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SeaBattery™ User's Guide

1. Components Density Melting Solubility Odor Appearance Points H20 Lead 11 34 621 F None None Silver Gray Lead Sulfate 6 20 1950 F 40mg l 60 F None White Powder Lead Dioxide 9 40 554 F None None Brown Powder Sulfuric Acid About 1 30 203 240 F 100 Sharp penetrating Clear Colorless pungent Liquid Fiberglass Separator N A N A Slight None White Fibrous Case Material Acrylonitrile Butadine N A N A None None Solid Styrene ABS Continued on next page Power Sonic MSDS Page 2 of 6 Section 4 Flammability Data Components Flashpoint Explosive Comments Limit Lead and Sulfuric Acid None None None Hydrogen LEL 4 1 Sealed batteries can emit hydrogen if overcharged float voltage gt 2 40 VPC Fiberglass Separator N A N A Toxic vapors may be released In case of fire wear self contained breathing apparatus Acrylonitrile Butadine Styrene ABS None N A Temp over 527 F 300 C may release combustible gases In case of fire wear self contained breathing apparatus Section 5 Reactivity Data Stability Unstable Conditions to Avoid Stable x Prolonged overcharge on high current ignition sources Sulfuric acid remains stable at all temperatures Incompatibility Materials to Avoid Sulfuric acid Contact with combustibles and organic materials may cause fire and explosion Also reacts violently with strong reducing agents metals sulfur trio
2. Nominal Voltage Minimal Voltage 48 36 24 18 12 9 6 4 5 Complete discharge is not advised but batteries can usually be recovered by using a special charging 3 rev 07242009 procedure If the battery is completely discharged and will not accept a charge try initializing the charge with a higher voltage to induce current flow When current is flowing reduce the voltage Refer to the Recharge Methods technical notes located in Appendix B The SeaBattery Power Module may produce a small amount of gas in the discharge cycle especially during rapid discharge Before use purge any significant bubbles from the SeaBattery Power Module case A small amount of gas trapped under the diaphragm will not cause a problem it will go into solution under pressure and the flexibility of the diaphragm allows for limited expansion and contraction of volume When the SeaBattery Power Module is brought to the surface the depressurization will cause the compensating oil to foam This is normal and will form into a single bubble within about an hour after which it should be purged See Venting above CAUTION The SeaBattery Power Module is capable of discharging very high currents and must not be shorted Cables and connectors can quickly be destroyed by the high current resulting from a short circuit INSPECTION The diaphragm should be filled so that the top of the urethane diaphragm is approximately 1 3 8 1 1 2 below the top of the bo
3. Important Do s and Don ts Handling Installation Charging We ve Got The Power Features of Power Sonic Sealed Lead Acid Batteries Sealed Maintenance Free The valve regulated spill proof construction allows trouble free safe operation in any position There is no need to add electrolyte as gases generated during the charge phase are recombined in a unique oxygen cycle Power Sonic sealed lead acid batteries can be operated in virtually any orientation without the loss of capacity or electrolyte leakage However upside down operation is not recommended Long Shelf Life A low self discharge rate up to approximately 3 per month may allow storage of fully charged batteries for up to a year depending on storage temperatures before charging becomes critical However we strongly recommend that all batteries should be recharged within six months of receipt as it will enhance their long term life Please refer to this Technical Manual and individual battery specification sheets for more details Design Flexibility Same model batteries may be used in series and or parallel to obtain choice of voltage and capacity The same battery may be used in either cyclic or standby applications Over 80 models available to choose from Deep Discharge Recovery Special separators advanced plate composition and a carefully balanced electrolyte system ensure that the battery has the ability to recover from excessively
4. When using a taper current charger the charger time should be limited or a charging cut off circuit be incorporated to prevent overcharge Please contact our technical department if you need assistance with this In a taper current charging circuit the current decreases in proportion to the voltage rise When designing a taper charger always consider power voltage fluctuations In this event the internal resistance drop will convert to heat Heat generated by the circuit should be measured and if required a heat sink should be incorporated in the design D R O Figure 17 Taper current charging circuit Charge Current Battery Voltage Charger Current Battery Voltage Charge Time Figure 18 Taper current charging characteristics for this type of basically unregulated charger POWER SONIC Rechargeable Batteries 15 Overcharging As a result of too high a charge voltage excessive current will flow into the battery after reaching full charge causing decomposition of water in the electrolyte and premature aging At high rates of overcharge a battery will progressively heat up As it gets hotter it will accept more current heating up even further This is called thermal runaway and it can destroy a battery in as little as a few hours Undercharging If too low a charge voltage is applied the current flow will essentially stop before the battery is fully charged This allows some of the lead sulfate to remain
5. as hazardous waste Do not discharge acid to sewer Waste Disposal Method Spent Batteries send to secondary lead smelter for recycling Follow applicable federal state and local regulations Neutralize as in preceding step Collect neutralized material in sealed container and handle as hazardous waste as applicable A copy of this MSDS must be supplied to any scrap dealer or secondary lead smelter with the battery Precautions to be Taken in Handling and Storing Store batteries in a cool dry well ventilated area that are separated from incompatible materials and any activities which may generate flames sparks or heat Keep all metallic articles that could contact the negative and positive terminals on a battery and create a short circuit condition Electrical Safety Due to the battery s low internal resistance and high power density high levels of short circuit current can be developed across the battery terminals Do not rest tools or cables on the battery Use insulated tools only Follow all installation instructions and diagrams when installing or maintaining battery systems Fiberglass Separator Fiberglass is an irritant to the upper respiratory tract skin and eyes For exposure up to 10F use MSA Comfoll with type H filter Above 10F use Ultra Twin with type H filter This product is not considered carcinogenic by NTP or OSHA Section 8 Control Measures Respiratory Protection None required un
6. necessary to set the charge voltage according to specified charge and temperature characteristics Inaccurate voltage settings cause over or under charge This charging method can be used for both cyclic and standby applications BATT LOAD Figure 15 Constant voltage charging circuit Charge Current m o ao 22 90 25 amp 2 En 26 Battery Voltage p hh Charge Time Figure 16 Constant voltage charging characteristics 14 We ve Got The Power Constant Current Charging Constant current charging is suited for applications where discharged ampere hours of the preceding discharge cycle are known Charge time and charge quantity can easily be calculated however an expensive circuit is necessary to obtain a highly accurate constant current Monitoring of charge voltage or limiting of charge time is necessary to avoid excessive overcharge While this charging method is very effective for recovering the capacity of a battery that has been stored for an extended period of time or for occasional overcharging to equalize cell capacities it lacks specific properties required in today s electronic environment Taper Current Charging This method is not recommended as it is somewhat abusive of sealed lead acid batteries and can shorten service life However because of the simplicity of the circuit and low cost taper current charging is extensively used to charge multiple numbers and or for cyclic charging
7. C amperes 16 We ve Got The Power Two Step Constant Voltage Charging This method uses two constant voltage devices In the initial charge phase the high voltage setting is used When charging is nearly complete and the charge voltage has risen to a specified value with the charge current decreased the charger switches the voltage to the lower setting This method allows rapid charging in cycle or float service without the possibility of overcharging even after extended charging periods Temperature compensated Select Rs to give correct float voltage 2 275 Vicell at desired min current 0 6 R3 Imax 2 for float applications Select Risw to turn on Q2 at desired current Isw Risw 0 6 2 45 Vicell for cyclic applications Figure 19 Dual stage current limited battery charger Charge Current oc D o S 5 So D0 82 so 00 5 Battery Voltage p Charge Time Figure 20 Two step constant voltage charging characteristics Charging in Series Lead acid batteries are strings of 2 volt cells connected in series commonly 2 3 4 or 6 cells per battery Strings of Povver Sonic batteries up to 48 volts and higher may be charged in series safely and efficiently However as the number of batteries in series increases so does the possibility of slight differences in capacity These differences can result from age storage history temperature variations or abuse Fully charged batteries sho
8. Must supply two positive charges electrons and is and lead electrode left positive is left negative H SO Figure 1 Chemical reaction when a battery is being discharged Charge During the recharge phase of the reaction the cycle is reversed The lead sulfate PbSO and water are electrochemically converted to lead Pb lead dioxide PbO and sulfuric acid 2H SO by an external electrical charging source With energy from the charging battery the lead sulfate is broken down and with oxygen from ionized water lead oxide is deposited on the positive electrode and lead is deposited on the negative electrode H SO H O Figure 2 Chemical reaction when a battery is being charged POWER SONIC Rechargeable Batteries 3 Theory of Operation Oxygen Recombination To produce a truly maintenance free battery it is necessary that gases generated during overcharge are recombined in a so called oxygen cycle Should oxygen and hydrogen escape a gradual drying out would occur eventually affecting capacity and battery life During charge oxygen is generated at the positive and reacts with and partially discharges the sponge lead of the negative As charging continues the oxygen recombines with the hydrogen being generated by the negative forming water The water content of the electrolyte thus remains unchanged unless the charging rate is too high In case of rapid generation of oxygen exceeding the absorbing capacit
9. Service Life The expected life of a battery expressed in the number of total cycles or years of standby service to a designated remaining percentage of original capacity Shelf Life The maximum period of time a battery can be stored without supplementary charging Standby Service An application in which the battery is maintained in a fully charged condition by trickle or float charging State of Charge The available capacity of a battery at a given time expressed as a percentage of rated capacity Sulfation The formation or deposit of lead sulfate on the surface and in the pores of the active material of the batteries lead plates If the sulfation becomes excessive and forms large crystals on the plates the battery will not operate efficiently and may not work at all Thermal Runaway A condition in which a cell or battery on constant potential charge can destroy itself through internal heat generation Valve Regulated Lead Acid Battery VRLA See SLA Battery listed above POWER SONIC Rechargeable Batteries EN Mp We employ IQC PQC and ISO 9001 Quality Management Systems to test materials monitor manufacturing processes and evaluate finished products prior to MH20845 shipment All our batteries are 100 tested with advanced Certificate of UL Certificate of IS09001 computer equipment prior to being released for sale Power Sonic management and staff are committed Our batteries are manufactured to i
10. Special characteristics or information No special characteristics listed for this product Superlinear XL 0370 5634 Orange Page 2 of 4 8 2 Engineering Controls Localized ventilation is recommended 8 3 Personal Protective Equipment Eyes Face Safety Glasses Hands Cotton Gloves for handling molten plastic Skin Protective clothing for contact with molten plastic Respirator NIOSH approved respirator for dust generation from normal processing operations Hygiene Wash thoroughly after handling and before eating or drinking SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES Physical Condition Solid Pellet Odor Odorless at ambient temperature Characteristic plastic odor during heating Flash Point Over 400 F Flammability solid gaseous Not reasonably applicable Minimum limit of Explosion Not reasonably applicable Maximum limit of Explosion Not reasonably applicable Vapor Pressure Not reasonably applicable Relative density 0 5 1 5 g ml Bulk density No data available Water solubility Insoluble pH Value Not reasonably aplicable VOC Content Less than 5 parts per million SECTION 10 STABILITY AND REACTIVITY This product is stable and non reactive Hazardous decomposition of products can occur if overheated or ignited SECTION 11 TOXICOLOGICAL INFORMATION Based on our experience and the information available no adverse health effects are expected if handled as recommended with suitable precautions for designat
