Exide PORTFOLIO PAR20 User's Manual
Contents
1. 22 CAPACITY TESTING a 22 Capacity TS SA NEN RU m IUE 22 PAGE 10 11 11 11 11 12 12 12 13 13 13 13 13 14 14 14 14 15 16 18 23 PAGE 10 17 20 21 PAGE 25 26 el FIGURE Fig 1 Fig Fig Fig Fig Fig Fig Fig Fig O ON O OF Bb OOD O Fig mb Fig N Fig CO Fig A Fig dal Fig O Fig N Fig 00 Fig co Fig N O Fig N Fig N N Fig TABLE oo D APPENDIX A B LIST OF ILLUSTRATIONS DESCRIPTION Typical System Spacing Packaged Modules Unpacking Modules Handling Lifting Strap Placement Handling Module Typical System Arrangements I Beam Hardware Installation l Beam Support Installed Tip Over Procedure Shackle Strap Usage Tip Over Procedure Photo Module with Base Assembly After Tip Over Horizontal Stacking Shackle Strap Usage Handling and Stacking Horizontal Modules Hardware Installation Sequence Installing Hardware Completed Horizontal Stack Positioning Horizontal Base Modules Tie Plate Assemblies Stack Connections Terminal Plate Kit Materials 4 Assembly Protective Cover Materials amp Assembly Sample Record Form LIST OF TABLES DESCRIPTION Temperature Effects on Life Absolyte GX Stacking Limitations Initial Charge Voltages Float Voltage Effects on Life Equalize Charge Voltages APPENDICES DESCRIPTI2. SECTION 92 80 2008 07 Installation and Operating Instructions For ABSOLYTE GX Batteries INDUSTRIAL POWER A Division of EXIDE Technologies SECTION 1 SECTION 2 2 0 2 1 2 2 2 3 2 3 1 2 4 2 5 SECTION 3 3 0 3 1 SECTION 4 4 0 4 1 4 2 SECTION 5 5 0 5 1 5 2 5 3 5 4 5 5 5 6 o 5 7 1 5 8 5 9 5 10 SECTION 6 6 0 6 1 6 2 6 3 6 4 TABLE OF CONTENTS A E E E E E Bi PEO 6 SAFETY MESSAGES e Ae 6 General Ito Mal tios ti 6 oulturic Acid KT d CG 6 EE 6 Electrical Shock e EE 6 Static Discharge Precautions for Batteres 6 Pomo AA 6 imponan Mess ad O MERCI TID iia 6 DELIVERY INFORMATION ten s EE 7 Receipt of Shipment NE TTE 7 Concealed Damage o Po EA 7 STORAGE INFORMATION sonia ratas 7 Storage Prior to Stalin ia 7 orage ee EE 7 eremi pone ee INSTALLATION 51 7 E ac MNT Uu sai u eee see 7 Space ee E le den 7 Battery Location 4 Ambient Temperature Requirements ooccocccnccncccnccncnnncnonanonnnnnncnonanonaconaninons 7 Cajas Ela o A eo a 9 o c 9 xs diee A UU T T 9 as o PA I O o m 9 Connecting Cables Battery System to Operating Equipment c ooccccccccncccnnccnconnncnonnnccnonnnonononos 9 x QS MERE UT en o A 9 Slacking L
3. jr e da po L1 S a QQ pp Lee re Leser LEE pop Lee ie je jet ESA EE EE ESE EE ECH JIWYO 1199 1199 JIWYO 1199 1199 1 N3IY4NO JIDHAVHO ADVLIOA YSDYVHO JINLVWIIANL ADVLIOA WALSAS seiBojouu28 JUE 10 vuoisiaig Y _ _ _ _ _ _ _ _ _ _ ALVd TIVLSNI ALVG 3nNVIN AdAL S 1139 JO ON YIMOd TVIHASNON E E JIJINNN NOILVOOT AYSLLVE SSAYCCV el m E JO 39 Vd T1Vldas ANVdINOO e J1Y0d384 JINVNILNIVIA A4311VW9 311 1OSS8V Figure 22 2 24 APPENDIX A Temperature Corrected Float Voltages Expressed in Volts per Cell Float Voltage at 25 Float Voltage at 77 F 2 23 2 24 2 25 2 26 2 27 2 23 2 24 2 25 2 26 2 27 3 235 2 30 4 235 235 2 29 2 33 5 234 235 J __ 2 29 2 33 6 234 25 __ 2 29 2 33 7 233 234 235 J 2 28 2 32 7 8 233 234 235 J 2 28 2 32 9 232 233 234 235 2 28 2 32 10 232 233 234 235 2 28 2 32 2 31 2 31 o 3 2 27 2 27 2 31 2 27 2 31 229 2 31 2 35 229 229 226 227 228 229 2 30 2 28 2 28 2 27 2 30 2 34 2 30 2 34 2 29 2 33 ech Ww NO N o zl o Al A NTN Oo E ON Co o oj o 25 o NwN 2 o 2 26 2 30 2 26 2 30 2 25 2 27 2 29 2 25 2 25 2 25 2 24 225 226 227 228 2 24 225 226 227 2
4. When all system assembly has been completed as well as initial testing including initial charge and cell float volt age readings all covers should be installed Covers should remain in place at all times during normal opera tion of the battery system 11 1 Module Clear Cover Installation Refer to Figure 21 for Module Clear Cover installation Install standoff legs and standoff keys first as shown The cover is then installed by grasping it so that the GNB logo is upright Locate slots at bottom of cover to the bot tom standoff legs and slide in place Locate holes at top of cover and install to top standoff legs Refer to Figure 21 SECTION 12 INITIAL CHARGE 12 0 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 charger positive terminal and battery negative terminal to charger negative terminal Failure to perform the initial charge within the time limits stated in section 4 2 will affect the performance and life of the battery and may void the warranty General 12 1 Constant Voltage Method Constant voltage is the only charging method allowed Most modern chargers are of the constant voltage type Determine the maximum voltage that may be applied to the system equipment This voltage divided by the num ber of cells
5. 30 24 2 33 18 2 35 12 2 Record cell voltages hourly during the last 3 hours of the charge time If after the charge time has completed but the lowest cell voltage has continued to rise you may extend the charge monitoring cell voltages hourly until the lowest cell voltage ceases to rise 3 Proceed to Step 3 BILL OF MATERIALS MODULE CLEAR COVER MATERIALS DESCRIPTION QTY PER SYSTEM 3 Cwe 2 Sumofleg otandoff Key V PARTS SHOWN KEY KEY THREADS ARE INSERTED KEY IS PUSHED INTO THE Q STANDOFF LEG INTO THE HOLE CHANNEL HOLE KEY SHANK TRAY CHANNEL IN THE CHANNEL KEEPS IT CENTERED STANDOFF LEG IS PARTIALLY LET GO OF THE KEY TURN KEEP TURNING THE LEG THREADED ONTO THE KEY LEG CLOCKWISE KEY WILL UNTIL IT TIGHTENS STILL TWO HANDS USED ROTATE UNTIL IT HITS DO NOT OVER TIGHTEN THE CHANNEL Assembly Instructions Install standoff legs and standoff keys to module channel as shown The cover is then installed by grasp ing it so that the GNB logo is upright Locate slots at bottom of cover to bottom standoff legs and slide in place Locate holes at top of cover and install to top standoff legs Standoff legs need not be removed to access cells simply remove protective cover Module Clear Cover Materials and Assembly Figure 21 18 STEP 3 1 The initial charge is complete Charger voltage can now be reduced to float voltage setting per Section 13 2 For a target float charge of 2 25 VPC
6. 6 UNPACKING PACKAGED MODULES Figure 2 6 0 General Do not remove shipping materials if a storage period is planned unless charging is required per Section 4 2 The battery modules are generally packed in groups Lag bolts retain the modules to the shipping pallet together with a protective hood bolted in place Modules are also bolted together at the top adjacent channels See Figure 2 6 1 Accessories NOTE Check accessory package against packing list to assure completeness Do not proceed with instal lation until all accessory parts are available Accessories are packed separately and will include the following Layout wiring diagram Installation and operating instructions Lifting straps and lifting shackles Bottom Supports beams Hardware bag for beam installation Hardware bag for module to module connections Standard clear covers op clear covers Clear cover mounting brackets and assembly hardware Terminal plates Terminal plate mounting bracket Terminal plate hardware kit Terminal Plate Cover and assembly hardware Module tie plates and hardware where required Lead Tin Plated copper connectors Hardware bag for connectors NO OX ID A grease e Battery warning label e Battery nameplate Cell numerals with polarity indicators e Shims leveling e Seismic Shims where required Alignment drift pins Hegistered Trademark of Sanchem Inc 6 2
