature difference is 5 F 3 C If cell temperature is the problem review the location instructions in Section 5 0 to ensure proper location of the battery system An equalizing charge should be given when e the float voltage of any cell is less than 2 17 volts per cell e the float voltage range after six months is OUTSIDE the 0 08 volts of the nominal setting Do NOT equalize DDS DDm DDV mSeries and SC type cells if they are within the following voltage limits 0 09 volts of the nominal value as determined in Section 8 2 1 Procedure No 1 After one year 0 05 volts of the nominal value as determined in Section 8 2 1 Procedure No 1 Do NOT equalize DGX type cells if they are within the following voltage limits New 0 13 volts of the nominal value as determined in Section 8 2 1 Procedure No 1 After six months 0 08 volts of the nominal value as determined in Section 8 2 1 Procedure No 1 After one year 0 06 volts of the nominal value as determined in Section 8 2 1 Procedure No 1 20 Publication No US VR OM 002 www enersys com March 2008 8 3 1 Equal
20. cycling applications Furthermore the tubular positive plate design holds the active material in position providing excellent high cycling ability 1200 cycles to 80 DOD Both utilize gas recombinant technology to minimize maintenance PowerSafe batteries utilize calcium alloy grids NO cadmium which float at a lower current than antimony Sb Lower float currents in conjunction with superior and uniform thermal management reduce the chances of thermal runaway Temperature compensation chargers are also recommended PowerSafe VRLA batteries typically do not require special battery rooms because excess hydro gen is not emitted under normal operating conditions In addition the modules make installation fast and easy 1 2 Precautions BEFORE UNPACKING STORING HANDLING INSTALLING OPERATING OR PERFORMING MAINTENANCE ON THE ENERSYS VRLA BATTERY SYSTEM READ THE FOLLOWING INFORMATION THOROUGHLY It is important to read understand and strictly follow the instructions in this manual If the following precautions are not fully understood or if local conditions are not covered contact your nearest EnerSys sales service representative for clarification or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service Also refer to all applicable federal state and local regulations and industry standards YOU SHOULD BE TRAINED IN HANDLING INSTALLING OPERATING AND MAINTAINING
21. e described in IEEE std 1188 An equalizing charge as described in Section 8 3 must have been given within the last 7 days Battery should be returned to float for 7 days before the test 1 2 24 Make sure all battery connections are clean tight and free of corrosion While the battery is on float read and record voltage of each cell temperature of at least every tenth cell and battery terminal float voltage Disconnect the battery charger Select the discharge rate based upon the critical load and time period The test discharge current is equal to the rated discharge current divided by the K Factor see Table 11 1 for the initial battery temperature With the variable load bank having an ammeter in series and a voltmeter across the battery terminals connect the load simultaneously starting the timing device Maintain the correct current while periodically reading and recording total battery voltage When the minimum total voltage has been reached it is desirable to read and record each cell voltage including an intercell connector Observe the battery for intercell connector heating Calculate the capacity using the following formula Capacity at 77 F 25 C 100 5 Where test discharge time to specified voltage Where Ts rated discharge time to specified voltage Recharge the battery preferably using an equalizing charge Section 8 3 to minimize the recharge time Publication No US V
22. ed load Adjust the charger to provide the recommended float voltage at the battery terminals Do NOT use float voltages HIGHER or LOWER than those recommended Otherwise reduced battery life or reduced capacity will result Check and record battery terminal voltage monthly for accurate calibration If the VOLTS PER CELL average voltage is above or below the range recommended Procedure 1 adjust the charger to provide proper voltage as measured at the battery terminals When the mSeries DDm DDS DDV and SC type cells are new expect to see variations in float voltage from cell to cell within a string These cell voltages should be within 0 09 volts of the nominal setting After one year in service the mSeries DDm DDS and DDV type cells will float within 0 05 volts of the nominal setting When the DGX type cells are new expect to see variations in float voltage from cell to cell within a string within 0 13 volts of the nominal setting After six months in service the cells will float within 0 08 volts and after one year 0 06 volts of the nominal setting Publication No US VR OM 002 19 March 2008 www enersys com Powerfull Solutions 8 3 Equalizing Charge Under NORMAL conditions an equalizing charge is NOT required An equalizing charge is a special charge given to a battery when nonuniformity in voltage has developed between cells It is given to restore all cells to a fully charged condition Nonuniformity of