11. accepted by the battery drops to less than 0 01 x C amps 1 of rated capacity the battery is fully charged and the charger should be disconnected or switched to a float voltage of 2 25 to 2 30 volts cell The voltage should not be allowed to rise above 2 45 0 05 volts cell Charging for Standby Operation Standby applications generally do not require that the battery be charged as fast or as frequently as in cycle operation However the battery must be kept constantly charged to replace the energy that is expended due to internal loss and deterioration of the battery itself Although these losses are very low in Power Sonic batteries they must be replaced at the rate the battery self discharges at the same time the battery must not be given more than these losses or it will be overcharged To accomplish this a constant voltage method of charging called float charging is used The recommended constant float voltage is 2 25 2 30 volts per cell Maintaining this float voltage will allow the battery to define its own current level and remain fully charged without having to disconnect the charger from the battery The trickle current for a fully charged battery floating at the recommended charge voltage will typically hover around the 0 001C rate LOmA for a 10AH battery for example The float charger is basically a constant voltage power supply As in cycle chargers care must be exercised not to exceed the initial charge current of 0 30 x
12. at the 20 hour rate 0 05C At any ambient temperature the higher the rate of discharge the lower the available capacity This relationship is shown in Figure 6 120 110 80 60 40 Capacity Ratio 20 0 40 30 20 10 0 10 20 30 40 50 60 Temperature C Figure 6 Effect of Temperature on Capacity Power Sonic batteries may be discharged at temperatures ranging from 40 C to 60 C 40 F to 140 F and charged at temperatures from 20 C to 50 C 4 F to 122 F While raising ambient temperature increases capacity it also decreases useful service life It is estimated that battery life is halved for each 10 C 18 F above normal room temperature N Final Voltage 1 75 VICell 1 70 wicell NS C Rated Capacity Discharge Time 1 50 V Cell NN 40 104 F 1 35 ViCell 20 C 68 F 0 C 32 F 0 05C 0 1C 0 2C 0 5C 1C 2C Discharge Current A Figure 7 Relationship between current and discharge time for different ambient temperatures POWER SONIC Rechargeable Batteries 9 Performance Data Shelf Life amp Storage Low internal resistance and special alloys in the electrodes assure a low self discharge rate and consequently a long shelf life If kept at 20 C 68 F about 60 70 of the nominal capacity remains after one year of storage Due to the self discharge characteristics of this type of battery it is imperative that they be charged within 6 months of storag
13. charged state This value will decrease over the life of the battery and is also a function of temperature and of time after charge voltage settling will occur shortly after disconnecting from charge NOTE The SeaBattery Power Module should be charged with a constant voltage current limiting charger See CHARGERS next section DO NOT USE AN AUTOMOTIVE TYPE BATTERY CHARGER THIS TYPE OF CHARGER WILL OVERCHARGE THE BATTERY WARNING SEVERE OVERCHARGING CAN RESULT IN FORMATION OF A LARGE AMOUNT OF EXPLOSIVE GAS WHICH MAY RESULT IN MECHANICAL RUPTURE OF THE DIAPHRAGM AND OR FIRE AND OR EXPLOSION 2 rev 07242009 CHARGERS A bench power source with current limited to 25C as calculated above can be used Specially designed battery chargers are available from DSP amp L for each SeaBattery Power Module configuration Contact DSP amp L for further battery charger information The following instructions apply to these chargers Once powered up and connected to the battery the two red charger lights will turn on The lower light indicates power on and low rate while the upper light indicates high rate When the battery reaches full charge the high rate light will go out The high rate set point voltage will vary as a function of temperature and battery condition It may have to be re tuned as the battery ages due to a natural decrease in battery capacity Charging time depends on battery and charger capacity and on the initi
14. controls may be required Personal Protective Equipment PPE Respiratory A NIOSH certified air purifying respirator with a Type 95 R or P particulate filter may be used in conjunction with an organic vapor cartridge under conditions where airborne concentrations are expected to exceed exposure limits see Section 2 Protection provided by air purifying respirators is limited see manufacturer s respirator selection guide Use a NIOSH approved self contained breathing apparatus SCBA or equivalent operated in a pressure demand or other positive pressure mode if there is potential for an uncontrolled release exposure levels are not known or any other circumstances where air purifying respirators may not provide adequate protection A respiratory protection program that meets OSHA s 29 CFR 1910 134 and ANSI Z88 2 requirements must be followed whenever workplace conditions warrant a respirator s use Skin Not required based on the hazards of the material However it is considered good practice to wear gloves when handling chemicals Eye Face While contact with this material is not expected to cause irritation the use of approved eye protection to safeguard against potential eye contact is considered good practice Other Protective Equipment A source of clean water should be available in the work area for flushing eyes and skin Impervious clothing should be worn as needed Suggestions for the use of specific protective materials ar
15. is not a RCRA listed hazardous waste However it should be fully characterized for toxicity prior to disposal 40 CFR 261 Use which results in chemical or physical change or contamination may subject it to regulation as a hazardous waste Along with properly characterizing all waste materials consult state and local regulations regarding the proper disposal of this material Container contents should be completely used and containers should be emptied prior to discard Container rinsate could be considered a RCRA hazardous waste and must be disposed of with care and in full compliance with federal state and local regulations Larger empty containers such as drums should be returned to the distributor or to a drum reconditioner To assure proper disposal of smaller empty containers consult with state and local regulations and disposal authorities 14 TRANSPORT INFORMATION DOT Shipping Description Not hazardous Note Material is unregulated unless in container of 3500 gal or more then provisions of 49 CFR Part 130 apply for land shipment IMDG Not regulated IATA Not regulated 15 REGULATORY INFORMATION EPA SARA 311 312 Title III Hazard Categories MSDS 776507 Page 6 of 6 Acute Health No Chronic Health No Fire Hazard No Pressure Hazard No Reactive Hazard No SARA 313 and 40 CFR 372 This material contains the following chemicals subject to the reporting requirements of SARA 313 and 40 CFR 372 None Ca
16. loss of capacity and prevents electrolyte stratification which greatly reduces capacity The battery boxes are filled with Drakeol 35 high purity white mineral oil to provide isolation from seawater and pressure compensation The batteries have low self discharge characteristics increasingly better at cold depths The AGM technology produces a minimal gas buildup during normal charge and discharge cycles eliminating the need for potentially problematic mechanical venting systems Gas is manually vented through a valve molded into the diaphragm The flexible urethane diaphragm is transparent allowing the battery and interior wiring to be visually inspected without disassembly IMPORTANT 1 A small gas bubble 2 3 in diameter under the diaphragm valve is normal Manual venting is recommended when the bubble diameter exceeds about 6 in 15 cm See Venting Page 2 2 To ensure long life at rated capacity a Do NOT overcharge DO NOT EVER use an automotive type battery charger b Store in charged condition at reduced temperature 40 deg to 50 deg F if possible A float charger is recommended c For maximum battery life do not discharge battery below 75 of rated voltage d Your SeaBattery Power Module should always be charged in an upright position to allow for gas to migrate out of the battery cells CAUTION These batteries can deliver very high currents if shorted Exposed male connector pins with applied power shoul
17. on the electrodes which will eventually reduce capacity Batteries which are stored in a discharged state or left on the shelf for too long may initially appear to be open circuited or will accept far less current than normal This is caused by a phenomenon called sulfation When this occurs leave the charger connected to the battery Usually the battery will start to accept increasing amounts of current until a normal current level is reached If there is no response even to charge voltages above recommended levels the battery may have been in a discharged state for too long to recover Caution Never charge or discharge a battery in a hermetically sealed enclosure Batteries generate a mixture of gases internally Given the right set of circumstances such as extreme overcharging or shorting of the battery these gases might vent into the enclosure and create the potential for an explosion when ignited by a spark If in any doubt or if concepts of proper use and care are unclear please ensure that you contact Power Sonic s technical department Charging for Cycle Operation Cyclic applications generally require that recharging be done in a relatively short time The initial charge current however must not exceed 0 30 x C amps Just as battery voltage drops during discharge it slowly rises during charge Full charge is determined by voltage and inflowing current When at a charge voltage of 2 45 0 05 volts cell the current
18. plastic The case materials impart great resistance to shock vibration chemicals and heat Flame Retardant FR battery cases and lids are available where the end application dictates Long Service Life PS PSH and PSG Series Have a design life of up to five years in standby applications In cyclical applications up to 1 000 charge discharge cycles can be expected depending on average depth of discharge PG Series Have a design life of up to 10 years in float applications Please consult this Technical Manual and product specifications to become aware of the many factors that effect product life The information contained within is provided as a service to our customers and is for their information only The information and recommendations set forth herein are made in good faith and are believed to be accurate at the date compiled Power Sonic Corporation makes no warranty expressed or implied POWER SONIC Rechargeable Batteries 1 Battery Construction Terminals Depending on the model batteries come either with AMP Faston type terminals made of tin plated brass post type terminals of the same composition with threaded nut and bolt hardware or heavy duty flag terminals made of lead alloy A special epoxy is used as sealing material surrounding the terminals Plates electrodes Power Sonic utilizes the latest technology and equipment to cast grids from a lead calcium alloy free of antimony The small amount of calci
19. the SeaBattery Power Module Remove the valve cap invert box and slightly inflate with compressed air The mineral oil can be reused keep it clean 2 Remove the bolts securing the top to the battery box Note the tightness of each bolt before removal The bolts are tightest toward the middle of the frame and looser toward the corners Bolt torques are Center bolt 100 in lb 11 3 Nm Surrounding bolts 100 in lb 11 3 N m Corner bolts 50 in Ib 5 7 Nm 3 Remove the top of the battery box and the diaphragm Note the blue green marine grade lubricant present between the diaphragm and the battery box surfaces 4 Pour out the remaining mineral oil into a clean dry bucket SAVE 6 rev 07242009 10 11 12 13 14 Disconnect the wires from the battery terminals Carefully note how wires were run and connected Compare to the appropriate wiring diagrams in Appendix A When removing terminations be careful not to short circuit the terminals during this process A short circuit can be VERY dangerous Remove old batteries from the box Removing some of the white plastic spacers may help Prepare new batteries for installation The new batteries must be modified to allow oil to freely enter the individual cells The following is our recommended field modification which offers satisfactory results while differing from the factory procedure a Pry off top plastic plate that covers cell vents b Secure rubber vent caps with 3M 5