7. 9 through 11 to perform the tip over procedure The module l Beam assembly tip over should be per formed first This procedure can be performed using a portable boom crane or fork lift in conjunction with the lift ing straps and lifting shackles supplied A Install lifting strap using lifting shackles in channel base holes at each end of module upper front channel as shown in Figure 9 B Center the lifting hook onto strap and lift until strap is under tension and raises bottom of module from floor surface C While exerting manual force on the upper front of module lower hoist until module is in horizontal posi tion See Figures 10 and 11 D After tip over procedure when module is horizontal install the four lifting shackles and two lifting straps as shown in Figure 12 to position and handle battery in horizontal position UPPER FRONT CHANNEL S ca FLOOR LINE FLOOR LINE a TIP OVER PROCEDURE SHACKLE STRAP USAGE Figure 9 NOTE for Figure 9 1 One strap with shackles used for tip over procedure 2 Observe channel hole used as well as direction of shackle insertion 3 Tip over procedure for single modules only TIP OVER PROCEDURE MODULE AFTER TIP OVER Figure 10 Figure 11 HORIZONTAL STACKING SHACKLE STRAP USAGE Figure 12 Where floor anchoring is required position module l Beam assembly in desired location Mark floor through l beam holes and remove module base assembly Install floor anchorin
8. CO OLD O CO SE t CO OO O OD OD 1 09 co INM co sr SF SE SE SE SF SE SE SE SE LO LO LO LO LC LOO LO PLO LO LO e CN co sr t COTR CO OQ O CN WOON D O Figure 22 1 x 23 NUN NENNEN 28 23 ADDITIONAL COMMENTS SLN3ANINOO TWNOILIdOV ap Lee joe j jo post L _ Sez je j je jer L po ez Sead et ev loop BEE j j jt j jh pp ez 1e 19 oer L pp ozy dof j ijs eet AAA AA E E EA AE pp ez j ea j ert op zz L Let op tez et L pp poz joe jor y Sez Le 164 oe op ez 181 18r po B L2 12 y L ee joe jew foa loop cee d j js oa op jr l S 199 Leet op ez Lee 186r jee L Lec je jew j jee LL LL l l1 19 Te _ pp Lee po j J y jog pp 19e Le pes oer L _ po ez esp j eet j eet L Le op pL j jc pp zp 19 je foa EEE RSS T IP Tp 4 1 alo po
9. connected in series will establish the maxi mum volts per cell VPC that is available Table C lists 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 Temperature Correction of Charger Voltage V corrected V25 C T actual 25 C x 0055 V C Or V corrected V77 F T actual 77 F x 003V PF Please refer to Appendix A for standard values STEP 1 1 Set constant voltage charger to maximum setting with out exceeding 2 35 VPC Example For a target charge of 2 35 VPC on a 24 cell system you would set the charger voltage to 56 4 volts Depending on the battery s state of charge the charger may go into current limit at the beginning and decline slowly once the target charge voltage is reached 2 Record time and current at regular intervals every hour as a minimum 3 Continue charging the battery until there is no further drop in charge current over 3 consecutive hours This could take days if the battery has been in storage for a long time 4 When the current has stabilized proceed to step 2 STEP 2 1 Continue the charge for the time listed in Table C depending on the charger voltage setting The time is IN ADDITION to the time spent charging in Step 1 Example charge for 12 hours if the charger voltage is set to 2 35 VPC TABLE C EQUALIZE CHARGE 77 F CELL VOLTS TIME HOURS 2
10. not l beam edges Refer back to Figure 1 Refer to layout wiring diagram for seismic shim require ments 8 2 2 Stack Tie Plates At this time stack tie plates should be installed It will be necessary to temporarily remove the hardware fastening the base modules to the I beams 14 To achieve maximum stack stability especially where seismic conditions may exist as well as proper interfacing of inter stack connections metal tie plates are provided The plates used on stacks end to end are 3 x 1 x 1 8 with two 9 16 holes Use one tie plate at each interface to connect the module channels of adjacent stacks See Figure 18 M10 SERRATED VU FLANGE BOLT TIE PLATE ef M10 SERRATED E FLANGE NUT E TOP MODULE TIE PLATE ASSEMBLIES HORIZONTAL STACKS Figure 18 Position plates on the module channels and secure with hardware as shown Where stacks have different heights for example a 3 high stack adjacent to 4 high stack install plates on shorter stack top module and adjacent module Torque hardware to 47 Newton meters 35 Ft Lbs 8 2 3 Horizontal Stacking When all base modules are set in place continue with stacking of subsequent modules Procedures for assem bly of multiple horizontal stacks are the same as outlined in section 8 1 3 Also consult layout wiring diagram Each stack should be built up in sequence to the same level until the top modules in all stacks are the last to be installed The us
11. or surveillance After installation any additional equipment installed after the battery should not compromise access to the battery system A minimum aisle space of 36 inches from modules 33 inches from clear covers should be available adjacent to the battery system See Figure 1 for typical space alloca tions required Following the spacing requirements will aid in maintenance of the battery and help maintain air flow to battery surfaces to enhance heat dissipation NOTE When planning system space requirements allow at least 6 inches past system total length wherever a ter minal plate assembly is to be located Figure 1A Allow 4 5 minimum between back to back stacks Figure 1B See Figure 1 for typical space allocations required For total length width and height dimensions of connected systems consult layout wiring diagram for the particular system 5 2 Battery Location amp Ambient Temperature Requirements It is recommended that the battery unit be installed in a clean cool dry location Floors should be level A location having an ambient temperature of 24 C 75 F to 25 C 77 F will result in optimum battery life and performance Temperatures below 25 C 77 F reduce battery charge efficiency and discharge performance Temperatures above 25 C 77 F will result in a P P P P P LLAMA MMMM 4 5 MINIMUM FOR EASE OF ASSEMBLY AND COOLING L 36 MIN 33 MIN AISLE WAY 1111111111111 1 11 1181 L