23. ff any accumulation of dust on the cell covers with a cloth dampened in clean water WARNING Do NOT use any type of oil solvent detergent petroleum based solvent or ammonia solution to clean the jars or covers These materials will have an adverse affect and cause permanent damage to the battery jar and cover and will void the warranty 22 Publication No US VR OM 002 www enersys com March 2008 Enersys Solutions 11 1 2 Battery Taps To clean mild corrosion from the battery 1 Disconnect the battery 2 Remove corrosion by wiping with a cloth dampened with bicarbonate of soda solution mix 1 gallon 41 of water with 1 5000 of bicarbonate of soda Follow with a cloth dampened with clear water 3 Dry with aclean cloth 4 With asmall paintbrush apply a light coat of heated NO OX ID grease to the entire bolted connection NOTE If optional catalyst vents are used no cleaner of any kind other than water may be used on the vent caps Use of cleaners other than water may reduce or completely remove the effectiveness of the vents 11 1 3 Corrosion Cleaning If routine cleaning of the bolted connections has been neglected heavy post corrosion may occur This will require a major cell post cleaning job requiring the unbolting and removing of the connectors The performance of the battery under load could be adversely affected and this condition could present a safety hazard
24. gh channels in accordance with local state and federal regulations Publication No US VR OM 002 www enersys com March 2008 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for PowerSafe mSeries Lead Acid Battery Systems that should be followed during the installation and maintenance of the battery system Only a qualified EnerSys service representative who is knowledgeable in batteries and the required precautions should perform servicing of the batteries Keep unauthorized personnel away from batteries Misuse of this equipment could result in human injury and equipment damage event will EnerSys be responsible or liable for either indirect or consequential damage or injury that may result from the use of this equipment CAUTION Do not dispose of the batteries in a fire The batteries may CAUTION explode Do not open or mutilate the batteries Released electrolyte is CAUTION harmful to the eyes and skin and may also be toxic This unit contains sealed lead acid batteries Lack of preventative WARNING Maintenance could result in batteries exploding and emitting gasses and or flame An authorized trained technician must perform annual preventative maintenance Failure to replace a battery before it becomes exhausted may WARNING 22056 the case to crack possibly releasing electrolyte from inside the battery and resulting in secondary faults such as odor smoke
25. ightning bolt mark enclosed in a triangle The danger symbol is used to indicate imminently hazardous situations locations and conditions which if not avoided WILL result in death serious injury and or severe property damage The warning symbol is an exclamation mark in triangle The warning symbol is used to indicate potentially hazardous situations and conditions which if not avoided COULD result in serious injury or death Severe property damage COULD also occur The caution symbol is an exclamation mark enclosed a triangle The caution symbol is used to indicate potentially hazardous situations and conditions which if not avoided may result in injury Equipment damage may also occur Other warning symbols may appear along with the Danger and Caution symbol and are used to specify special hazards These warnings describe particular areas where special care and or procedures are required in order to prevent serious injury and possible death Electrical warnings Explosion F warnings Publication No US VR OM 002 March 2008 The electrical warning symbol is a lightning bolt mark enclosed in a triangle The electrical warning symbol is used to indicate high voltage locations and conditions which may cause serious injury or death if the proper precautions are not observed The explosion warning symbol is an explosion mark enclosed in a triangle The explosion warning symbol is used to indicate locations and conditions