20. 0 146 The use of appropriate respiratory protection is advised when concentrations exceed any established exposure limits see Sections 2 and 8 Do not wear contaminated clothing or shoes Use good personal hygiene practices Empty containers retain residue and may be dangerous Do not pressurize cut weld braze solder drill grind or expose such containers to heat flame sparks or other sources of ignition They may explode and MSDS 776507 Page 4 of 6 cause injury or death Empty drums should be completely drained properly bunged and promptly shipped to the supplier or a drum reconditioner All containers should be disposed of in an environmentally safe manner and in accordance with governmental regulations Before working on or in tanks which contain or have contained this material refer to OSHA regulations ANSI Z49 1 and other references pertaining to cleaning repairing welding or other contemplated operations Storage Keep container s tightly closed Use and store this material in cool dry well ventilated areas away from heat and all sources of ignition Store only in approved containers Keep away from any incompatible material see Section 10 Protect container s against physical damage 8 EXPOSURE CONTROLS PERSONAL PROTECTION Engineering controls If current ventilation practices are not adequate to maintain airborne concentrations below the established exposure limits see Section 2 additional engineering
21. 0 AH 1 40 28 00 2 62 26 20 5 00 25 00 18 60 18 60 35 0 AH 1 75 35 00 3 30 33 00 6 20 31 00 25 00 25 00 36 0 AH 1 80 36 00 3 35 33 50 6 12 30 60 22 30 22 30 40 0 AH 2 00 40 00 3 80 38 00 6 70 33 50 24 00 24 00 55 0 AH 2 75 55 00 5 10 51 00 8 80 44 00 30 60 30 60 75 0AH 3 75 75 00 7 20 72 00 13 60 68 00 47 00 47 00 100 0 AH 5 00 100 00 9 20 92 00 15 80 79 00 55 20 55 20 110 0 AH 5 50 110 00 10 30 103 00 17 70 88 50 61 80 61 80 140 0 AH 7 00 140 00 13 50 135 00 24 00 120 00 84 00 84 00 210 0 AH 10 50 210 00 20 00 200 00 36 00 180 00 168 00 168 00 Table 2 Capacities for various multiples of the 20 hour discharge current PS PSH and PSG models POWER SONIC Rechargeable Batteries 5 Capacity Table 3 shows capacities for various multiples of the 20 hour discharge current for PG models Rated 20 Hour Rate 10 Hour Rate Capacity 5 Hour Rate 1 Hour Rate 28 0 AH 35 0 AH 42 0 AH 56 0 AH 65 0 75 0 AH 92 0 AH 103 0 AH 124 0 AH 144 0 AH 153 0 AH 210 0 AH Table 3 PG Series batteries by industry convention are rated at their 10 hour rate Capacity expressed in ampere hours AH is the product of the current discharged and the leng
22. 1C Amp initial charging current A Vicellli and 245V Celi Constant Voltage at 20 C Charged Volume Charge Voltage Constant 2 45V cell After 50 Discharge After 100 Discharge Charging Current Initial at 0 1C Amp Figure 13 Typical charge characteristics for cycle service where charging is non continuous and peak voltage can be higher Charge Charging Charged Volume Current Voltage A Vicell Charge at 0 1C Amp initial charging current A and 2 35V Cell Constant Voltage at 20C Charged Volume w Charge Voltage Constant 2 35V cell After 50 Discharge After 100 Discharge Charging Current Initial at 0 1C Amp Figure 14 Typical characteristics for standby service type charge Here charging is continuous and the peak charge voltage must be lower POWER SONIC Rechargeable Batteries 13 Charging Constant Voltage Charging Constant voltage charging is the best method to charge Power Sonic batteries Depending on the application batteries may be charged either on a continuous or non continuous basis In applications where standby power is required to operate when the AC power has been interrupted continuous float charging is recommended Non continuous cyclic charging is used primarily with portable equipment where charging on an intermittent basis is appropriate The constant voltage charge method applies a constant voltage to the battery and limits the initial charge current It is
23. 400 fast set adhesive or hot melt glue c Slice tops of rubber vent caps in an X pattern d Using funnel partially fill each individual cell with oil to about half full Install new modified batteries in box Connect the wires to the battery terminals following the note from Step 5 above Compare to the appropriate wiring diagrams in Appendix A When connecting terminations be careful not to short circuit the terminals during this process A short circuit can be VERY dangerous Reconnect terminals to diaphragm feedthrough connector Test voltage and polarity at connector Using funnel COMPLETELY fill each individual cell with oil Clean the old lubricant off the urethane diaphragm and the battery box with Isopropyl alcohol Partially fill box with oil before final assembly Make sure the sealing surfaces are clean and oil free and apply a bead of non hardening marine grade lubricant e g AquaLube to the box surface just outside the sealing ridge Reassemble diaphragm and box top being careful not to pinch any wires Retighten frame bolts to previous torque specifications as noted in instruction 2 Center bolt each side 100 in lb 11 3 N m Surrounding bolts 100 in lb 11 3 Nm Corner bolts 50 in Ib 5 7 Nm Torque procedure a Install center bolt on each side Torque to 50 in lbs 5 7 N m b Install corner bolts Torque to 50 in lbs 5 7 N m c Install surrounding bolts on each side Torque to 50 in lbs 5 7 Nm d Tight
24. 5 0 68 0 68 1 4 AH 0 07 1 40 0 13 1 30 0 24 1 20 0 85 0 85 2 0 AH 0 10 2 00 0 19 1 90 0 34 1 70 1 24 1 24 2 3 AH 0 115 2 30 0 225 2 25 0 39 1 95 1 38 1 38 2 5 AH 0 125 2 50 0 22 2 20 0 40 2 00 1 50 1 50 2 8 AH 0 14 2 80 0 25 2 50 0 48 2 40 1 70 1 70 2 9AH 0 145 2 90 0 26 2 60 0 49 2 45 1 80 1 80 3 2 AH 0 16 3 20 0 30 3 00 0 54 2 70 2 00 2 00 3 4 AH 0 17 3 40 0 33 3 30 0 58 2 90 2 20 2 20 3 5 AH 0 175 3 50 0 33 3 40 0 59 2 95 2 17 2 17 3 8 AH 0 19 3 80 0 35 3 50 0 64 3 20 2 40 2 40 4 5AH 0 225 4 50 0 41 4 10 0 64 3 20 2 75 2 75 5 0 AH 0 25 5 00 0 43 4 30 0 80 4 00 3 00 3 00 5 4AH 0 27 5 40 0 50 5 00 0 90 4 50 3 60 3 60 5 5 AH 0 275 5 50 0 54 5 40 0 95 4 75 3 70 3 70 6 0 AH 0 30 6 00 0 56 5 60 0 98 4 90 3 60 3 60 6 5 AH 0 325 6 50 0 61 6 10 1 10 5 50 4 03 4 03 7 0 AH 0 35 7 00 0 63 6 30 1 19 5 95 4 34 4 34 7 2AH 0 36 7 20 0 70 7 00 1 30 6 50 4 60 4 60 8 0 AH 0 40 8 00 0 78 7 75 1 40 7 00 4 80 4 80 8 5 AH 0 425 8 50 0 81 8 10 1 50 7 50 6 50 6 50 9 0 AH 0 45 9 00 0 83 8 30 1 54 7 70 5 60 5 60 10 0 AH 0 50 10 00 0 93 9 30 1 70 8 50 6 20 6 20 10 5 AH 0 53 10 50 0 98 9 80 1 87 9 35 6 82 6 82 12 0 AH 0 60 12 00 1 15 11 50 2 10 10 50 7 30 7 30 13 0 AH 0 65 13 00 1 22 12 20 2 30 11 50 8 00 8 00 14 0 AH 0 70 14 00 1 30 13 00 2 50 12 50 8 45 8 45 18 0 AH 0 90 18 00 1 70 17 00 3 20 16 00 11 10 11 10 20 0 AH 1 00 20 00 1 85 18 50 3 40 17 00 12 40 12 40 21 0AH 1 05 21 00 2 00 20 00 3 70 18 50 13 00 13 00 26 0 AH 1 30 26 00 2 40 24 00 4 40 22 00 16 10 16 10 28
25. Communication Standard 29 CFR 1910 1200 2 3 Potential Health Effects Routes of entry for solids include eye and skin contact ingestion and inhalation Refer to Section 4 for First Aid Measures 2 4 Potential Environmental Effects None Known SECTION 3 COMPOSITION INFORMATION ON INGREDIENTS Superlinear XL 0370 5634 Orange Page 1 of 4 This product does not contain chemicals that are considered hazardous under 29 CFR 1910 1200 SECTION 4 FIRST AID MEASURES Eyes Flush with water If irritation persists seek medical attention Skin For thermal burns immediately flush with cold water Do not attempt to remove polymer from In skin Seek medical attention Inhalation Leave exposed area and seek fresh air If irritation persists seek medical attention Ingestion Do not induce vomiting Seek medical attention SECTION 5 FIRE FIGHTING MEASURES Wear protective clothing and use self contained breathing equipment Extinguishing media to include water foam CO2 and dry chemical SECTION 6 ACCIDENTAL RELEASE MEASURES Spilled material may cause a slip hazard Vacuum or sweep material and place in a disposal container SECTION 7 HANDLING AND STORAGE Handling See 8 3 Personal Protective Equipment Storage Keep container closed to prevent contamination SECTION 8 EXPOSURE CONTROLS PERSONAL PROTECTION 8 1 Exposure Guidelines This product does not contain chemicals that are considered hazardous under 29 CFR 1910 1200
26. E OBTAINED FROM THE USE OF THIS INFORMATION OR THE PRODUCT THE SAFETY OF THIS PRODUCT OR THE HAZARDS RELATED TO ITS USE No responsibility is assumed for any damage or injury resulting from abnormal use or from any failure to adhere to recommended practices The information provided above and the product are furnished on the condition that the person receiving them shall make their own determination as to the suitability of the product for their particular purpose and on the condition that they assume the risk of their use In addition no authorization is given nor implied to practice any patented invention without a license Material Safety Data Sheet K www aschulman com A Schulman Your Success SECTION 1 PRODUCT AND COMPANY IDENTIFICATION Product Name Superlinear XL 0370 5634 Orange Description Thermoplastics Item Number 1016887 Revision Date January 29 2009 Contact for Information Manufacturer Identification A Schulman Inc 1183 Home Ave Akron OH 44310 Environmental Affairs 1 800 532 7786 8 00 am 5 00 pm EST Monday through Friday Customer Service 1 800 54 RESIN Email ea us aschulman com SECTION 2 HAZARDS IDENTIFICATION 2 1 Emergency Overview HMIS US only Health 1 Fire Hazard 1 Reactivity 0 NFPA Health 0 Flammability 0 Reactivity 0 2 2 OSHA Regulatory Status All ingredients are encapsulated by the polymer and therefore not considered hazardous by the OSHA Hazard
27. PULSE IL4FS CHARGER Major Power 24V charger 1 Ground black 2 24 volts white 3 24 volts red 4 Ground green PowerSonic PS 12400 NB typ SeaBattery 48 18 Wiring and Connector pin out Rev 090407 FEMALE CONNECTOR PINOUT DIAGRAM for 48V SeaBattery IMPULSE IL4FS CHARGER Major Power 48V charger mod charger per DSPL spec Major Power 48 Volt Battery Charger Modification and Adjustment Instructions 1 Ground black 2 48 volts white 3 48 volts red 4 Ground green PowerSonic PS 12180 NB typ APPENDIX B PowerSonic Maintenance Free Rechargeable Battery Application Manual ent lt Sealed Lead Acid Batteries Technical Manual POWER 575 Z ml ET OMNI 4 We ve Got The Power Table of Contents Features of Power Sonic Sealed Lead Acid Batteries Battery Construction Theory of Operation Battery Capacity Battery Capacity Selector Performance Data Discharge Open Circuit Voltage Temperature Shelf Life and Storage Battery Life Over Discharge Charging Charging Techniques Summary Charging Characteristics Charging Methods Constant Voltage Charging Constant Current Charging Taper Current Charging Overcharging Undercharging Charging for Cycle Operation Charging for Standby Operation Two Step Constant Voltage Charging Charging in Series Charging in Parallel Temperature Compensation Top Charging Charging Efficiency
28. SeaBattery M Power Module User s Guide DeepSea Power amp Light 4033 Ruffin Rd San Diego CA 92123 USA Phone 858 576 1261 Fax 858 576 0219 E mail info deepsea com Web www deepsea com DSPL Eng 730 001 Rev 07242009 TABLE OF CONTENTS GENERAL DESCRIPTION 1 ABS TYPE APPROVED PRODUCT CHARGING CHARGERS STANDARD CONNECTORS DISCHARGING INSPECTION MOUNTING BATTERY STORAGE LIFE EXPECTANCY SHIPPING CUSTOMER MODIFICATIONS SEABATTERY POWER MODULE WARRANTY BATTERY REPLACEMENT as O O O PB WO O W N APPENDIX A Wiring Diagrams for SeaBattery power module 6v 12v 24v 48v APPENDIX B PowerSonic Maintenance Free Rechargeable Battery Application Manual APPENDIX C MSDS sheets for SeaBattery batteries oil rotational molded plastic i rev 07242009 GENERAL DESCRIPTION Each molded orange polyethylene box contains multiple batteries in one of four configurations 1 Two 12V 40AH batteries connected in parallel to provide 12V 80AH SB12 80 2 Two 12V 40AH batteries connected in series to provide 24V 40AH SB24 40 3 Four 12v 18Ah batteries connected in series to provide 48V 18Ah SB48 18 4 Three 6V 58Ah batteries connected in parallel to provide 6V 174Ah SB06 174 All batteries are maintenance free rechargeable lead acid cells which utilize Absorbent Glass Matt electrolyte The non liquid suspended electrolyte permits the batteries to be operated in any orientation without spillage or
29. a nba y JI ydes 5141 J8 UuOZIJOU 9U UO SI sel duly 581 1 0 U9J9JJIp YLM WOJJ pew sd ues uonp lidde oyloeds e 104 n f s 19dold sjepow Jelleq IIUOS I8MOA Jofew 104 soul Aoede SMOUS 1 S HM ELQ luos s moq 40 saul Ausedeg g e n sdury osieyosig 00S 006 002 00 08 09 0S 0 0E 02 8 4 89 2 02 dual jusiquiy u ba c 2 3 Q Q Z Q o amp TI o Ajoede O I 2 A09 2002 192 09 71 2001 I90 A0Z 2090 199 19 2020 IBO AGL L 201 0 IBO AGL L 260 0 39V110A 143 TVNI4 0901 sjuauno U YIM Auen yorum S BENOA Jo no paya sawn abJeyasiq Say au SF eyds q 10399195 A edeo oyeg Performance Data Discharge During discharge the voltage will decrease The graphs in Figure 4 illustrate this for different discharge rates and ambient temperatures C is the rated capacity of a battery C for model PS 610 6V 1 1 AH is 1 1AH By convention the rating of nearly all sealed lead acid batteries is based on a 20 hour 0 05C discharge rate For larger batteries used for telecom and large UPS systems our PG Series the convention is to use a 10 hour rate 0 1C An important feature of Power Sonic batteries is shown in the discharge curves namely the voltage tends to remain high and almost constant for a relatively l