12. surfaces are free of dirt and grease by wiping with clean dry wipers isopropyl alcohol may be used to ensure proper label adhesion 10 1 Cell Numerals A set of pressure sensitive cell numerals and system polarity labels are supplied and should be applied at this time Cell numerals should be applied to the cell being identified Designate the positive terminal cell as 1 with succeeding cells in series in ascending order BILL OF MATERIALS TOP TERMINAL PLATE ASSEMBLY A PLATE TOP TERMINAL II 3 LOCKWASHER Mi0O__ CS 4 FLAT WASHER MIO 16 5 PNULMOXSD 8 amp 8 6 BOLT M10X40 8 7 COVERFROT 2 8 X COVRBACKK 2 M BECA III QA nn _ Terminal Plate Kit Materials amp Assembly Figure 20 10 2 The system polarity labels should be applied next to the positive and negative system terminals System Polarity Labels 10 3 Apply pressure sensitive warning label provided on a prominently visible module side or end Warning Label 10 4 Battery Nameplate For future reference and warranty protection apply pressure sensitive nameplate on a prominently visible module Fill in date of installation and the specified capac ity and rate SECTION 11 PROTECTIVE MODULE COVERS 11 0 General Each module is provided with a transparent protective cover to help prevent accidental contact with live electrical con nections and to provide easy visual access to the system
13. ules and one single cell module Assemblies can be rotat ed 180 for proper polarity location 8 1 1 Locate bottom l beam supports and M10 serrated flange bolts and nuts I beam supports and seismic shims should be attached to the appropriate module assembly shown on the layout wiring diagram prior to removal from ship ping pallet Consult layout wiring diagram for proper loca tion of positive negative terminals relative to l beam Bottom Supports I beams NOTE Failure to use seismic shims on systems where seismic shims are indicated will result in the assembly not meeting seismic certification crite ria Secure beam support to a module channel as shown in Figures 7 amp 8 with access slots outward Torque hardware to 47 Newton meters 35 Ft Lbs using insulated tools The side of the l beam will be approxi mately 3 2mm 125 away from the end of the channels Fl M10 SERRATED FLANGE BOLT SS M10 SERRATED FLANGE NUT Ir SEISMIC SHIM I BEAM HARDWARE INSTALLATION Figure 7 I BEAM SUPPORT INSTALLED Figure 8 Similarly install the remaining beam on the other side of the module 8 1 2 Handling The module l beam assembly may now be removed from the pallet using methods outlined in Section 6 5 See Figures 4 and 5 Remaining modules may be removed in a similar manner 8 1 3 Tip Over Procedure In order to stack modules in the horizontal position refer to Figures
14. 28 2 24 2 25 226 227 228 2 23 2 24 2 25 226 227 2 23 2 24 2 25 226 227 2 23 224 225 226 227 2 22 223 2 24 225 226 224 2 224 224 2 28 2 32 2 28 2 32 227 228 229 230 231 227 228 229 230 231 226 227 228 229 230 226 227 228 229 230 2 25 2 25 24 225 226 227 228 223 224 225 226 227 223 224 225 226 227 222 223 224 225 226 222 223 224 225 226 Battery Temperature F Battery Temperature 2 22 2 26 2 22 2 26 2 22 2 26 2 21 2 25 2 21 2 25 2 21 2 25 3 2 20 2 24 2 20 2 24 221 225 221 225 220 221 222 223 22 220 221 222 223 224 221 222 223 224 220 221 222 223 220 221 222 223 221 222 223 221 220 220 M 2 22 2 22 221 222 223 221 222 223 220 221 222 220 2 EMEN NENNEN NENNEN 00 7 2 21 2 21 2 20 NE L 220 11 12 13 14 15 16 18 19 E 21 22 24 25 E 28 EI 223 2 22 2 22 222 25 APPENDIX B MAXIMUM STORAGE INTERVAL BETWEEN FRESHENING CHARGES VERSUS AVERAGE STORAGE TEMPERATURE Days Fe ceo ceo N ceo 4 enjeueduue jualquuy mere Maximum Storage Interval Months e Ou E Ou O on E E X N SO el N ol sti O O N CO O eo
15. C Proceed with stacking of remaining modules checking that stack is plumb in both axes as stacking progress es before torquing hardware Be certain to check the layout wiring diagram for correct horizontal orientation to provide proper polarity interconnection as stacking progresses See Figure 16 for completed assembly HANDLING AND STACKING HORIZONTAL MODULES Figure 13 M10 SERRATED X FLANGE BOLT osx E Mun SERRATED F FLANGE NUT ra HARDWARE INSTALLATION SEQUENCE Figure 14 INSTALLING COMPLETED HARDWARE HORIZONTAL STACK Figure 15 Figure 16 8 2 Horizontal Multiple Stacks 8 2 1 Stacking Base Modules It is recommended that all of the first modules with bottom supports attached see Section 8 1 1 be placed in position first A chalk line floor mark should be used to assure all stacks will be in a straight line This applies for stacks end to end or end to end and back to back Refer to Sections 6 5 and 8 1 3 for handling and tip over procedures For stacks end to end module ends should be butted together so that module side channel ends meet see Figure 17 LEVEL MODULES BENEATH I BEAMS IN BOTH AXES TO ACHIEVE PROPER INTERFACING OF CHANNEL ENDS AND INSTALLATION OF INTER STACK CONNECTORS POSITIONING HORIZONTAL BASE MODULES Figure 17 For stacks back to back the two base modules are posi tioned to provide a minimum 4 5 spacing between the bottoms of the modules
16. CLEANING 18 0 Unit Cleaning Periodically clean cell covers with a dry 2 paintbrush to remove accumulated dust If any cell parts appear to be 22 damp with electrolyte or show signs of corrosion contact your local GNB representative CAUTION Do not clean plastic parts with solvents detergents oils mineral spirit or spray type cleaners as these may cause crazing or cracking of the plastic materials SECTION 19 MAINTENANCE 19 0 Connections Battery terminals and intercell connections should be cor rosion free and tight for trouble free operation Periodically these connections should be inspected CAUTION DO NOT WORK ON CONNEC TIONS WITH BATTERY CONNECTED TO CHARGER OR LOAD If corrosion is present disconnect the connector from the terminal Gently clean the affected area using a suede brush or Scotch Brite scouring pad Apply a thin coating of NO OX ID A grease to the cleaned contact surfaces reinstall connectors and retorque connections to 11 3 Newton meters 100 inch pounds All terminal and intercell connections should be retorqued at least once every vear to 11 3 Newton meters 100 inch pounds NOTE Design and or specifications subject to change without notice If questions arise contact your local sales representative for clarification SECTION 20 CAPACITY TESTING 20 0 Capacity Testing When a capacity discharge test is desired it is recom mended that it be performed in ac
