Element® SLS Railway Diesel Starting Batteries I&O Manual GB4007
Contents
1. deg C 10 20 25 30 40 50 so C80 32 50 68 77 86 104 122 140 deg F Temperature 2 8 0 VENTILATION Clean all ventilating openings to remove any collection for dirt or dust that might prevent the free circulation of air AS explained in Section 1 0 explosive gases can be produced if abnormal operating conditions exist e g charger malfunction 9 0 MAINTENANCE Because this is an Element battery there is little to do regarding maintenance operations The top of the battery should be kept clean and dry and may be washed to remove any accumulated foreign matter In the unlikely event of an accidental contamination with electrolyte or lead contain the spill and notify your local GNB representative who is equipped to handle any environmental concerns Spill kits can be ordered through your local sales representative by calling 1 888 563 6300 Never attempt to add water to the battery it has been designed to function without any such additions over its entire life Any attempt to remove the vent caps shall void the warranty 9 1 Each Shop Visit Tray Covers Remain in Place e Check the battery State of Charge SOC by measuring the Open Circuit Voltage OCV with No Load attached to the battery A fully charged battery will show an OCV of 68 8 volts per set or 34 4 volts per tray If the battery is more then 15 discharged with OCV less than 67 8 volts per set or 33 9 volts per tray apply a Boost Charge2. SLS RAILWAY DIESEL STARTING BATTERIES INSTALLATION AND OPERATING INSTRUCTIONS 1 0 SAFETY Assign battery and charger care to properly trained personnel Follow your company s Safety Instructions when working with or near diesel starting batteries Thoroughly familiarize yourself with industry and government guidelines OSHA ANSI etc for charging handling and maintaining diesel batteries In normal use the Element battery will not generate or release hydrogen gas will not release acid mist and will not leak acid This is because Element batteries are designed differently than conventional lead acid batteries in order to operate with low maintenance However there is the possibility that under abnormal operating conditions or as a result of damage misuse and or abuse these potentially hazardous conditions hydrogen gassing acid mist and leaking electrolyte could occur Batteries contain sulfuric acid which can cause burns and other serious injury In the event of contact with sulfuric acid flush immediately and thoroughly with water Secure medical attention immediately When working with batteries wear rubber apron and rubber gloves Wear safety goggles or other eye protection Batteries could generate explosive gases which when released can explode and cause blindness and other serious injury If the safety vent opens while the explosive gases are being generated e g In the event of a charger mal
3. accelerated rates of self discharge For every 18 F 10 C increase above 77 F 25 C the time interval for initial maintenance charging should be halved Thus if a battery were stored at 95 F 85 C the initial charge should be performed within 1 5 months and recharged at 1 5 month intervals thereafter Storage beyond these periods without proper charge can result in excessive sulphation of plates and positive grid corrosion which is detrimental to battery performance and life Failure to charge accordingly may void the battery s warranty 11 0 REMEMBER THESE IMPORTANT FACTS For maximum battery life and performance always be aware of these potential problem areas and take the appropriate action to correct them should they occur SHORT CIRCUITS Cause electrical leaks that run batteries down CARELESSNESS Running battery down with lights or accessories left on when engine is not running POOR DIRTY CONNECTIONS Corrosion builds up resistance that impedes often stops the flow of power to and from the battery LOW REGULATOR SETTINGS Limit the flow of recharging current to the battery thereby starving it HIGH OR UNCONTROLLED REGULATOR Permits excessive flow of current to the battery causing excessive loss of water and premature failure 12 0 WARRANTY AND RECORDS Diesel starting batteries are warranted against manufacturing defects or factors under GNB control There are many factors under the control of the