30. age a function of the discharge rate is reached It is the voltage point at which 100 of the usable capacity of the battery has been consumed or continuation of the discharge is useless because of the voltage dropping below useful levels The final discharge voltages per cell are shown in Table 1 Page 4 Discharging a sealed lead acid battery below this voltage or leaving a battery connected to a load will impair the battery s ability to accept a charge To prevent potential over discharge problems voltage cut off circuits as shown in Figure 12 may be used UU Figure 12 Circuits of Over Discharge Preventative Device Charging Dependable performance and long service life depend upon correct charging Faulty procedures or inadequate charging equipment result in decreased battery life and or unsatisfactory performance The selection of suitable charging circuits and methods is as important as choosing the right battery for the application Power Sonic batteries may be charged by using any of the conventional charging techniques Constant Voltage Constant Current Taper Current Two Step Constant Voltage To obtain maximum service life and capacity along with acceptable recharge time and economy constant voltage current limited charging is recommended 12 We ve Got The Power To charge a Power Sonic SLA battery a DC voltage between 2 30 volts per cell float and 2 45 volt
31. al state of charge If the charger is well tuned the battery should not produce gas during the charging cycle and the diaphragm valve may remain closed The battery should be checked for gas production especially toward the end of the charging cycle If there is a stream of bubbles rising from one or more of the cells and the charger high rate light is still on then the battery is being overcharged and the charger is incorrectly tuned Contact DSP amp L for charger tuning information Batteries may be charged either inside or outdoors If a battery is being charged outdoors great care must be taken to protect the charger from rain or sea spray as the chargers are not weatherproof Prolonged unprotected exposure to salt spray may damage the charger electronics A large heavy plastic bag can be used to cover and protect the charger STANDARD CONNECTORS A right angle diaphragm penetrator is installed in the SeaBattery Power Module diaphragm and is molded to a 16 gage 4 conductor underwater power cable SO 16 4 terminated with an Impulse IL4FS female 4 pin connector The connector polarity is shown below FEMALE CONNECTOR PINOUT DIAGRAM for all SeaBatteries 1 Ground 2 Volts 3 Volts 4 Ground DISCHARGING For optimal results the SeaBattery Power Module should not be overly discharged For maximum life of your SeaBattery Power Module do not reduce the voltage below the minimum values shown 25 depth of discharge
32. ant Do s and Don ts Charging Batteries should not be stored in a discharged state or at elevated temperatures f a battery has been discharged for some time or the load was left on indefinitely it may not readily take a charge To overcome this leave the charger connected and the battery should eventually begin to accept charge Continuous over or undercharging is the single worst enemy of a lead acid battery Caution should be exercised to ensure that the charger is disconnected after cycle charging or that the float voltage is set correctly Although Power Sonic batteries have a low self discharge rate which permits storage of a fully charged battery for up to a year it is important that a battery be charged within 6 months after receipt to account for storage from the date of manufacture to the date of purchase Otherwise permanent loss of capacity might occur as a result of sulfation To prolong shelf life without charging store batteries at 10 C 50 F or less Although it is possible to charge Power Sonic batteries rapidly i e in 6 7 hrs it is not normally recommended Unlimited current charging can cause increased off gassing and premature drying It can also produce internal heating and hot spots resulting in shortened service life Too high a charge current will cause a battery to get progressively hotter This can lead to thermal runaway and can destroy a battery in as little as a few hours Caution Never charge or d
33. arbon Responsible Party Penreco 138 Petrolia Street Karns City PA 16041 9799 For Additional MSDSs 1 800 762 0942 Technical Information 1 800 245 3952 EMERGENCY OVERVIEW 24 Hour Emergency Telephone Numbers Spill Leak Fire or Accident California Poison Control System 800 356 3129 Call CHEMTREC North America 800 424 9300 Others 703 527 3887 collect Health Hazards Precautionary Measures None Anticipated Physical Hazards Precautionary Measures Keep away from all sources of ignition Appearance Transparent water white Physical form Liquid Odor Odorless NFPA Hazard Class HMIS Hazard Class Health 0 Least Health 0 Least Flammability 1 Slight Flammability 1 Slight Reactivity 0 Least Physical Hazard 0 Least 2 COMPOSITION INFORMATION ON INGREDIENTS No hazardous components identified per 29 CFR 1910 1200 OTHER COMPONENTS WEIGHT EXPOSURE GUIDELINE Limits Agency Type MSDS 776507 Page 2of6 White Mineral Oil 100 See Oil Mist If Generated CAS 8042 47 5 REFERENCE EXPOSURE GUIDELINE Limits Agency Type Oil Mist If Generated 5 mg m3 ACGIH TWA CAS None 10 mg m3 ACGIH STEL 5 mg m3 OSHA TWA 2500 mg m3 NIOSH IDLH 5 mg m3 NOHSC TWA Note State local or other agencies or advisory groups may have established more stringent limits Consult an industrial hygienist or similar professional or your local agencies for further information 1 10 000 PPM All components are l
34. arge Voltage The voltage reached by the cell or battery at the end of charge while the charger is still attached Energy Density Ratio of battery energy to volume or weight expressed in watt hours per cubic inch or pound Gas Recombination The process by which oxygen gas generated from the positive plate during the final stage of charge is absorbed into the negative plate preventing loss of water High Rate Discharge A very rapid discharge of the battery Normally in multiples of C the rating of the battery expressed in amperes Impedance The resistive value of a battery to an AC current expressed in ohms Q Generally measured at 1000 Hz at full charge Internal Resistance The resistance inside a battery which creates a voltage drop in proportion to the current draw Negative Terminal The terminal of a battery from which electrons flow in the external circuit when a battery discharges See Positive Terminal Nominal Voltage Nominal Capacity The nominal value of rated voltage the nominal value of rated capacity The nominal voltage of a lead acid battery is 2 volts per cell Open Circuit Voltage The voltage of a battery or cell when measured in a no load condition Overcharge The continuous charging of a cell after it achieves 100 of capacity Battery life is reduced by prolonged overcharging Parallel Connection Connecting a group of batteries or cells by linking all terminals of the same polarity This in
35. by the pressure load caused by the trapped gas bubble To ensure many recharging cycles over the life of the cells it is preferable to slightly undercharge them on each cycle This is because one cell will usually achieve full charge before the others and a stream of gas bubbles will rise from that cell If the battery is charged beyond this point there may be some slow bubble formation after it is disconnected from the charger This gas formation should stop within about an hour VENTING Excess gas that accumulates can be vented easily by slowly and carefully loosening the chromed valve cap and bleeding the gas Do NOT remove cap Be careful to minimize loss of compensating oil It is under slight positive pressure caused by the stretch of the urethane diaphragm Batteries should always be charged in an upright position Charging in an inverted position may result in gas being trapped inside the cells Keep a close watch on batteries during their first charge cycle after shipment or storage or after a significant temperature change by watching for bubbles flowing from the cells Do not exceed 25 x C amps charging current where C is the amperage capacity of your SeaBattery Power Module For example to charge a 12v 80 amp hr battery the maximum charging current should be less than 25 x 80 20 amps Charge until a single cell starts venting and measure the battery voltage at that point This is the reference battery voltage value for the fully
36. ce a serious aspiration pneumonia Patients who aspirate these oils should be followed for the development of long term sequelae Inhalation exposure to oil mists below current workplace exposure limits is unlikely to cause pulmonary abnormalities 5 FIRE FIGHTING MEASURES Flammable Properties Flash Point gt 370 F gt 187 8 C ASTM D 92 COC OSHA Flammability Class Not applicable LEL UEL No Data Autoignition Temperature No Data Unusual Fire amp Explosion Hazards This material may burn but will not ignite readily Vapors are heavier than air and can accumulate in low areas If container is not properly cooled it can rupture in the heat of a fire Extinguishing Media Dry chemical carbon dioxide foam or water spray is recommended Water or foam may cause frothing of materials heated above 212 F Carbon dioxide can displace oxygen Use caution when applying carbon dioxide in confined spaces Fire Fighting Instructions For fires beyond the incipient stage emergency responders in the immediate hazard area should wear bunker gear When the potential chemical hazard is unknown in enclosed or confined spaces or when explicitly required by DOT a self contained breathing apparatus should be worn In addition wear other appropriate protective equipment as conditions warrant see Section 8 Isolate immediate hazard area keep unauthorized personnel out Stop spill release if it can be done with minimal risk Move undamaged container
37. cornea inflammation of the nose throat and bronchial tubes possible erosion of tooth enamel Lead Compounds May cause anemia damage to kidneys and nervous system and damage to reproductive system in both males and females Carcinogenicity Sulfuric acid The National Toxicological Program NTP and The International Agency for Research on Cancer IARC have classified strong inorganic acid mist containing sulfuric acid as a Category 1 carcinogen a substance that is carcinogenic to humans The ACGIH has classified strong inorganic acid mist containing sulfuric acid as an A2 carcinogen suspected human carcinogen These classifications do not apply to liquid forms of sulfuric acid or sulfuric acid solutions contained within a battery Inorganic acid mist sulfuric acid mist is not generated under normal use of this product Misuse of the product such as overcharging may result in the generation of sulfuric acid mist Lead Compounds Human studies are inconclusive regarding lead exposure and an increased cancer risk The EPA and the International Agency for Research on Cancer IARC have categorized lead and inorganic lead compounds as a B2 classification probable possible human carcinogen based on sufficient animal evidence and inadequate human evidence Medical Conditions Generally Aggravated by Exposure Inorganic lead and its compounds can aggravate chronic forms of kidney liver and neurological diseases Contact of battery electr
38. creases the capacity of the battery group Polarity The charges residing at the terminals of the battery Positive Terminal The terminal of a battery toward which electrons flow through the external circuit when the cell discharges See Negative Terminal Rated Capacity The capacity of the cell expressed in amperes Commonly a constant current for a designated number of hours to a specified depth of discharge at room temperature Recombination The state in which the gasses normally formed within the battery cell during its operation are recombined to form water Series Connection The connection of a group of cells or batteries by linking terminals of opposite polarity This increases the voltage of the battery group Self Discharge The loss of capacity of a battery while in stored or unused condition without external drain Separator Material isolating positive from negative plates In sealed lead acid batteries it normally is absorbent glass fiber to hold the electrolyte in Suspension SLA Battery Sealed lead acid battery generally having the following characteristics Maintenance free leak proof position insensitive Batteries of this type have a safety vent to release gas in case of excessive internal pressure build up Hence also the term Valve regulated battery Gel Cells are SLA batteries whose dilute sulfuric acid electrolyte is immobilized by way of additives which turn the electrolyte into a gel
39. d be handled with extreme care they can be easily shorted against any metal surface If a short circuit persists for more than about a second connectors and cabling may be destroyed and fire could result ALWAYS verify polarity Many devices can be damaged by reverse polarity See wiring diagrams below in Standard Connectors and in Appendix ABS Type Approved Product A SeaBattery power module with an embossed ABS Type Approved Product logo see below on the lid is certified by DeepSea Power amp Light to have been built to the design and production standards referenced in the ABS Certificate of Product Design Assessment PDA 09 HS434990 1 PDA 19June2009 and ABS Certificate of Manufacturing Assessment MA 5 1693747 25 June 2009 Copies of both Certificates are available on line at DeepSea com 1 rev 07242009 TYPE APPROVED PRODUCT CHARGING The battery should always be fully charged before use and should be stored in a fully charged state See BATTERY STORAGE page 5 The battery cells are of starved electrolyte construction and produce very little if any gas while charging However once the battery is fully charged a cell will start to produce gas if it continues to be charged IT IS EXTREMELY IMPORTANT NOT TO OVERCHARGE THE BATTERY The evolution of gas that results from overcharging will slowly reduce the capacity of the cells by drying out the electrolyte In an extreme case the diaphragm can be damaged