17. IMITaUONS eeh 10 ss o E O 10 er EE 10 B edncm 10 cc MERE Tm 10 hies co e n 10 Recommended Installation Equipment and Gupples 10 NOE ETE PA TUM 11 Handling of Modules AA Ue o In A 11 SECTION 7 7 0 SECTION 8 8 0 8 1 1 8 1 2 8 1 3 8 2 8 2 1 8 2 2 8 2 3 SECTION 9 9 0 9 1 9 2 9 3 9 4 9 5 SECTION 10 10 0 10 1 10 2 10 3 10 4 SECTION 11 11 0 11 1 SECTION 12 12 0 12 1 SYSTEM ARRANGEMENT S aurora NAE 11 Module ArfangeltTigPl S smart ora aia bic ar 11 SYOTEMASSEMBIY EE 11 Modul Assembly Identification strict UNO RE UE US 11 Bottom Supports IDE ci POETE T 12 Handing CP WO GUIS E t T TOO OT acta STET 12 NRO A t T TEE 12 leide ah MIDI Sta EN TOO 14 Stacking Base MOQUIES NER 14 Se Ml A A o ee 14 Horizontal SLACKING EE TTE O PO DRM 14 zB zeuie meemegeillcc c 14 mcd iz Dal e RN T oO Rm canes 14 Connections System Terminals nnnnannnneennnnnennnnsennnnrnrnnrrnrrrrrnrrrrnnrrrrnsrrrrenrrrrnsrreresererenerene 15 Connections nterMODULE serorei a ae EERE 15 Connections ent 15 Heide Un e EE 15 Connections EE 15 Ja zyIgeepuEscih 15 o T rc A 15 eI EUR m T
18. LL MMMM MANNA FIGURE 1A HORIZONTAL END TO END PPP gg lp ggg ggg gg lg IP P Pg Pg MP P Pg Pg M P P Pg Pg P P P Pg P P P P P P 36 MIN 33 MIN AISLE WAY FRONT OF MODULE e 4 5 MINIMUM FOR EASE OF ASSEMBLY AND COOLING 36 MIN 33 MIN AISLE WAY Pg pg P gg p ag LLAMA AMMA FIGURE 1B HORIZONTAL BACK TO BACK FIGURE 1 TYPICAL SYSTEMS TOP VIEW TABLE A TEMPERATURE EFFECTS ON LIFE Maximum Annual Maximum Percent Average Battery Battery Reduction Temperature Temperature In Battery Life 25 77 F 50 122 F 0 30 C 86 F 50 C 122 F 30 35 C 95 F 50 C 122 F 50 40 C 104 F 50 C 122 F 66 45 C 113 F 50 C 122 F 75 50 C 122 F 50 C 122 F 83 For example If a battery has a design life of 20 years at 77 F 25 C but the actual annual average battery temperature is 95 F 35 C the projected life of the battery is calculated to be only 10 years The battery temperature shall not be allowed to exceed 50 C 122 F Minimum battery temperature is 40 C 40 F Temperature records shall be maintained by the user in accordance with the maintenance schedule pub lished in this manual 5 3 Temperature Variations Sources of heat or cooling directed on portions of the bat tery can cause temperature variations within the strings resulting in cell voltage differences and eventual compro mise of battery performance Heat sources such as heaters sunli
19. N M OD OD OD OF OD OD CD CD co 5 enjyeJeduue eBeJ0jS 1ueiquiy 26 APPENDIX C BONDING amp GROUNDING OF BATTERY RACK INTRODUCTION 1 To insure personnel safety and equipment protection operation and reliability the battery rack should be connected to the Common Bonding Network CBN 2 Electrical continuity between modules is provided through the use of serrated hardware Testing has shown that standard sys tems are compliant with the GR 1089 CORE Issue 4 Section 9 requirements of the Bonding and Grounding tests GROUNDING KIT INSTALLATION OPTIONAL 1 Each kit consists of the following components 2 6 AWG 12 in 90 cables 4 C shaped beam clamps 4 1 4 20 x 0 75 in bolts 4 1 4 20 x 1 00 in bolts 2 Using 1 1 4 20 x 1 00 in bolt per beam clamp connect 1 beam clamp to the l beam flange and 1 beam clamp to the back flange of the module see Figure 1 Be sure to securely tighten the bolts such that the paint is penetrated see Figure 2 3 Attach each end of cable assembly to a beam clamp using 1 1 4 20 x 0 75 in bolt per end see Figure 3 Tighten hardware securely 4 Repeat Steps 2 and 3 for the second horizontal support I beam Figure 1 Beam Clamp Installation Figure 2 Adequate Paint Penetration Figure 3 Cable Assembly Installation CONNECTING TO THE CBN 1 The recommended location for attaching the frame ground is the back channel on the u
20. ON Temperature Corrected Float Voltages Maximum Storage Interval Between Freshening Charges Versus Average Storage Temperature Bonding and Grounding of Battery Rack SECTION 1 GENERAL 1 0 General Information CAUTION Before proceeding with the unpacking handling instal lation and operation of this sealed lead acid storage battery the following information should be reviewed thoroughly The safety procedures should be strictly adhered to when working with Absolyte GX batteries SECTION 2 SAFETY MESSAGES 2 1 Sulfuric Acid Burns T DANGER SULFURIC ACID SULFURIC ACID BURNS CAN CAUSE BLINDNESS OR SEVERE BURNS e Batteries contain sulfuric acid which can cause burns and other serious injury In the event of contact with sulfu ric acid flush immediately and thoroughly with water Secure medical attention immediately When working with batteries wear rubber apron and rub ber gloves Wear safety goggles or other eye protection These will help prevent injury if contact is made with the acid 2 2 ue EYES Explosive Gases e FLAMES acid batteries or more of generated gases are recombined within the ty valve may open and release these gases through the SY DANGER SPARKS EXPLOSIVE GASES SMOKING Hydrogen gas formation is an inherent feature of all lead Absolyte GX VRLA batteries however significantly reduce hydrogen formation Tests have shown that 99 cell under normal operating con
21. Recommended Installation Equipment and Supplies Fork lift portable boom crane or A Frame hoist GX2000 Module Weight 315 kg 695 Ib GX3000 Module Weight 447 kg 985 Ib GX2000 3 Cell Module Weight 478 kg 1050 Ib Bottom Support I beams Height 10 mm 4 in Chalk line e Line Cord Torpedo level Plastic Plywood straight edge 1 2 x 4 x 48 Torque wrenches 100 in lbs 35 ft lbs e Ratchet wrench with 10 13 17 19 mm and 1 2 in sockets Box wrenches 10 13 17 19 mm sizes Vinyl electrical tape Paper wipers 3M Scotch Brite scour pads Hammer drill Floor anchoring Registered trademark of 3M 6 3 Unpacking Carefully remove bolts and protective shipping hood See Figure 3 Remove the bolts holding modules to shipping pallet Also remove hardware bolting upper channels of modules together Do not remove modules at this time Base supports for horizontally stacked modules are more easily attached before removing modules from pallet see Section 8 System Assembly Note Placement of modules on shipping pallet has no relationship to final installation and should be disregarded UNPACKING MODULES Figure 3 6 4 Handling of Modules The design of the modular tray permits handling by a fork lift portable crane or by a hoist sling Whichever method is used make sure equipment can safely handle the mod ule weight See Section 6 2 for module weights Always use the two lifting s