26. izing Charge Method Ener 4 Solutions Constant voltage charging is the method for giving an equalizing charge To perform equalizing charge follow the procedure below 1 Determine the maximum voltage that may be applied to the system equipment 2 Divide this voltage by the number of cells connected in a series This is the MAXIMUM VOLTS PER CELL to be used for the equalizing charge This number should NOT exceed 2 35 VOLTS PER CELL average 3 Use Table 8 2 to determine the equalize charge time The times listed are the number of hours to charge the battery system AFTER the charge current has been stabilized for three hours Stabilization occurs when the current level remains constant for three hours TABLE 8 2 TIME hours AFTER CURRENT STABILIZATION 3 hours without change AT AMBIENT TEMPERATURES FROM 70 90 F 21 32 C TIME hours AFTER CURRENT STABILIZATION 3 hours without change AT AMBIENT TEMPERATURES FROM 55 69 F 13 20 48 24 CAUTION During charge if the cell battery temperature exceeds 105 F 40 C stop the charge immediately and allow the temperature to decrease below 90 F 32 C Failure to follow this warning may result in severe overcharge and damage to the cell battery Publication No US VR OM 002 March 2008 www enersys com 21 Powerfull Solutions 9 0 BATTERY TAPS Connections made to a battery for tapping a ce
27. le 4 1 give the battery freshening charge before the end of the recommended storage interval See Section 7 for charging information PowerSafe VRLA mSeries DDm DDS and DDV batteries must be charged in the horizontal position Charging in the vertical position could void the warranty 4 Repeat the freshening charge for each additional storage interval until the battery is installed Storage at higher temperatures will result in accelerated rates of self discharge and possible deterioration of battery performance and life Storage times exceeding the above may result in plate sulfation which may adversely affect electrical performance and expected life 5 Maximum total storage time prior to installation is two 2 years from date of shipment from the factory to the customer Freshening charges are required before the end of the storage time period or more frequently as noted in Table 4 1 6 FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY S WARRANTY Publication No US VR OM 002 9 March 2008 www enersys com Power Full Solutions 4 3 Advanced Preparation If storage time is likely to be exceeded make advance preparation to have an adequate charger available and adjacent to an appropriate AC supply voltage Positioning of the cells to accept temporary intercell connectors is another consideration of advance planning Keep cells on styrofoam pads until the cells are installed on the rack when applicable Make every effort t
28. lts per cell Table 7 1 lists recommended initial charge voltages per cell and charge time for the initial charge Select the HIGHEST voltage the system allows for the initial charge without exceeding 2 35 volts per cell 16 TABLE 7 1 CELL VOLTS TIME Hours TIME Hours TIME Hours Initial Charge Temp 60 90 F Temp 40 59 Temp lt 39 F 16 32 5 15 lt 4 2 27 60 120 240 2 30 48 96 192 2 32 48 96 2 35 24 48 Connect battery positive terminal to charger bus positive terminal Connect battery negative terminal to charger bus negative terminal Raise the voltage to the maximum value permitted by the equipment as shown in Table 7 1 Do NOT exceed 2 35 volts under any conditions When charging current has decreased and stabilized i e no further reduction for three hours charge for the hours shown in Table 7 1 or until the lowest cell voltage ceases to rise CAUTION Monitor the battery temperature during the charge If the cell battery temperature exceeds 105 40 C stop the charge immediately and allow the temperature to decrease below 90 F 32 C Failure to follow this warning may result in severe overcharge and damage to the cell battery Publication No US VR OM 002 www enersys com March 2008 En er Power Full Solutions 8 0 OPERATION 8 1 General The sealed design of the VRLA batteries makes it impossible to mea
29. nN PowerSafe Safety Storage Operating and Maintenance Manual VRLA Battery Systems mSeries DDm DDS DGX DDV and SC Power Full Solutions Publication No US VR OM 002 March 2008 N PowerSafe Safety Storage Operating and Maintenance Manual VRLA Battery Systems mSeries DDm DDS DGX DDV and SC When working with any EnerSys Modular Battery System be sure to refer to the Installation Manual specified for that system and Rack Assembly Instructions included in the rack shipment Publication US VR OM 002 March 2008 En er Full Solutions This manual provides full instructions regarding safety storage operation and maintenance for EnerSys valve regulated lead acid batteries as well as certain installation considerations maximize safety and performance read the accompanying Installation Manual thoroughly Failure to observe the precautions as presented may result in injury or loss of life 2008 by EnerSys All rights reserved This document is proprietary to EnerSys This document cannot be copied or reproduced in whole or in part without the express written permission of EnerSys Please check our website for literature updates www enersys com Publication No US VR OM 002 www enersys com March 2008 GENERAL SAFETY INSTRUCTIONS Warnings in this manual appear in any of three ways Danger Warning Caution The danger symbol is a l