40. deep discharge Economical The high watt hour per dollar value is made possible by the materials used in a sealed lead acid battery they are readily available and low in cost Easy Handling No special handling precautions or shipping containers surface or air are required due to the leak proof construction Please refer to the declaration of non restricted status for D O T and 1 as listed in the Literature section of our website www power sonic com Compact Power Sonic batteries utilize state of the art design high grade materials and a carefully controlled plate making process to provide excellent output per cell The high energy density results in superior power volume and power weight ratios Low Pressure Valve Regulators All batteries feature a series of low pressure one way relief valves These valves safely release any excessive accumulation of gas inside the battery and then reseal High Discharge Rate Low internal resistance allows discharge currents of up to ten times the rated capacity of the battery Relatively small batteries may thus be specified in applications requiring high peak currents Wide Operating Temperature Range Power Sonic batteries may be discharged over a temperature range of 40 C to 60 C 40 F to 140 F and charged at temperatures ranging from 20 C to 50 C 4 F to 122 F Rugged Construction The high impact resistant battery case is made of non conductive ABS
41. der normal conditions If battery is overcharged and concentrations of sulfuric acid are known to exceed PEL use NIOSH or MSH approved respiratory protection Engineering Controls Store and handle batteries in a well ventilated area If mechanical ventilation is used components must be acid resistant Protective Gloves Eye Protection None needed under normal conditions If battery case is None needed under normal conditions If handling damaged or damaged use rubber or plastic elbow length gauntlets broken batteries use chemical splash goggles or face shield Other Protective Clothing or Equipment None needed under normal conditions In case of damaged or broken battery use an acid resistant apron Under severe exposure or emergency conditions wear acid resistant clothing Work Hygienic Practices Handle batteries carefully to avoid damaging the case Do not allow metallic articles to contact the battery terminals during handling Avoid contact with the internal components of the battery Continued on next page Power Sonic MSDS Page 5 of 6 Section 9 Regulatory Information NFPA Hazard Rating for Sulfuric Acid Flammability 0 E IE 2 Health 3 Transportation Batteries Non Restricted Status North America Surface and Air Shipments Our nonspillable lead acid batteries are listed in the U S Department of Transportation s DOT hazardous materials regulations but are excepted from thes
42. e otherwise permanent loss of capacity might occur as a result of sulfation The rate of self discharge varies with the ambient temperature At room temperature 20 C 68 F it is about 3 per month At low temperatures it is nearly negligible at higher ambient temperatures self discharge increases To obtain maximum battery life and performance batteries should be recharged as soon as possible after each use and not stored in a discharged state If possible batteries should be stored at 20 C 68 F or lower and recharged every six months when not in use ze s 5 52 m 9 m o 7 o m 2 9 G a 9 6 9 12 Storage Period Months Figure 8 Self Discharge Characteristics Battery Life Cyclic Use The number of charge discharge cycles depends on the capacity taken from the battery a function of discharge rate and depth of discharge operating temperature and the charging method 120 100 80 60 Discharge Discharge Discharge Depth 100 Depth 50 Depth 30 40 Retention Capacity 1 Discharge Current 0 2C Final Voltage 1 7V Cell 2 Charge Current 0 1C 3 Ambient Temperature 20 C to 25 C 68 F to 77 F 200 400 600 800 1000 1200 Number of Cycles Figure 9 Relationship between depth of discharge and number of cycles as well as increases of capacity during the early cycles 10 We ve Got The Power Performance Data Battery Life continued Standby Use The fl
43. e EPA when recycled however state and international regulations may very CERCLA superfund and EPCRA a Reportable Quantity RQ for spilled 100 sulfuric acid under CERCLA superfund and EPCRA Emergency Planning Community Right to Know Act is 1 000lbs State and local reportable quantities for spilled sulfuric acid may vary b Sulfuric acid is a listed Extremely Hazardous Substance under EPCRA with a Threshold Planning Quantity TPQ of 1 000165 EPCRA Section 302 Notification is required if 1 000lbs or more of sulfuric acid is present at one site The quantity of sulfuric acid will vary by battery type Contact Power Sonic Corporation for additional information d EPCRA Section 312 Tier 2 reporting is required for batteries if sulfuric acid is present in quantities of 500lbs or more and or lead is present in quantities of 10 00lbs or more e Supplier Notification This product contains toxic chemicals which may be reportable under EPCRA Section 313 Toxic Chemical Release Inventory Form R requirements If you are a manufacturing facility under SIC codes 20 through 39 the following information is provided to enable you to complete the required reports Continued on next page Power Sonic MSDS Page 6 of 6 Regulatory Information continued f Toxic Chemical CAS Number Approximate by weight Lead 7439 92 1 60 Sulfuric Acid 7664 93 9 10 30 Arsenic 7440 38 2 0 2 If you distribut
44. e Limit TSCA Toxic Substance Control Act SARA Superfund Amendments amp Reclamation Act VOC Volatile Organic Chemical N E Not Established Prepared By smf Superlinear XL 0370 5634 Orange Page 4 of 4
45. e based on readily available published data Users should check with specific manufacturers to confirm the performance of their products 9 PHYSICAL AND CHEMICAL PROPERTIES Note Unless otherwise stated values are determined at 20 C 68 F and 760 mm Hg 1 atm Appearance Transparent water white Physical State Liquid Odor Odorless pH No Data Vapor Pressure mm Hg lt 1 Vapor Density air 1 gt 1 Boiling Point Range 590 F 310 C approximate Freezing Melting Point No Data Solubility in Water Insoluble Specific Gravity 0 86 0 88 Evaporation Rate nBuAc 1 lt 1 Bulk Density 7 17 lbs gal Flash Point gt 370 F gt 187 8 C ASTM D 92 COC MSDS 776507 Page 5 of 6 Flammable Explosive Limits No Data 10 STABILITY AND REACTIVITY Stability Stable under normal ambient and anticipated storage and handling conditions of temperature and pressure Conditions To Avoid Avoid all possible sources of ignition see Sections 5 and 7 Materials to Avoid Incompatible Materials Avoid contact with strong oxidizing agents Hazardous Decomposition Products carbon nitrogen and sulfur oxides Hazardous Polymerization Will not occur 11 TOXICOLOGICAL INFORMATION No definitive information available on carcinogenicity mutagenicity target organs or developmental toxicity 12 ECOLOGICAL INFORMATION Not evaluated at this time 13 DISPOSAL CONSIDERATIONS This material if discarded as produced
46. e capacity of a cell or battery by applying a small constant current e Charge equalization brings all of the cells in a battery or string to the same state of charge Closed Circuit Voltage Test A test method in which the battery is briefly discharged at a constant current while the voltage is measured Cutoff Voltage The final voltage of a cell or battery at the end of charge or discharge Cycle A single charge and discharge of a cell or battery Deep Cycle A cycle in which the discharge continues until the battery reaches it s cut off voltage usually 80 of discharge Direct Current DC The type of electrical current that a battery can supply One terminal is always positive and the other always negative Discharge The process of drawing current from a battery Deep Discharge the discharge of a cell or battery to between 80 and 100 of rated capacity Depth of Discharge the amount of capacity typically expressed as a percentage removed during discharge Self Discharge the loss of capacity while stored or while the battery is not in use Self Discharge Rate the percent of capacity lost on open circuit over a specified period of time Drain The withdrawal of current from a battery Electrode Positive or negative plate containing materials capable of reacting with electrolyte to produce or accept current Electrolyte Conducts ions in a cell Lead acid batteries use a sulfuric acid solution End of Ch
47. e regulations since they meet all of the following requirements found at 49 CFR 173 159 d NMFC 60680 Class 65 e When offered for transport the batteries are protected against short circuits and securely packaged as required by 49 CFR 173 159 d 1 e The batteries and outer packaging are marked with the words NONSPILLABLE BATTERY as required by 49 CFR 173 159 d 2 and batteries comply with the vibration and pressure differential tests found in 49 CFR 173 159 d 3 and crack test found at 49 CFR 173 159 d 4 International Our non spillable lead acid batteries also are excepted from the international hazardous materials also known as dangerous goods regulations since they comply with the following requirements vibration and pressure differential tests found in Packing Instruction 806 and Special Provision A67 of the International Air Transport Association IATA Dangerous Goods Regulations The vibration and pressure differential tests found in Packing Instruction 806 and Special Provision A67 of the International Civil Aviation Organization ICAO Technical Instructions for the Safe Transport of Dangerous Goods by Air and vibration pressure differential and crack tests found in Special Provision 238 1 and 238 2 of the International Maritime Dangerous Goods IMDG Code Regulatory Information RCRA Spent lead acid batteries are not regulated as hazardous waste by th
48. e this product to other manufacturers in SIC codes 20 through 39 this information must be provided with the first shipment in a calendar year The Section 313 supplier notification requirement does not apply to batteries which are consumer products Not present in all battery types Contact Power Sonic Corporation for further information TSCA Ingredients in Power Sonic Corporation s batteries are listed in the TSCA Registry as follows Components CAS Number TSCA Status Electrolyte Sulfuric Acid H2SO4 7664 93 9 Listed Inorganic Lead Compound Lead Pb 7439 92 1 Listed Lead Oxide PbO 1317 36 8 Listed Lead Sulfate PbSO4 7446 14 2 Listed Arsenic As 7440 38 2 Listed Calcium Ca 7440 70 2 Listed Tin Sn 7440 31 5 Listed Power Sonic Corporation 7550 Panasonic Way San Diego CA 92154 Tel 619 661 2020 Fax 619 661 3650 E Mail quality assurance power sonic com Website http www power sonic com MSDS 776507 Page 1 of 6 penreco MATERIAL SAFETY DATA SHEET Penreco Drakeol Mineral Oil USP Grades 1 PRODUCT AND COMPANY IDENTIFICATION Product Name Penreco Drakeol Mineral Oil USP Grades Synonyms Penreco Drakeol 19 Penreco Drakeol 21 Penreco Drakeol 25 Penreco Drakeol 32 Penreco Drakeol 33 Penreco Drakeol 34 Penreco Drakeol 35 Penreco Drakeol 350 Penreco Drakeol 35G Penreco Drakeol 400 Chemical Family Petroleum Hydroc
49. eal during diaphragm stretch For example a 2 Dia hole is cut to fit a 3 4 Dia threaded wire feed through Customer modifications or field battery replacement voids the SeaBattery Power Module warranty SEABATTERY POWER MODULE WARRANTY DeepSea Power amp Light certifies each SeaBattery Power Module to be made with the finest materials available built to exacting manufacturing standards and comprehensively tested before shipping This attention to detail has made the SeaBattery Power Module a stable of the offshore industry for over 25 years DeepSea Power amp Light DSPL will replace any SeaBattery Power Module that is found to be defective in manufacture during a period of one year after receipt of delivery Except for such replacement the sale or any subsequent use of the SeaBattery Power Module is without warranty or liability DeepSea Power amp Light will support its customers with test results field experience and engineering data relating solely to its product Customers are solely responsible for determining the SeaBattery Power Module s suitability for their application and integration into their system The customer is directed to read the SeaBattery Power Module User s Guide for recommended care and handling of the SeaBattery Power Module No other warranty is stated or implied BATTERY REPLACEMENT Field Replacement Procedure recommended as an emergency procedure only 1 Drain approximately 1 2 of the oil out of
50. ed uses SECTION 12 ECOLOGICAL INFORMATION Refer to Section 6 SECTION 13 DISPOSAL CONSIDERATIONS Superlinear XL 0370 5634 Orange Page 3 of 4 Preferred options for disposal are 1 recycling 2 incineration with energy recovery and 3 landfill Treatment storage transportation and disposal must be in accordance with applicable Federal State Provincial and Local regulations SECTION 14 TRANSPORT INFORMATION This Product is not regulated under the following regulations United States Department of Transportation DOT United States Coast Guard Regulations International Maritime Organization IMO regulations International Civil Aviation Organization ICAO regulations International Air Reports Association IATA regulations Canadian Transportation of Dangerous Goods TDG regulations European Agreement Concerning the International Carriage of Dangerous Goods by Road ADR regulations European Agreement Concerning the International Carriage of Dangerous Goods by Rail RID regulations Australian Dangerous Goods ADG regulations SECTION 15 REGULATORY INFORMATION Reference Section 3 All Components of this product are on or exempt from listing on the US TSCA inventory and on Canadian DSL inventory SARA Title 111 Reporting Not Required SECTION 16 OTHER INFORMATION Definitions CAS Chemical Abstract Number DSL Domestic Substance List OSHA Occupational Safety and Health Act PEL Permissible Exposur