22. ar basis Monthly checks are recommended See Section 15 0 Records If battery float voltage is above or below the correct value adjust charger to provide proper voltage as measured at the battery terminals 13 3 Recharge All batteries should be recharged as soon as possible fol lowing a discharge with constant voltage chargers To recharge in the shortest period of time raise the charger output voltage to the highest value which the connected system will permit Do not exceed the voltages and times listed in Table E in Section 14 2 13 4 Determining State of Charge If the normal connected load is constant no emergency load connected the following method can be used to determine the approximate state of charge of the battery The state of charge can be identified to some degree by the amount of charging current going to the battery When initially placed on charge or recharge following a dis charge the charging current read at the charger amme ter will be a combination of the load current plus the cur rent necessary to charge the battery The current to the battery will start to decrease and will finally stabilize when the battery becomes fully charged If the current level remains constant for three consecutive hours then this reflects a state of charge of approximately 95 to 98 For most requirements the battery is ready for use If the normal connected load is variable i e telecommuni cations the following method
23. at one type of measurement cannot be converted or related easily to another Reference ohmic values are of dubious value because so many factors can affect the way the readings are made and displayed by the devices Connector configuration and AC ripple as well as differences between readings of temperature and probe placement will prevent the ohmic devices from generating consistent and meaningful data The meters work better with monoblocs and small capac ity VRLA products and less well with large gt 800 Ah VRLA and flooded battery designs Users should be par ticularly skeptical of data taken on series parallel VRLA battery configurations as the feedback signal to the device may follow unforeseen paths that can overwhelm it It is best for users to establish their own baseline values for their battery as specifically configured Do not rely on reference values If users wish to enhance normal maintenance and record keeping with ohmic measurements GNB recommends the trending of this data over time Use a first set of read ings taken 6 months after initial charge and installation as the baseline data Because cell positioning within the string connector configuration to a particular cell can affect the reading always compare each cell at baseline to itself in the new data Standalone ohmic data is not suf ficient to justify warranty cell replacement Responsible ohmic device manufacturers acknowledge that there is no direc
24. at regular intervals every hour as a minimum C Continue charging the battery until there is no further drop in charge current over 3 consecutive hours D When the current has stabilized proceed to step 2 21 STEP 2 A Continue the charge for the time listed in Table E depend ing on the charger voltage setting The time is IN ADDITION to the time spent charging in Step 1 Example charge for 12 hours if the charger voltage is set to 2 35 VPC EQUALIZE CHARGE 77 CELL VOLTS TIME HOURS 2 30 24 2 33 18 2 35 12 B Record cell voltages hourly during the last 3 hours of the charge time If after the charge time has completed but the lowest cell voltage has continued to rise you may extend the charge monitoring cell voltages hourly until the lowest cell voltage ceases to rise C Proceed to Step 3 STEP 3 The Equalize charge is now complete Charger voltage can now be reduced to float voltage setting per Section 13 2 For a target float charge of 2 25 VPC on a 24 cell system you would set the charger voltage to 54 volts SECTION 15 RECORDKEEPING 15 0 Pilot Cell A pilot cell is selected in the series string to reflect the general condition of cells in the battery The cell selected should be the lowest cell voltage in the series string fol lowing the initial charge See Section 12 0 Initial Charge Heading and recording pilot cell voltage monthly serves as an indicator of battery con
25. cordance with IEEE 1188 latest revision An equalizing charge as described in Section 14 2 must be performed within 7 days prior to the capacity test The batteries must be returned to float charging immediately after the equalize charge completes After the capacity discharge has completed the batteries can be recharged in the shortest amount of time by fol lowing the equalize charge procedure described in Section 14 2 JEEE 1188 Recommended Practice for Maintenance Testing and Replacement of Valve Regulated Lead Acid VRLA Batteries for Stationary Applications ABSOLYTE BATTERY MAINTENANCE REPORT DATE INDUSTRIAL POWER A Division of EXIDE Technologies PAGE 1 OF SERIAL NUMBER COMPANY ADDRESS BATTERY LOCATION NUMBER INSTALL DATE CHARGER VOLTAGE MANUF DATE TEMPERATURE Ohmic Cell C R lI Temp No Volts TYPE No of CELLS CHARGER CURRENT Ohmic SYSTEM VOLTAGE VO LO MioO0 DO O TIN TOO sr LO N OIOIOIO ii Temp Ohmic C R I o x gt Cell No 104 105 106 107 108 109 110 112 113 114 116 C R I Temp gt D el le lc o r lt len lw lee Let loo O ZI O G G G G G o MININIXIN ININ 60 oo 69 60 o9 od o6 oo oo o E oO E 0 EY Ca Oo0 Cx co sr to F OIOI OIT CN SF
26. covered by GNB Safety Precautions If so contact the nearest GNB representative for guidance with your particular safety problem also refer to applicable federal state and local regulations as well as indus try standards 2 3 1 Static Discharge Precautions for Batteries When maintaining a connected battery string care must be taken to prevent build up of static charge This danger is particularly significant when the worker is electrically isolated i e working on a rubber mat or an epoxy painted floor or wearing rubber shoes Prior to making contact with the cell discharge static elec tricity by touching a grounded surface Wearing a ground strap while working on a connected battery string is not recommended 2 4 Safety Alert The safety alert symbol on the left appears througout this manual Where the symbol appears obey the safety message to avoid personal injury 2 5 Important Message The symbol on the left indicates an impor tant message If not followed damage to and or impaired performance of the battery may result SECTION 3 DELIVERY INFORMATION 3 0 Receipt of Shipment Immediately upon delivery examine packaging for possible damage caused in transit Damaged packing material or staining from leaking electrolyte could indicate rough han dling Make a descriptive notation on the delivery receipt before signing If cell or unit damage is found request an inspection by the carrier and file a dama