30. o get the battery connected to the charger before expiration of the storage period thereby avoiding the additional labor cost of preliminary freshening charges WARNING Failure To Charge As Noted Voids The Battery s Warranty 10 Publication No US VR OM 002 www enersys com March 2008 Enersys Solutions BEFORE INSTALLATION READ THIS SECTION THOROUGHLY 5 0 INSTALLATION CONSIDERATIONS 5 1 General If you have any questions concerning the installation considerations contact your EnerSys sales service representative for clarification or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service When planning the system space requirements consider the following space e ventilation environment e battery system configuration e temperature e floor loading distance from operating equipment floor anchoring Table 5 1 will assist you to ensure that all requirements for installation location are considered TABLE 5 1 CONSIDERATION RECOMMENDATION Space Aisle space should be in accordance with the National Electric Code NEC Article 110 16 or local codes Clearance from wall equipment 4 10 cm minimum Environment Clean cool and dry The location should be selected to keep water oil and dirt away from all cells Temperature Ambient temperature between 72 78 F 23 26 C Elevated temperatures reduce oper
31. recautions If not contact EnerSys Reserve Power Service 2 1 Safety Equipment and Clothing When working with any battery system be sure you have the necessary tools and safety equipment including but not limited to e insulated tools e rubber apron e face shields e rubber gloves e safety goggles emergency eye wash e fire extinguisher e acid spill cleanup kit e and shower if available ALWAYS remove all jewelry rings watches chains etc e keep sparks flames and smoking materials away from the battery NEVER lay tools or other metallic objects on the battery modules Using the correct tools and wearing proper safety equipment will help prevent injury should an accident occur Publication No US VR OM 002 3 March 2008 www enersys com Power Full Solutions 2 3 Safety Precautions 2 3 1 Sulfuric Acid Burns Because VRLA cells are sealed they normally do not present an acid danger However they do contain sulfuric acid which can cause burns other serious injuries Always wear protective clothing AND use the correct safety tools gt In case of SKIN CONTACT with sulfuric acid IMMEDIATELY 1 REMOVE contaminated CLOTHING 2 FLUSH the area THOROUGHLY with WATER 3 Get MEDICAL ATTENTION if required In case of EYE CONTACT with sulfuric acid IMMEDIATELY 1 FLUSH THOROUGHLY for at least 15 minutes with large amounts of WATER 2 Get MEDICAL ATTENTION In case of sulfuric acid CONTAC
32. rtain group of cells to provide a voltage other than the total battery voltage is NOT recommended and can void the warranty Tapping results in an imbalance of the system during charging and discharging causing unsatisfactory operation 10 0 PILOT CELL One cell in a battery is usually selected as a pilot cell becomes an indicator of the general condition of the entire battery with regard to voltage gravity and temperature Designate as the pilot cell the cell with the lowest cell voltage in the series string following the initial charge Pilot cell readings serve as an interim indicator between regularly scheduled voltage and gravity readings of the complete battery The temperature sensor should be connected to the negative post of the pilot cell Read and record the pilot cell voltage on a monthly basis between regularly scheduled individual cell readings 11 0 MAINTENANCE Batteries lose some initial charge during shipment and storage Depending on storage time a battery may require a freshening charge See Section 4 0 for battery storage times 11 1 Battery Cleaning Observe the battery for cleanliness at regular intervals Keep cell terminals and connectors free of corrosion Terminal corrosion could adversely affect the performance of the battery and it could present a safety hazard 11 1 1 Standard Cleaning To perform a standard cleaning of the battery follow the procedures below 1 Disconnect the battery 2 Wipe o