51. en center bolts to 100 in lbs 11 3 N m e Tighten surrounding bolts to 100 in Ibs 11 3 f Corner bolts remain at 50 in lbs 5 7 Nm Diaphragm should not protrude beyond box edges more than 2 3 mm 7 rev 07242009 15 Fill box with oil until the full to top of the valve stem Physically pull up on the valve stem and fill with oil up to maximum height where top of urethane diaphragm is approximately 1 3 8 1 1 2 below the bottom surface of the box top 16 Place seal cap on valve stem and release 8 rev 07242009 APPENDIX A Wiring diagrams for SeaBattery Power Module 6v 12 24v 48v SeaBattery 6 174 Wiring and Connector pin out Rev 090407 FEMALE CONNECTOR PINOUT DIAGRAM for 6V SeaBattery IMPULSE IL4FS CHARGER Major Power 6V charger mod charger per DSPL spec Major Power 6 Bolt Battery Charger Modification and Adjustment Instructions 1 Ground 2 6 volts 6 volts 4 Ground black white red green PovverSonic PS 6580 typ SeaBattery 12 80 Wiring and Connector pin out Rev 090407 FEMALE CONNECTOR PINOUT DIAGRAM for 12V SeaBattery IMPULSE IL4FS CHARGER Major Power 12V charger 1 Ground black 2 12 volts white 3 12 volts red 4 Ground green PowerSonic PS 12400 NB typ SeaBattery 24 40 Wiring and Connector pin out Rev 090407 FEMALE CONNECTOR PINOUT DIAGRAM for 24V SeaBattery IM
52. er cloth with high heat and oxidation resistance The material further offers superior electrolyte absorption and retaining ability as well as excellent ion conductivity Case Sealing Depending on the model the case sealing is ultrasonic epoxy or heat seal Container Case and lid material is ABS high impact resin with high resistance to chemicals and flammability Case and cover are made of non conductive ABS plastic to UL94 HB or UL94 V O This case has molded in dividers for each 2 volt cell U L s component recognition program for emergency lighting and power batteries lists Power Sonic under file number MH20845 Theory of Operation The basic electrochemical reaction equation in a lead acid battery can be written as Pb 2H SO PbO Discharging PbSO 2H 0 PbSO Porous Lead Sulfuric Acid Porous Lead Sulfate Water Lead Sulfate Active material Electrolyte Lead Dioxide Active material Electrolyte Active material of negative plate Active material of negative plate of positive plate of positive plate Charging Discharge During the discharge portion of the reaction lead dioxide PbO is converted into lead sulfate PbSO at the positive plate At the negative plate sponge lead Pb is converted to lead sulfate PbSO This causes the sulfuric acid 2H SO in the electrolyte to be consumed Reacts with Reacts with sulfate sulfuric acid to ions to form lead form lead sulfate sulfate Pb supplies
53. eries in close proximity to objects which can produce sparks or flames and do not charge batteries in an inverted position Avoid exposing batteries to heat Care should be taken to place batteries away from heat emitting components If close proximity is unavoidable provide ventilation Service life is shortened considerably at ambient temperatures above 30 C 86 F To prevent problems arising from heat exchange between batteries connected in series or parallel it is advisable to provide air space of at least 0 4 10mm between batteries Do not mix batteries with different capacities different ages or of different makes The difference in characteristics will cause damage to the batteries and possibly to the attached equipment Battery cases and lids made of ABS plastic can sustain damage if exposed to organic solvents or adhesives For best results and generally acceptable performance and longevity keep operating temperature range between 40 C 40 F and 60 C 140 F It is good practice to ensure that the connections are re torqued and the batteries are cleaned periodically Do not attempt to disassemble batteries Contact with sulfuric acid may cause harm Should it occur wash skin or clothes with liberal amounts of water Do not throw batteries into a fire batteries so disposed may rupture or explode Disassembled batteries are hazardous waste and must be treated accordingly 20 We ve Got The Power Import
54. erminal voltage drops to 1 75 V cell At this point the battery has already delivered 100 of its rated capacity 0 01 x 100 hrs 1C Amp Hrs Continuing the discharge to zero volts will keep the battery under load for a further period of time squeezing out every bit of stored energy This type of deep discharge is severe and is likely to damage the battery The sooner a severely discharged battery is recharged the better its chances to fully recover Discharge Current Final Discharge Voltage Per Cell 0 1C or below or intermittent discharge 0 17C or current close to it 0 6C or current close to it From 1C to 2C or current close to it 3C or current close to it and above Table 1 Final discharge voltage per cell 4 We ve Got The Power Capacity The capacity of a battery is the total amount of electrical energy available from a fully charged cell or cells Its value depends on the discharge current the temperature during discharge the final cut off voltage and the general history of the battery Table 2 shows capacities for various multiples of the 20 hour discharge current for PS PSH and PSG models Rated 20 Hour Rate 10 Hour Rate 5 Hour Rate 1 Hour Rate Capacity Amps AH Amps AH Amps At Amps AH 0 5 AH 0 025 0 50 0 045 0 45 0 08 0 40 0 30 0 30 0 8 AH 0 04 0 80 0 072 0 72 0 13 0 65 0 48 0 48 1 1 AH 0 055 1 10 0 10 1 00 0 19 0 9
55. ischarge a battery in an airtight enclosure Batteries generate a mixture of gases internally Given the right set of circumstances such as extreme overcharging or shorting of the battery these gases might vent into the enclosure and create the potential for an explosion when ignited by a spark Generally ventilation inherent in most enclosures is sufficient to avoid problems When charging batteries in series positive terminal of one battery is connected to the negative terminal of another the interconnecting cables must all be of equal length and resistance to insure equalization of the load All batteries in the string will receive the same amount of charge current though individual battery voltages may vary When charging batteries in parallel positive terminals are connected to the positive terminal and negative terminals to the negative all batteries in the string will receive the same charge voltage but the charge current each battery receives will vary until equalization is reached High voltage strings of batteries in series should be limited to twenty 6 volt or ten 12 volt batteries when a single constant voltage charger is connected across the entire string Differences in capacity can cause some batteries to overcharge while others remain undercharged thus causing premature aging of batteries It is therefore not advisable to mix batteries of different capacities make or age in a series string To minimize the effects of cell o
56. isted on the TSCA inventory 3 HAZARDS IDENTIFICATION Potential Health Effects Eye Not known to be an eye irritant Skin Not known to be a skin irritant No harmful effects from skin absorption have been reported Inhalation Breathing No harmful effects reported Ingestion Swallowing No harmful effects reported from ingestion Signs and Symptoms Effects of overexposure may include irritation of the nose and throat irritation of the digestive tract and diarrhea Cancer No evidence of cancer has been demonstrated in several well conducted animal studies Target Organs No data available for this material Developmental No data available for this material Pre Existing Medical Conditions None Known 4 FIRST AID MEASURES Eye If irritation or redness develops move victim away from exposure and into fresh air Flush eyes with clean water If symptoms persist seek medical attention Skin First aid is not normally required However it is good practice to wash any chemical from the skin Inhalation Breathing First aid is not normally required If breathing difficulties develop move victim away from source of exposure and into fresh air Seek immediate medical attention MSDS 776507 Page 3 of 6 Ingestion Swallowing First aid is not normally required however if swallowed and symptoms develop seek medical attention Note To Physicians Acute aspirations of large amounts of oil laden material may produ
57. leakage by inverting the box and looking for water bubbles Water can be drained from the case when in this position through the vent valve After rough usage always check for damage loose bolts and for debris such as rocks trapped between the case lid and the diaphragm MOUNTING The SeaBattery Power Module case is very durable but it is heavy and must be well secured Often a simple frame of angle stock around the base with a ratchet cargo strap over the top is sufficient For a more 4 rev 07242009 robust tie down needed for extremely rough usage such as a towed systems that might crash into the bottom designers can consider a top frame of angle stock with tie rod pull downs DO NOT mount the SeaBattery Power Module so the clamp flange is bearing any weight The weight of the battery may cause cold flow deformation of the plastic flange which can result in leakage Vibration resistance The SeaBattery Power Module is inherently resistant to vibration However some SeaBattery Power Module owners take the added precaution of placing a solid 3 8 thick 80 Shore neoprene sheet under the SeaBattery Power Module case as a vibration and shock cushion BATTERY STORAGE Recommended Storage Temperature 40C 40F to 10C SOF Storage at a low ambient temperature reduces the self discharge rate Higher temperatures will cause the battery to self discharge more rapidly and produce excess gas which should be vented NOTE The SeaBat
58. life is maximized and operation is trouble free Material Safety Data Sheets MSDS t is important that you familiarize yourself with these prior to handling installing and disposing of all batteries If there are any questions raised from these please contact Power Sonic s technical department Handling Always wear insulated gloves when handling batteries especially when connecting series and parallel groups of batteries Follow all precautions as described in our Materials Safety Data Sheets MSDS This information is subject to change depending upon government legislation Visit our website www power sonic com for up to date copies of these e If equipment is to be stored for a long period of time the batteries should be disconnected to avoid undue drain on the batteries and any potential for damage to the equipment Installation Fasten batteries tightly and make provisions for shock absorption if exposure to shock or vibration is likely When installing the battery within a piece of equipment fix it securely at the lowest practicable point The battery should not be attached to any piece of equipment during burn in testing Do not apply undue force to the terminals or bend them Avoid applying heat to the terminals through processes such as soldering If soldering to the battery terminals is unavoidable it must be accomplished within 3 seconds using a soldering iron no greater than 100 watts Do not place batt
59. lifornia Proposition 65 Warning This material contains the following chemicals which are known to the State of California to cause cancer birih defects or other reproductive harm and are subject to the requirements of California Proposition 65 CA Health amp Safety Code Section 25249 5 None Known Carcinogen Identification This material has not been identified as a carcinogen by NTP IARC or OSHA EPA CERCLA Reportable Quantity None Canada Domestic Substances List Listed WHMIS Class Not regulated This product has been classified in accordance with the hazard criteria of the Controlled Products Regulations CPR and the MSDS contains all the information required by the CPR This material is listed on the following inventories Australian AICS Canadian DSL Chinese European EC EINECS Japanese ENCS Korean ECL Philippine PICCS 16 OTHER INFORMATION Issue Date 04 09 03 Previous Issue Date 07 26 01 Revised Sections New Format MSDS Number 776507 Status Final Disclaimer of Expressed and Implied Warranties The information presented in this Material Safety Data Sheet is based on data believed to be accurate as of the date this Material Safety Data Sheet was prepared HOWEVER NO WARRANTY OF MERCHANTABILITY FITNESS FOR ANY PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS EXPRESSED OR IS TO BE IMPLIED REGARDING THE ACCURACY OR COMPLETENESS OF THE INFORMATION PROVIDED ABOVE THE RESULTS TO B