27. d floor anchoring should be provided Such anchoring is the responsibility of the user Where non seismic conditions are anticipated anchoring is recommended for maximum stability Four 9 16 14 3 mm holes are provided in the l Beam for anchoring 5 7 Connecting Cables Battery System to Operating Equipment The Absolyte cell is a UL recognized component Battery performance is based on the output at the battery terminals Therefore the shortest electrical connections between the battery system and the operating equipment results in maximum total system performance DO NOT SELECT CABLE SIZE BASED ON CURRENT CARRYING CAPACITY ONLY Cable size selection should provide no greater voltage drop between the bat tery system and operating equipment than necessary Excess voltage drop will reduce the desired support time of the battery system 5 7 1 Paralleling Where it is necessary to connect battery strings in paral lel in order to obtain sufficient load backup time it is important to minimize the differences in voltage drop between the battery strings in parallel in order to promote equal load sharing upon discharge Therefore equal resistance of cable connections for each parallel string is important When paralleling multiple strings to a load or common bus please follow these guidelines Each parallel string must have the same number of cells same string voltage The cables connecting the positive and negative term
28. dition between scheduled overall individual cell readings 15 1 Voltmeter Calibration Panel and portable voltmeters used to indicate battery float voltages should be accurate at the operating voltage value The same holds true for portable meters used to read individ ual cell voltages These meters should be checked against a standard every six months and calibrated when necessary 15 2 Records The following information must be recorded at installation and annually for every year of operation after installation These records must be maintained throughout the life of the battery and made available for review by GNB repre sentatives for capacity or life related warranty claims Failure to collect and store these maintenance data will void the warranty Please review the warranty statement specific to the application for any additional requirements Individual cell voltages Overall string voltage Ambient temperature immediately surrounding battery Battery temperature at several places throughout the string Recommend 1 reading per battery stack More data points are recommended for larger batteries and to check for temperature gradients Readings on the tray cell cover or negative terminal are good places to mea sure battery temperature Take readings away from HVAC sources Float current measured at stack to stack connections optional Ohmic measurements optional Baseline ohmic read ings of individual cells should b
29. ditions Under abnormal operating conditions e g charger malfunction the safe vent The gases can explode and cause blindness and other serious injury Keep sparks flames and smoking materials away from the battery area and the explosive gases All installation tools should be adequately insulated to minimize the possibility of shorting across connections Never lay tools or other metallic objects on modules as shorting explosions and personal injury may result 2 3 Electrical Shock and Burns DANGER ELECTRICAL SHOCK AND BURNS RISK OF SHOCK DO NOT TOUCH UNINSULATED TERMINALS OR CONNECTORS HIGH VOLTAGE Multi cell systems attain high voltages therefore extreme caution must be exercised during installation of a battery system to prevent serious electrical burns or shock Interrupt the AC and DC circuits before working on batteries or charging equipment Ensure that personnel understand the risk of working with batteries and are prepared and equipped to take the nec essary safety precautions These installation and operating instructions should be understood and followed Assure that you have the necessary equipment for the work including insulated tools rubber gloves rub ber aprons safety goggles and face protection CAUTION If the foregoing precautions are not fully understood clarification should be obtained from your nearest GNB representative Local conditions may introduce situations not
30. e of a line chord attached to upper mod ule corners of opposite end modules as stacking pro gresses aids in alignment This completes the mechanical assembly of the battery system For installation of intermodular connections and terminal plate assembly see Section 9 For installation of protective module cover see Section 11 SECTION 9 ELECTRICAL CONNECTIONS 9 0 Post Preparation All cell posts were greased at the factory Using either a brass bristle suede shoe brush or 3M Scotch Brite scour ing pad brighten the flat copper terminal surfaces to ensure lowest resistance connections Apply a thin film of NO OX ID A grease supplied to all terminal surfaces bolts and washers This will preclude oxidation after connections are completed 9 1 Connections System Terminals Each system is supplied with a terminal plate assembly for the positive and negative termi nations These should always be used to provide proper connection to the operating equipment and cell terminals Any attempt to connect load cables directly to cell termi nal may compromise battery system performance as well as the integrity of cell post seals Refer to layout wiring diagram for location of terminal plate assembly in your battery configuration Assemble Terminal Support Bracket to module channel using hardware indi cated items 3 4 5 6 Hardware will be located in a bag labeled K17 417240P for top termination or K17417256 for side term
31. e taken 6 months from the date of initial charge Retorque connectors as part of annual maintenance ONCE PER YEAR READINGS ARE THE ABSOLUTE MINIMUM REQUIRED TO PROTECT WARRANTY More frequent readings are recommended especially for critical sites Good record keeping will prevent minor issues from escalating into more serious problems over time See Figure 22 for a sample record keeping form SECTION 16 TAP CONNECTIONS 16 0 Tap Connections Tap connections are not to be used on a battery This can cause overcharging of the unused cells and undercharging of those cells supplying the load thus reducing battery life SECTION 17 TEMPORARY NON USE 17 0 Temporary Non Use An installed battery that is expected to stand idle longer than the maximum storage interval see Section 4 2 should be treated as stated below The maximum storage interval is 6 months if stored at 25 C 77 F Give the battery an equalizing charge as per Section 14 Following the equalizing charge open connections at the bat tery terminals to remove charger and load from the battery Hepeat the above after every 6 months 25 C 77 F or at the required storage interval See Section 4 2 for adjust ments to storage intervals when the storage temperature exceeds 25 C 77 F To return the battery to normal service re connect the bat tery to the charger and the load give an equalizing charge and return the battery to float operation SECTION 18 UNIT