4. F 2 20 2 23 65 F to 90 F 2 23 2 27 50 F to 65 F 2 2 1 2 31 Less than 50 F 2 31 2 35 The effect of the locomotive work schedule on the correct float voltage is determined with experience If the battery is used for starting very frequently float voltages should be set at the higher end of the range indicated at the appropriate temperature similarly for infrequent battery usage float voltages should be set at the lower end of the range 7 2 Two Step Charging For two step charging the following strategy should be followed Bulk Charge Charge at temperature compensated constant voltage between 2 33 and 2 38 vpc Charge for 6 hours or until current decreases to Current stated in Table B or until temperature reaches 104 F 40 C Switch to float charge TABLE B Battery Current amps SLS 710 21 3 SLS 550 16 5 SLS 520 15 6 SLS 500 15 0 SLS 500E 15 0 Float Charge Charge at temperature compensated constant voltage between 2 20 and 2 35 voc If temperature exceeds 131 deg F 55 deg C decrease voltage to 2 20 vpc The maximum charge rate for each battery type is SLS 710 180 amps SLS 550 138 amps SLS 520 132 amps SLS 500 125 amps SLS 500E 125 amps Voltage tolerances 1 and current tolerances 0 5 amp Chart 1 Two Step Charging FLOAT CHARGE N w N N N 0 N N Voltage volts per cell
5. battery user that can damage the battery The most important user controlled factor is the battery float voltage set on the voltage regulator of the locomotive generating or charging system Many battery users rou tinely keep records of monthly readings of voltage regulator output with the engine at idle and at operating speed As explained in Section 7 0 correct adjustment of the bat tery float voltage is critical in ensuring battery performance To keep the warranty valid quarterly For additional information In the USA call 1 800 GNB RAIL In Canada call 1 800 268 2698 In Mexico call 1 771 791 4972 records of voltage regulator output or battery float voltages together with the temperature range for which adjustment is made must be kept Such records can alert the user to the existence of abnormal conditions in his application that can adversely affect the battery Preventive actions can then be taken promptly to ensure the battery is not damaged 13 0 RECYCLING U S Federal and State Regulations require that lead acid batteries be handled and disposed of in compliance with strict guidelines GNB offers disposal service for lead acid batteries In the USA call 1 888 438 5865 to arrange pick up or to get additional information In Canada call 1 800 231 9081 In Mexico call 1 630 862 2225 GNB Industrial Power USA Tel 800 872 0471 Canada Tel 800 268 2698 www exide com www tpscrail com GB4007 2013 01 Z99
6. maximum voltage is 2 35 VPC temperature correction does not apply above this voltage Tana 25 C x 0055V C corrected Vn or V Ta 77 F x 003V F corrected 7 77 F See Section 6 0 Voltage Regulator for recommended float voltage ranges at various ambient temperature ranges 4 0 INSTALLING THE BATTERY BLOCKING Negligence in properly blocking the battery in the compartment could permit battery shifting and may cause damage All trays should be securely blocked but care should be taken to avoid over tight wedging Clearance of about 1 8 should be left between the blocking and the battery trays 5 0 TERMINAL CONNECTIONS Make original connections clean and tight Inspect terminal connections regularly and keep them clean and tight Corrosion can be reduced by greasing connections with NO OX grease after cleaning with household ammonia or baking soda in water 1 Ib gal water 6 0 VOLTAGE REGULATOR The battery is only one part of a total system all of the parts of which are interrelated and interdependent The battery simply stores energy in a chemical form for use when the generating system is not running It is not a source of power but merely a reservoir The battery supplies power for starting but as soon as the engine is running the generating system must replace the power withdrawn from the battery Input from the generating system to the battery is controlled by the voltage reg
7. of 2 35 volts per cell or 75 2 volts per set until the charge current is reduced to a value that is equal to 3 amps per 100 Amp hour of the C 8 capacity rating e Monitor the battery temperature to make sure it does not exceed 104 F 40 9 2 Annual Health Check Tray Covers Removed e Check the SOC by measuring the OCV with No Load attached to the battery per the Shop Visit instructions Section 9 1 e Check all inter cell connections and terminal connections to assure a torque reading of 100 in los Confirm this torque reading by turning the torque wrench clockwise only Do not re torque by first loosing and re tightening e Check the OCV of all cells It should be 2 15 volts per cell with No Load attached to the battery No cell should read lower than 30 millivolts from the average OCV of all the cells in the battery system e Re torque the tray bolts to 160 in lbs e Clean all of the terminal connections with Scotch Brite Green and apply Sanchem Inc NO OX ID A grease to them 10 0 STORAGE OF SPARE BATTERIES Spare charged batteries should be given regular good housekeeping care A clean cool dry place free from dust and debris should be selected for storage space lf stored at temperatures of 77 F 25 C or below the battery should receive an initial charge see Section 3 0 within 3 months and recharged at 3 month intervals thereafter Storage at elevated temperatures will result in