33. sure specific gravity asa state of charge indicator The state of charge can be identified to some degree by the amount of charging current going to the battery exceeding 2 35 volts per cell 8 1 1 Determining the State of Charge The following method can be used to determine the state of charge of the battery 1 Place the battery on charge recharge following a discharge Read the ammeter The charging current will be a combination of the load current plus the current necessary to charge the battery 2 The battery becomes fully charged when the current to the battery starts to decrease and stabilize 3 When the current level remains constant for three consecutive hours the state of charge is approximately 95 to 98 Full charge can be assumed For most requirements the battery is ready for use NOTE Optional catalyst vents may be used on mSeries and DDM cells A White paper discussion about the use of catalyst vents can be found on the EnerSys website at www enersys com Publication No US VR OM 002 17 March 2008 www enersys com Power Full Solutions 8 2 Float Operation In this type of operation the battery and the critical load circuits are continuously connected in parallel with a constant voltage charger The charger should be capable of e charging the battery from the discharged condition while supplying the DC power to the connected DC load providing the required constant float voltage e pro
34. ternal ohmic measurements when compared with baseline value or the average value may indicate the beginning of a problem inside the cell Then corrective actions can be taken to avoid a battery system failure EnerSys recommends that you follow IEEE 1188 standards for internal ohmic measurements for VRLA cell types 2 Every 12 months read and record the following e individual cell or unit voltages volts e cell to cell connection resistance ohms e terminal connection resistance ohms e ambient temperature the immediate battery environment or Any connection resistance that exceeds the base value by more than 20 should be corrected by the procedures of Section 11 3 If corrosion is present the connections clean according to Section 11 1 4 Whenever the battery is given an equalizing charge an additional set of readings should be taken and recorded THE ABOVE FREQUENCY OF RECORD TAKING IS THE ABSOLUTE MINIMUM TO PROTECT THE WARRANTY This data will be required for any warranty claim made on the battery For system protection and to suit local conditions requirements more frequent readings quarterly are desirable Sample record charts are provided on the following pages Make a copy of the chart to use for your permanent records 26 Publication No US VR OM 002 www enersys com March 2008 BATTERY MAINTENANCE REPORT DDm DDS DDV mSeries and SC COMPANY DATE PAGE 1 of ADDRESS B
35. th installation until all accessory parts are available Accessories are packed in a separate carton and may include but are not limited to the following TABLE 6 1 ACCESSORIES CHECK IF RECEIVED Connector Hardware in a plastic bag Intercell Connectors Nuts Bolts e Washers Lifting Straps Lifting Platform Height adjustable lifting platform for supporting cells at module level Base beams Terminal Plate Kits Terminal Plate Connectors Cell Number Set Mounting Hardware Miscellaneous Brackets Specialty Items Rack NO OX ID Grease Rack Assembly Instructions Assembly Drawing Bill of Materials Installation Manual 14 Publication No US VR OM 002 www enersys com March 2008 6 3 Recommended Installation Equipment and Supplies Power Full Solutions Before working with the battery system be sure that you have the proper protective clothing safety equipment and insulated tools as specified in Section 2 0 The following is a list of equipment typically recommended for installation of a PowerSafe VRLA Battery System TABLE 6 2 EQUIPMENT RECOMMENDED CHECK IF ON HAND Forklift or Portable Lift Crane Chalk Line Torpedo Level Plastic Torque Wrench 10 200 in Ibs Torque Wrench 50 100 ft lbs Floor Anchors User supplied per battery system and stress analysis Floor Shims User supplied
36. the system an increased shock hazard exists between the terminal of opposite polarity and ground If a second unintentional ground develops within the already unintentionally grounded system a short circuit may occur and cause explosion or fire gt gt Therefore should you be required to work on a grounded battery system make absolutely sure you use the correct safety precautions equipment and clothing IMPORTANT If you have ANY questions concerning safety when working with the battery system contact your nearest EnerSys sales service representative to clarify any of the noted safety precautions or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service 6 Publication No US VR OM 002 www enersys com March 2008 En Power Full Solutions 3 0 INSPECTING THE BATTERY SHIPMENT 3 1 General Precautions have been taken to pack the battery units individual cells or cabinets containing batteries for shipment to ensure their safe arrival However upon receipt you should inspect for evidence of damage that may have occurred during transit WARNING During inspections take precautions against electrical shock You are handling LIVE batteries 3 2 Visable External Damage IMMEDIATELY upon delivery while the carrier representative is still on site inventory all materials against the Bill of Lading and inspect for visible external d