32. ements that the upper bolts be installed first to reduce risk of accidental shorting WASHERS SHOULD BE INSTALLED WITH THE CURVED EDGE TOWARD THE CONNECTORS ran i BOLT WASHER CONNECTOR 15 Refer to layout wiring diagram for connector placement and materials list Figure 19 shows typical module connections intrastack connections and interstack connections 9 3 Connections Inter STACK Multiple stacks end to end are interconnected as shown in layout wiring diagram Follow the procedures in Sections 9 1 and 9 3 9 4 Torquing When all inter module and inter stack connections have been installed tighten all connections to 11 3 Newton meters 100 in Lbs Use insulated tools Recheck connec tions after the initial charge due to heating during charge A E M6 STAINLESS STEEL BOLT AND WASHER STACK CONNECTIONS Figure 19 9 5 Connection Check Again visually check to see that all module terminals are connected positive to negative throughout the battery Positive terminals have red cap Negative terminals have black cap Also measure the total open circuit voltage from terminal plate to terminal plate This should be approximately equal to 2 14 volts times the number of cells in the system e g a 24 cel system would read 24 x 2 14v 51 4 volts An incorrect voltage reading may mean connectors were installed incorrectly SECTION 10 IDENTIFICATION LABELS 10 0 Surfaces Make sure
33. ency discharge C Individual cell s float is more than 0 05 volts from average D Accurate periodic records See Section 15 of individ ual cell voltages show an increase in spread since the previous semi annual readings An annual equalize charge is recommended to help ensure uniform cell performance 14 2 Equalizing Charge Method Constant voltage charging is the method for giving an equalizing charge Determine the maximum voltage that may be applied to the system equipment This voltage divided by the number of cells connected in series will establish the maxi mum volts per cell that may be used to perform the equalizing charge in the shortest period of time not to exceed 2 35 VPC applicable at 77 F 25 C Refer to Table E for voltages and recommended time periods NOTE Charge volts listed in Table E are for 77 F For other temperatures a compensation factor of 003 V F 0055 V C per cell is recommended The minimum voltage is 2 20 VPC The maximum voltage is 2 35 VPC Temperature correction does not apply outside of this range V corrected V25 C T actual 25 C x 0055 V C or V corrected V77 F T actual 77 F x 003 V PF See Appendix A for standard values STEP 1 A Set constant voltage charger to maximum setting without exceeding 2 35 VPC Example For a target charge of 2 35 VPC on a 24 cell sys tem you would set the charger voltage to 56 4 volts B Record time and current
34. g and reposition module base assembly over anchoring Prior to installing nuts and washers check that assembly is level in both axes Level using shims provid ed When level fasten assembly and torque nuts to 47 Newton meters 35 Ft Lbs In order to complete stacking of a horizontal single stack refer to Figures 12 to 15 and steps A through C listed below NOTE The use of leveling shims is required when assembling any Absolyte GX system in order to meet seismic requirements Failure to use the shims to level each module and to fill spaces between tray channels during module assembly will result in the assembly not meeting seismic certification criteria In extreme cases stack to stack connectors cannot be installed A Using Section 6 5 and 8 1 3 and the layout wiring diagram position the next module on top of first so that channels of each mate with one another Use drift pins to align channel holes Make sure channel ends and sides of the upper and lower modules are flush Hemove lifting straps and install M10 serrated flange bolts and nuts in open holes finger tight Use leveling shims to fill gaps between trays See Figures 13 14 and 15 B At this time check to see that the first two modules are plumb front to back and side to side using wooden or plastic level together with plywood straight edge This is to insure proper alignment for module interconnec tion later on Torque hardware to 47 Newton meters 35 Ft Lbs
35. ge claim 3 1 Concealed Damage Within 10 days of receipt examine all cells for concealed damage If damage is noted immediately request an inspection by the carrier and file a concealed damage claim Pay particular attention to packing material exhibiting damage or electrolyte staining Delay in notifying carrier may result in loss of right to reimbursement for damages SECTION 4 STORAGE INFORMATION 4 0 Storage Prior to Installation Do not remove shipping materials if a storage period is planned unless charging is required per Section 4 2 4 1 Storage Location If the battery is not to be installed at the time of receipt it is recommended that it be stored indoors in a cool 25 C 77 F clean dry location 4 2 Storage Interval The storage interval from the date of battery shipment to the date of installation and initial charge should not exceed six 6 months If extended storage is necessary the battery should be charged at regular intervals until installation can be completed and float charging can be initiated When in extended storage it is advised to mark the battery pallets with the date of shipment and the date of every charge If the battery is stored at 77 F 25 C or below the battery should be given its initial charge refer to Section 10 within 6 months of the date of shipment and receive a freshening charge perform per Section 10 Initial Charge at 6 month intervals thereafter Storage at ele vated tempera
36. ght or associated equipment can cause such temperature variations Similarly air conditioning or outside air vents may cause cell string temperature variations Every effort should be made to keep temperature variations within 3 C 5 F 5 4 Ventilation The Absolyte battery is a Valve Regulated Lead Acid VRLA low maintenance design Tests have confirmed that under recommended operating conditions in station ary applications 99 or more of gases generated are recombined within the cell In most cases no special ventilation and or battery room is required Consult your local building and fire codes for requirements that may apply to your specific location Hydrogen and oxygen gases can be vented to the atmos phere under certain conditions Therefore the battery should never be installed in an air tight enclosure Sufficient pre cautions must be taken to prevent excessive overcharge 5 5 Floor Loading The floor of the area where the battery system is to be installed should have the capability of supporting the weight of the battery as well as any auxiliary equipment 9 The total battery weight will depend on the cell size num ber of cells as well as module configuration involved Consult layout wiring diagram for the battery system weight Prior to installation a determination should be made that the floor integrity is adequate to accommodate the battery system 5 6 Floor Anchoring Where seismic conditions are anticipate