8. SLS710 GNB InpUSTRIAL POWER A Division of Exide Technologies
9. e CAUTION Before placing the battery in service review and adhere to the Safety Guidelines listed in Section 1 0 3 0 INITIAL CHARGE Batteries lose some charge during shipment as well as during the period prior to installation A battery should be installed and given its initial charge as soon after receipt as possible Battery positive terminal should be connected to the charger positive terminal and the battery negative terminal should be connected to the charger negative terminal 3 1 Constant Voltage Method Constant voltage is the only recommended charging method POST THESE INSTRUCTIONS IN THE BATTERY MAINTENANCE AREA Determine the maximum voltage that may be applied to the system equipment This voltage divided by the number of cells connected in series 16 cells per battery tray will establish the maximum volts per cell VPC that is available Table A lists the recommended voltages and charge times for the initial charge Select the highest voltage the system allows to perform the initial charge in the shortest time period TABLE A Initial Charge 77 F Volts per Volts per Time Hrs Cell Battery Minimum 2 30 36 80 24 2 35 37 60 12 NOTE Time periods listed in Table A are for77 F 25 C For other temperatures a compensation factor of 0 003 V F 0 0055V C per cell is recommended The minimum voltage is 2 20 VPC temperature correction does not apply below this voltage The
10. function these explosive gases will be released Keep sparks flames and smoking materials away from the battery area Lift batteries with a hoist crane lift truck or similar equipment Move batteries on trucks conveyors or rollers Make sure equipment is of ample strength and properly installed CAUTION Do not use chain or wire rope slings e Never lay metal tools such as wrenches or other material on top of a battery e Disconnect the battery from the locomotive when performing main tenance and repair on the motor or the electrical system e Open or break the battery circuit before attempting repairs to terminal connections 2 0 RECEIVING BATTERIES Immediately upon delivery examine the battery for possible damage caused in transit Damaged packing material or staining from leaking electrolyte could indicate rough handling If there is evident damage the receipt should be signed and both copies carrier s and receiving copies marked Shipment Received Damaged The carrier should be called immediately and asked to make a Carrier s Inspection for Damage Report If concealed damage is later detected the carrier should be called immediately and requested to make a Carrier s Inspection for Concealed Damage Report After inspection by the carrier arrangements should be made with the local GNB Industrial Power representative to have the battery repaired before placing it in servic
11. ulator It is important to make sure that the regulator is known to be in a satisfactory operating condition and adjusted to the correct operating voltage If the voltage regulator is not in good operating condition or is adjusted to an incorrect operating voltage the battery will not function satisfactorily because the charge it receives will beinsufficient undercharge or excessive overcharged In severe cases of bad regulation and overcharging failure can take place within a year A bad regulator or one set too low can cause undercharge a condition that will literally starve the battery to death In this case more power is drawn out of the battery than is replaced As a result the battery gradually runs down until it is so low that it fails completely Undercharge is indicated by decreasing open circuit voltage readings The correct operating or battery float voltage to be set on the regulator is that which will maintain the battery in a fully charged condition This correct setting depends on two factors operating temperature and locomotive work schedule It is recommended that voltage regulator adjustments be made while the engine is at operating speeds See Section 7 for temperature compensated operating float voltages 7 0 OPERATING VOLTAGES 7 1 Single Step Charging Correct battery float voltage at different environmental temperatures are as follows Temperature Float Voltage Volts per Cell Greater than 90
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