60. nic solvent on the urethane diaphragm LIFE EXPECTANCY The SeaBattery Power Module life expectancy is approximately three years under normal use Intermittent use combined with cold storage can increase battery life while abuse including deep discharging can significantly shorten life expectancy Contact DSP amp L for applications that require continuous use and in situ recharging There are three options for battery replacement 1 Ship the SeaBattery Power Module back to DeepSea Power amp Light where the batteries will be replaced and refurbished 2 Order a new batteries from DSP amp L and install them in house 5 rev 07242009 3 While not recommended emergency field replacement is possible see Field Replacement Procedure See page 6 for instructions SHIPPING The SeaBattery Power Module is classified as a dry cell type battery by the DOT and can be shipped by air freight if needed Ground shipment of course is more cost effective but takes more time CUSTOMER MODIFICATIONS It is recommended that electrical penetrations be made through the urethane diaphragm although successful penetrations have been made through the case Holes cut through the diaphragm should be cut with a Cork and Rubber punch tool circular knife such as McMaster Carr p n 6122A12 rather than drilled Drilling causes ragged hole edges which have a tendency to initiate tearing Holes must be cut significantly undersize to maintain a tight s
61. nternational standards including JIS DIN and IEC and have UL and CE certification to providing the best possible service to satisfy our customer s needs and fulfill our undertaking to deliver top grade products on time and at a competitive price Corporate Headquarters and Domestic Sales Povver Sonic Corporation 7550 Panasonic Way San Diego CA 92154 USA Phone 619 661 2020 Fax 619 661 3650 Support technical support power sonic com Sales national sales power sonic com Customer Service customer service power sonic com International Sales Power Sonic Corporation P O Box 5242 Redwood City CA 94063 USA Phone 650 364 5001 Fax 650 366 3662 Sales international sales power sonic com European Sales Power Sonic Europe Ltd e 3 Buckingham Square Hurricane Way Wickford Essex 5511 8YQ England Phone 1268 560686 Fax 1268 560902 Sales sales power sonic co uk Website www power sonic co uk WWW power sonic com Copyright 2009 Power Sonic Corporation All rights reserved REVO109 APPENDIX C MSDS PowerSonic Maintenance Free Rechargeable Battery MSDS Penreco Drakeol 35 Mineral Oil MSDS Rotational molded plastic SuperLinear XL 0370 5634 PO ER Power Sonic MSDS Page 1 of 6 OS SON a MATERIAL SAFETY DATA SHEET PS PSH PSG PG and Power Sport Series Valve Regulated VRLA Batteries Absorbed Electrolyte AGM Section 1 Product Identification Man
62. oat service life or life expectancy under continuous charge depends on the frequency and depth of discharge the charge voltage and the ambient temperature At a float voltage of 2 25V to 2 30V cell and an ambient temperature of 20 C to 25 C 60 F to 77 F Power Sonic batteries should last four to five years before the capacity drops to 60 of its original rating Ambient Temperature 20 C 68 F Float Charging Voltage 2 25 2 30 V Cell Retention Capacity Years Figure 10 Indicates how capacity changes over time The graph in Figure 11 shows life characteristics in float standby service for ambient temperatures ranging from 15 C to 55 C 60 F to 130 F If prevailing ambient temperatures are well above 20 C to 25 C 68 F to 77 F the life expectancy of this type of battery in float service depends greatly on temperature compensated charging The typical temperature coefficient is 2mV cell 20 C and under N End of life defined as 60 of rated capacity N o ANONG Service Life Years K mono 30 40 Temperature C Figure 11 Service life at various ambient temperatures POWER SONIC Rechargeable Batteries 11 Performance Data Over Discharge To optimize battery life it is recommended that the battery be disconnected from the load either electronically or manually when the end volt
63. olyte acid with the skin may aggravate skin diseases such as eczema and contact dermatitis Overexposure to sulfuric acid mist may case lung damage and aggravate pulmonary conditions Emergency and First Aid Procedures Inhalation Sulfuric acid Remove to fresh air immediately If breathing is difficult give oxygen Lead Compounds Remove from exposure gargle wash nose and lips consult physician Ingestion Sulfuric acid Do not induce vomiting consult a physician immediately Lead Compounds Consult a physician immediately Eyes Sulfuric acid Flush immediately with water for 15 minutes consult a physician Lead Compounds Flush immediately with water for 15 minutes consult a physician Skin Sulfuric acid Flush with large amounts of water for at least 15 minutes remove any contaminated clothing If irritation develops seek medical attention Lead Compounds Wash with soap and water Continued on next page Power Sonic MSDS Page 4 of 6 Section 7 Precautions for Safe Handling and Use Steps to be Taken in Case Material is Released or Spilled There is no release of material unless the case is damaged or battery is misused overcharged If release occurs stop flow of material contain absorb all spills with dry sand earth or vermiculite Do not use combustible materials Neutralize spilled material with soda ash sodium bicarbonate lime etc Wear acid resistant clothing boots gloves and face shield Dispose of
64. ong period before declining to an end voltage For 6V For 12V Battery Battery 6 5 13 0 6 0 5 5 5 0 Terminal Voltage 4 5 4 0 20 40 60 2 4 6 810 20 k Minutes k Hours Discharge Time Figure 4 Discharge Characteristic Curves at 20 C 68 F Open Circuit Voltage Open circuit voltage varies according to ambient temperature and the remaining capacity of the battery Generally open circuit voltage is determined by the specific gravity of the electrolyte Discharging a battery lowers the specific gravity The open circuit voltage of a Power Sonic battery is 2 16 V cell when fully charged and 1 94 V cell when completely discharged As seen in Figure 4 under load the battery can deliver useful energy at less than 1 94 V cell but after the load is removed the open circuit voltage will bounce back to voltages shown in Figure 5 dependent upon residual capacity For 6V For 12V Battery Battery 6 8 Terminal Voltage 20 40 60 80 100 Residual Capacity Figure 5 Open Circuit Voltage Characteristics 8 We ve Got The Power Performance Data Temperature Actual capacity is a function of ambient temperature and rate of discharge At 20 C 68 F rated capacity is 100 The capacity increases slowly above this temperature and decreases as the temperature falls Even at 40 C 40 F however the Power Sonic battery will still function at better than 30 of its rated capacity when discharged
65. r battery differences charge the string in 24 volt battery groups through a constant current source with zener diode regulation across individual batteries or battery groups Recharge time depends on the depth of the preceding discharge and the output current of the charger To determine the approximate recharge time of a fully discharged battery divide the battery s capacity amp hrs by the rated output of the charger current amps and multiply the resulting number of hours by a factor of 1 75 to compensate for the declining output current during charge If the amount of amp hrs discharged from the battery is known use it instead of the battery s capacity to make the calculation POWER ly ENG 7 MUM M SONI ZM POWER SONIC Rechargeable Batteries 21 22 We ve Got The Power POWER SONIC Rechargeable Batteries 23 Active Material The active electro chemical materials used in the manufacture of positive and negative electrodes Ambient Temperature The prevailing surface temperature to which a battery is exposed Ampere Unit of measurement for electric current Ampere Hour The product of current amperes multiplied by time hours Used to indicate the capacity of a battery Also Amp Hr or A H Battery Two or more cells connected together most typically in series C Used to signify a charge or discharge rate equal to the capacity of a battery di
66. r respiratory tract skin and eyes For exposure up to 10F use MSA Comfoll with type H filter Above 10F use Ultra Twin with type H filter This product is not considered carcinogenic by NTP or OSHA Skin Contact Sulfuric acid Severe irritation burns and ulceration Lead Compounds Not absorbed through the skin Continued on next page Power Sonic MSDS Page 3 of 6 Ingestion Sulfuric acid May cause severe irritation of the mouth throat esophagus and stomach Lead Compounds May cause abdominal pain nausea vomiting diarrhea and severe cramping Acute ingestion should be treated by a physician Eye Contact Sulfuric acid Severe irritation burns cornea damage and possible blindness Lead Compounds May cause eye irritation Acute Health Hazards Sulfuric acid Severe skin irritation burns damage to cornea may cause blindness upper respiratory irritation Lead Compounds May cause abdominal pain nausea headaches vomiting loss of appetite severe cramping muscular aches and weakness and difficulty sleeping The toxic effects of lead are cumulative and slow to appear It affects the kidneys reproductive and central nervous systems The symptoms of lead overexposure are listed above Exposure to lead from a battery most often occurs during lead reclamation operations through the breathing or ingestion of lead dust or fumes Chronic Health Hazards Sulfuric acid Possible scarring of the
67. res however charge efficiency is reduced at temperatures above 45 C 113 F charge efficiency increases so rapidly that there is a danger of thermal runaway if temperature compensation is not precise The effect of temperature on charge voltage is less critical in float applications than in cyclic use where relatively high charge currents are applied for the purpose of short recharge times Temperature effects should definitely be considered when designing or selecting a charging system Temperature compensation is desirable in the charging circuit especially when operating outside the range of 5 C to 35 C 41 F to 95 F The temperature coefficient is 2mV cell C below 20 C 68 F in float use and 6mV cell C below 20 C in cyclic use For higher temperatures the charge voltage should be correspondingly decreased Ambient Charge Voltage Per Cell Temperature Cyclic Use V Float Use V 40 C 40 F 2 85 2 95 2 38 2 43 20 C 4 F 2 67 2 77 2 34 2 39 10 C 14 F 2 61 2 71 2 32 2 37 0 C 32 F 2 55 2 65 2 30 2 35 10 C 50 F 2 49 2 59 2 28 2 33 20 C 68 F 2 43 2 53 2 26 2 31 25 C 77 F 2 40 2 50 2 25 2 30 2 37 2 47 2 24 2 29 30 C 86 F 40 C 104 F 2 31 2 41 2 22 2 27 50 C 122 F 2 25 2 35 2 20 2 25 Table 4 Recommended charge voltages for different temperatures Top Charging All batte
68. ry lose capacity through self discharge it is recommended that a top up charge be applied to any battery that has been stored for a long period of time prior to putting the battery into service To successfully top charge a battery stored for more than 12 months the open circuit voltage must be higher than 2 0 volts per cell in this case always confirm open circuit voltage prior to attempting top up charging 18 We ve Got The Power Charging Efficiency The charging efficiency n of a battery is expressed by the following formula AH Discharged After Fully Charged n u AH Delivered to Battery During Charge The charging efficiency varies depending upon the state of charge of the battery temperatures and charging rates Figure 21 illustrates the concept of the state of charge and charging efficiency As shown in Figure 22 Power Sonic batteries exhibit very high charging efficiency even when charged at low charging rates 2 2 I u 9 m 6 5 o 50 State of Charge Figure 21 Charge efficiency vs state of charge Charge Efficiency 0 001 0 002 0 005 0 01 0 02 Charging Current xCA Figure 22 Charge efficiency vs charging current POWER SONIC Rechargeable Batteries 19 Important Do s and Don ts Power Sonic rechargeable sealed lead acid batteries are designed to provide years of dependable service Adherence to the following guidelines will ensure that battery
69. s from immediate hazard area if it can be done with minimal risk Water spray may be useful in minimizing or dispersing vapors and to protect personnel Cool equipment exposed to fire with water if it can be done with minimal risk Avoid spreading burning liquid with water used for cooling purposes 6 ACCIDENTAL RELEASE MEASURES This material may burn but will not ignite readily Keep all sources of ignition away from spill release Stay upwind and away from spill release Notify persons down wind of the spill release isolate immediate hazard area and keep unauthorized personnel out Stop spill release if it can be done with minimal risk Wear appropriate protective equipment including respiratory protection as conditions warrant see Section 8 Prevent spilled material from entering sewers storm drains other unauthorized drainage systems and natural waterways Dike far ahead of spill for later recovery or disposal Spilled material may be absorbed into an appropriate absorbent material Notify fire authorities and appropriate federal state and local agencies Immediate cleanup of any spill is recommended If spill of any amount is made into or upon navigable waters the contiguous zone or adjoining shorelines notify the National Response Center phone number 800 424 8802 7 HANDLING AND STORAGE Handling Do not enter confined spaces such as tanks or pits without following proper entry procedures such as ASTM D 4276 and 29CFR 191