37. uired to remain in the area 2 3 3 Electrical Shocks and Burns Multi cell battery systems can attain high voltage and or currents Do NOT touch uninsulated batteries connectors or terminals To prevent serious electrical burns and shock use EXTREME CAUTION when working with the system Always wear protective clothing and use nonconductive or insulated safety tools when working with ANY battery system Remove all jewelry that could produce a short circuit BEFORE working on the system 1 Disconnect ALL loads and power sources to the battery Use appropriate lockout tagout procedures 2 If working an assembled battery system sectionalize interrupt the battery sections into safe working voltage levels 3 Check the battery system grounding Grounding of the battery system is NOT recommended However grounding of the rack is recommended Publication No US VR OM 002 5 March 2008 www enersys com Ener 4 Solutions IF BATTERY SYSTEM IS GROUNDED system is intentionally grounded by connecting battery terminal to ground 1 increased shock hazard exists between the terminal of opposite polarity and ground i e dirt and acid on top of battery cell touching rack If an unintentional ground develops within the already grounded system a short circuit may occur and cause explosion or fire gt gt IF BATTERY SYSTEM IS GROUNDED 1 unintentional ground develops within
38. viding voltage for equalizing the battery It is highly recommended that the battery be charged with a temperature compensated charger with adjustment as stated in Table 8 1 If a temperature compensated charger is not used manual adjustments must be made according to Table 8 1 TABLE 8 1 AVERAGE AMBIENT TEMPERATURE RECOMMENDED FLOAT VOLTAGE 1 VOLTS CELL 25 2 33 Float voltage sustains the battery in a fully charged condition and makes it available to assume the emergency power requirements in the event of an AC power interruption or charger failure Constant voltage output charging equipment is recommended This type of charger properly adjusted to the recommended float voltages and the following recommended surveillance procedures will assist in obtaining consistent serviceability and optimum life 18 Publication No US VR OM 002 www enersys com March 2008 8 2 1 Enersys Solutions Float Charge Method A float charge is given after the battery has been given its initial charge To perform a float charge follow the procedure below after the battery has been given its initial charge 1 Determine that the VOLTS PER CELL nominal value is within the 2 23 to 2 27 range This can be done by measuring the total battery string voltage and dividing by the number of cells in the string Make sure the voltage does NOT exceed the maximum voltage for the connect
39. where molten exploding parts may cause serious injury or death if the proper precautions are not observed www enersys com IMPORTANT SAFETY INSTRUCTIONS DANGER A battery can present a risk of electrical shock and high short circuit current The following precautions should be observed when working with batteries 1 10 11 Verify that the Uninterruptible Power Supply UPS is and that power cord is disconnected from the power source Remove watches rings or other metal objects Use tools with insulated handles to prevent inadvertant shorts Wear rubber gloves and boots Do not lay tools or metal parts on top of batteries Determine if the battery is inadvertently grounded If inadvertently grounded remove source of ground Contact with any part of a grounded battery can result in electrical shock The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance Verify circuit polarities before making connections Disconnect charging source and load before connecting or disconnecting terminals Valve regulated lead acid VRLA batteries contain an explosive mixture of hydrogen gas Do not smoke cause a flame or spark in the immediate area of the batteries This includes static electricity from the body Use proper lifting means when moving batteries and wear all appropriate safety clothing and equipment Do not dispose of lead acid batteries except throu
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