70. s per cell fast is applied to the terminals of the battery Depending on the state of charge the cell may temporarily be lower after discharge than the applied voltage After some time however it should level off During charge the lead sulfate of the positive plate becomes lead dioxide As the battery reaches full charge the positive plate begins generating dioxide causing a sudden rise in voltage due to decreasing internal resistance A constant voltage charge therefore allows detection of this voltage increase and thus control of the current charge amount Additional information regarding charging methods can be found on pages 13 through 19 Charging Charging Characteristics During constant voltage or taper charging the battery s current acceptance decreases as voltage and state of charge increase The battery is fully charged once the current stabilizes at a low level for a few hours There are two criteria for determining when a battery is fully charged 1 the final current level and 2 the peak charging voltage while this current flows Charging Methods Selecting the appropriate charging method depends on the intended use cyclic or float service economic considerations recharge time anticipated frequency and depth of discharge and expected service life The key goal of any charging method is to control the charge current at the end of the charge Charge Charging Charged Volume Current Voltage Charge at 0
71. tery Power Module should be recharged at least once every 6 months while in storage at room temperature More frequent recharging is required when stored at higher temperatures A float charger is recommended WARNING When completely discharged the electrolyte is reduced nearly to water Avoid freezing conditions as the electrolyte can freeze and expand damaging the plates in the SeaBattery Power Module cells After the last deployment or battery use fully recharge the SeaBattery Power Module before storing Although the battery can be used in any position it should be stored upright The battery case does not need to be disassembled for storage Check the battery periodically for excess gas production and release any gas bubble During extended storage at elevated temperatures gas production may be more significant so more frequent checking may be necessary Any oil lost can be replaced prior to actual use Long term exposure to sunlight UV radiation can eventually cause some degradation in the mechanical properties of the urethane diaphragm Avoid storing the SeaBattery Power Module in full sunlight for extended periods Cover the battery for periods of exposure of longer than a week or two The plastic case is made of polyethylene which is impervious to most oils and solvents The connectors are molded neoprene contact with damaging oils or solvents e g diesel oil or organic solvents should be avoided Similarly do not use any orga
72. th of discharge time The rated capacity C of a Power Sonic battery PS PSH and PSG Series is measured by its performance over 20 hours of constant current discharge at a temperature of 20 C 68 F to a cut off voltage of 1 75 volts cell As an example model PS 610 with a rated capacity of 1 1 AH will deliver 55mA 1 20 of 1 1 AH or 0 05C for 20 hours before the voltage reaches an end voltage of 5 25 volts By cycling the battery a few times or float charging it for a month or two the highest level of capacity development is achieved Power Sonic batteries are fully charged before leaving the factory but full capacity is realized only after the battery has been cycled a few times or been on float charge for some time When a battery discharges at a constant rate its capacity changes according to the amperage load Capacity increases when the discharge current is less than the 20 hour rate and decreases when the current is higher POWER Yl come M SONI 6 We ve Got The Power 7 JudUaJINbes su 99W YoIUM AJelleq 9U szu s d lulod ey lelelpeauuuul aull SUL YdeJs y UO SenleA 9S9U JO UOND9SI9 U v 91890 S9 nUIUJ AIoedeo y SI S n PA S U OZ 40 sdwe g 3u p o d As neq e zo Aioedeo s dold ay auluuelep 0 lonpold ay eleos 8011J9A 9U UO SI pasdela aull ay pue aleos 104 UMOUY 31E U9JJn9 pue au p
73. ufacturers Name Emergency Telephone Numbers CHEMTREC Domestic 800 424 9300 Power Sonic Corporation CHEMTREC International 703 527 3887 7550 Panasonic Way Telephone Number for Information San Diego CA 92154 Power Sonic Corporation 619 661 2020 Date Issued November 19 2008 The information contained within is provided as a service to our customers and is for their information only The information and recommendations set forth herein are made in good faith and are believed to be accurate at the date compiled Power Sonic Corporation makes no warranty expressed or implied Section 2 Hazardous Ingredients Identity Information Components CAS Number Approx Wt OSHA PEL ACGIH TLV NIOSH ng m ng m ug m Inorganic Lead Lead Compounds 7439 92 1 65 75 50 150 10 Tin 7440 31 5 lt 0 5 2000 2000 N A Calcium 7440 70 2 lt 0 1 N A N A N A Electrolyte Dilute sulfuric Acid 7664 93 9 14 20 1000 1000 1000 Fiberglass Separator m 5 N A N A N A Case Material Acrylonitrile Butadine 9003 56 9 5 10 N A N A N A Styrene ABS Inorganic lead and electrolyte sulfuric acid are the main components of every Valve Regulated Lead Acid battery supplied by Power Sonic Corporation Other ingredients may be present dependent upon the specific battery type For additional information contact Power Sonic Corporation Technical Department Section 3 Physical Chemical Characteristics
74. uld never be mixed with discharged batteries when charging in series The discharged batteries should be charged before connection When a single constant voltage charger is connected across an entire high voltage string the same current flows through all cells in the string Depending on the characteristics of the individual batteries some may overcharge while others remain in a slightly undercharged condition To minimize the effects of individual battery differences use batteries of the same age amp hour and history and if possible charge in strings of no greater than 24 or 48 volts POWER SONIC Rechargeable Batteries Charging in Parallel Power Sonic batteries may be used in parallel with one or more batteries of equal voltage When connected in parallel the current from a charger will tend to divide almost equally between the batteries No special matching of batteries is required If the batteries of unequal capacity are connected in parallel the current will tend to divide between the batteries in the ratio of capacities actually internal resistances When charging batteries in parallel where different ratios of charge are to be expected it is best to make provisions to assure that the currents will not vary too much between batteries Holding a small resistance in series with each battery is all that is needed Temperature Compensation Power Sonic batteries perform well both at low and high temperatures At low temperatu
75. um and tin in the grid alloy imparts strength to the plate and guarantees durability even in extensive cycle service Lead dioxide paste is added to the grid to form the electrically active material In the charged state the negative plate paste is pure lead and that of the positive lead dioxide Both of these are in a porous or spongy form to optimize surface area and thereby maximize capacity The heavy duty lead calcium alloy grids provide an extra margin of performance and life in both cyclic and float applications and give unparalleled recovery from deep discharge Electrolyte Immobilized dilute sulfuric acid H S0 Leakproof Design amp Operational Safety The leak proof construction of Power Sonic batteries has ensured that our batteries have been approved for shipment by air both by D O T and 1 Copies of these approvals are available on our website www power sonic com 2 We ve Got The Power Relief valve In case of excessive gas pressure build up inside the battery the relief valve will open and relieve the pressure The one way valve not only ensures that no air gets into the battery where the oxygen would react with the plates causing internal discharge but also represents an important safety device in the event of excessive overcharge Vent release pressure is between 2 6 psi the seal ring material is neoprene rubber Separators Power Sonic separators are made of non woven glass fib
76. vided by one hour Thus C for a 1600 mAh battery would be 1 6 A C 5 for the same battery would be 320 mA and C 10 would be 160 mA Capacity The electrical energy available from a cell or battery expressed in ampere hours Available capacity ampere hours that can be discharged from a battery based on its state of charge rate of discharge ambient temperature and specified cut off voltage Rated capacity C the discharge capacity the manufacturer states may be obtained at a given discharge rate and temperature Capacity fade the loss of capacity due to inadequate recharging Cell The basic building block of a battery The nominal voltage of a lead acid cell is 2 volts Cell reversal the act of driving a cell into reverse polarity by excessive discharge e Primary cell cell or battery that can be discharged only once e Secondary cell the process is reversible so that charging and discharging may be repeated over and over Charge The conversion of electrical energy to chemical energy the process which restores electrical energy to a cell or battery e Charge retention a battery s ability to hold a charge It diminishes during storage e Charge acceptance quantifies the amount of electric charge that accumulates in a battery Float charge maintains the capacity of a cell or battery by applying a constant voltage 24 We ve Got The Power Charge Continued e Trickle charge maintains th
77. x In an emergency almost any type of oil can be used oils that will not damage rubber are best such as mineral oil high viscosity is best white oils silicon oil cooking oils or any oil that will not solidify at low temperatures WATER INSIDE CASE Unless completely flooded above the top of the battery some water inside the case should not cause battery failure A non hardening marine grade gasket lubricant e g AquaLube is used between the case and the diaphragm to help the seals properly seat BOLT TIGHNESS It is important that the bolts that secure the top to the case are tightened to the correct torque specifications The bolts around the perimeter of the box may loosen over time Check the torques periodically Tighten the center bolts on each side until the edge of the diaphragm begins to bulge at that point Tighten the bolts down less at the corners of the box thus maintaining a uniform bulge of approximately 1 mm between the top and the case The factory torque settings are Center bolt on each side 100 in lb 11 3 N m Surrounding bolts 100 in Ib 11 3 N m Corner bolts 50 in lb 5 7 Nem If the bolts are too loose the box will slowly leak oil Over tightening will cause deformation of the diaphragm extreme over tightening can cause the diaphragm to tear Inspect the SeaBattery Power Module after the first deployment or after submersion to a significant depth Water leakage has not been a common problem check for water
78. xide gas strong oxidizers and water Contact with metals may product toxic sulfur dioxide fumes and may release flammable hydrogen gas Lead Compounds Avoid contact with strong acids bases halides halogenates potassium nitrate permanganate peroxides nascent hydrogen and reducing agents Hazardous Decomposition or Byproducts Sulfuric acid Sulfur trioxide carbon monoxide sulfuric acid mist sulfur dioxide and hydrogen sulfide Lead Compounds High temperatures above the melting point are likely to produce toxic metal fume vapor or dust contact with strong acid or base or presence of nascent hydrogen may generate highly toxic arsine gas Hazardous Polymerization Polymerization Sulfuric acid will not polymerize Decomposition Products Sulfuric Dioxide Trioxide Hydrogen Sulfide Hydrogen Conditions to Avoid Prohibit smoking sparks etc from battery charging area Avoid mixing acid with other chemicals Section 6 Health Hazard Data Routes of Entry Sulfuric acid Harmful by all routes of entry Lead compounds Hazardous Exposure can occur only when product is heated oxidized or otherwise processed or damaged to create dust vapor or fume Inhalation Sulfuric Acid Breathing sulfuric acid vapors and mists may cause severe respiratory problems Lead Compounds Dust or fumes may cause irritation of upper respiratory tract or lungs Fiberglass Separator Fiberglass is an irritant to the uppe
79. y of the negative plate the pressure relief valve will open to release excessive gas Deep Discharge Power Sonic batteries are protected against cell shorting by the addition of a buffering agent that ensures the presence of acid ions even in a fully discharged state Power Sonic defines deep discharge as one that allows the battery voltage under load to go below the cut off or final voltage of a full discharge The recommended cutoff voltage varies with the discharge rate Table 1 shows the final discharge voltages per cell It is important to note that deep discharging a battery at high rates for short periods is not nearly as severe as discharging a battery at low rates for long periods of time To clarify let s analyze two examples Battery A Discharged at the 1C rate to zero volts C for a 4 AH battery for example is 4 amps Full discharge is reached after about 30 minutes when the battery voltage drops to 1 5V cell At this point only 50 of rated capacity has been discharged 1 C amps x 0 5 hrs 0 5C Amp Hrs Continuing the discharge to zero volts will bring the total amount of discharged ampere hours to approximately 75 because the rapidly declining voltage quickly reduces current flow to a trickle The battery will recover easily from this type of deep discharge Battery B Discharged at the 0 01 C rate to zero volts O OIC for a 4 AH battery is 40mA Full discharge is reached after 100 hours when the t

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