37. i nals of each string to the load or bus should be of the same size i e same capacity cross sectional area The cables connecting the positive and negative termi nals of each string to the load or bus should be of the same length Choose the shortest cable length that will connect the battery string that is furthest from the load and cut all cables used to connect each string to the load to this same length 5 8 Stacking Limitations There are recommended limits on stacked horizontal only battery configurations see Table B and consult your layout wiring diagram TABLE B Absolyte GX Stacking Limitations for the 2 Cell Tray GX System Non Seismic Seismic GX2000 6 High 6 High GX3000 6 High 6 High GX4000 6 High 6 High GX5000 6 High 6 High GX6000 6 High 6 High 3 Cell GX2000 trays provide UBC Zone 4 compliance when stacked 4 modules high and UBC Zone 1 compli ance at 8 modules high 5 9 Terminal Plates Each system is supplied with a terminal plate assembly for the positive and negative terminations These should always be used to provide proper connection to the oper ating equipment and cell terminals Any attempt to connect load cables directly to cell termi nal may compromise battery system performance as well as the integrity of cell post seals 5 10 Grounding It is recommended that the modules or racks be ground ed in accordance with NEC and or local codes See Appendix C for recommended procedure SECTION
38. ination Assemble Terminal Plate to Support Bracket and battery posts Hardware to attach to Support bracket is also located in the terminal plate kit It is recom mended that all connections be torqued to 11 Newton meters 100 in Lbs After making cable connections assemble Terminal Plate Covers Items 7 amp 8 to the Terminal Support Bracket using hardware indicated Hardware to assemble Terminal Plate Covers will be located in the ter minal plate kit Refer to Sections 9 0 and 9 2 for electrical contact surface preparation of terminal plate components Terminal plate assembly varies with termination location Refer to layout wiring diagram termination location on your battery Figure 20 shows top termination assembly with instructions Do not make connections to operat ing system at this time 9 2 Connections Inter MODULE Consult layout wiring diagram for correct quantity of lead tin plated copper connectors required for each connection Follow procedure in Section 9 0 and brighten lead tin plated surfaces coming in contact with copper posts Apply a thin film of NO OX ID A grease to these areas NOTE Apply a minimum amount of grease to cover the surface As a rule If you can see it it s too much Where multiple connectors are required across any single connection brighten both sides of connectors along the entire length Grease these areas as well It is recom mended when installing connectors on horizontal arrang
39. m 15 ao cinis icm E E 17 E d lie LADO C E 17 A o 17 EE 17 A A 17 Transparent Cover Installation ERN Emm 17 BATTERY CHARGING Rm 17 jns S ario RTT TU ATT 17 Constant Voltage Med E T 17 SECTION 13 13 0 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 SECTION 14 14 0 14 1 14 2 SECTION 15 15 0 15 1 15 2 SECTION 16 16 0 SECTION 17 17 0 SECTION 18 18 0 SECTION 19 19 0 SECTION 20 20 0 BATTERY OPERATION 19 Cycle Method of COperaton 19 Fioating Charge Method ura etario 19 Float Charge Float eet 19 SO E E e E OOO 19 Determining Gtaie ot Charge uk 19 exo Float e e TET oO OC 20 Float Current and Thermal Management 20 AG le Y CO ER 20 Ohmic EE Eu CC 20 EQUALIZING CHARGE E Tm 20 Ci cc HH 20 Egualzing e 21 Equalizing Charge Melodia rado diana 21 RECORDKEEPING costra iii 21 o RE 21 Voltmeter E en DEE 21 ROCONI A E 21 TAP CONNEC HON G e A 22 Tab GORNO TOR GE 22 TEMPORARY NON US E 22 Temporary e A cansion ienaa idd ai Ai ranci aginak 22 UNIT CLEANING isa ciao 22 BR o AAA UT T E A 22 CONNECTIONS MAINTENANCE 22 o o
40. may be used to check the state of charge of the battery Measure the voltage across a pilot cell See Section 15 for definition of pilot cell If the voltage is stable for 24 consecutive hours the battery reflects a state of charge of approximately 95 135 Effects of Float Voltage Float voltage has a direct effect on the service life of your battery and can be the cause of thermal instability A float voltage above the recommended values reduces service life Table D shows the effects of float voltage temperature corrected on battery life TABLE D FLOAT VOLTAGE EFFECTS ON LIFE Temperature corrected 25 77 F Percent Float voltage per cell Reduction Minimum Maximum in Battery Life 2 23 2 25 0 2 28 2 30 50 2 33 2 35 75 Voltage records must be maintained by the user in accor dance with the maintenance schedule published in this manual To obtain the optimum service life from the bat tery it is important to make sure the battery s float voltage is within the recommended range 13 6 Float Current and Thermal Management Increased float current can portend a condition known as thermal runaway where the battery produces more heat than it can dissipate VRLA batteries are more prone to thermal runaway because the recombination reaction that occurs at the negative plate and reduces water loss also produces heat High room temperature improper applica tions improper voltage settings and incorrect installation prac
41. n over 100 years of technological innovation the Network Power Division leads the industry with the most recognized global brands such as ABSOLYTE SONNENSCHEIN MARATHON SPRINTER RELAY GEL and GNB FLOODED CLASSIC They have come to symbolize quality reliability performance and excellence in all the markets served Exide Technologies takes pride in its commitment to a better environment Its Total Battery Management program an integrated approach to manufacturing distributing and recycling of lead acid batteries has been developed to ensure a safe and responsible life cycle for all of its products INDUSTRIAL POWER A Division of XIDE Technologies
42. on a 24 cell system you would set the charger voltage to 54 volts SECTION 13 BATTERY OPERATION 13 0 Cycle Method of Operation In cycle operation the degree of discharge will vary for dif ferent applications Therefore the frequency of recharg ing and the amount of charge necessary will vary Generally Absolyte GX cells require approximately 105 110 of the ampere hours removed to be returned to a full state of charge The upper voltage settings recommended given that the maxium charge current is 5 of the nominal C100 Amp hour rating and the ambient temperature is 25 77 F are as follows 2 28 0 02 VPC 0 2 DOD 2 33 0 02 VPC O 3 5 DOD 2 38 0 02 VPC gt 5 DOD Due to the variety of applications and charging equipment particularly in photovoltaic systems it is recommended that you contact a GNB representative when determining proper recharge profiles 13 1 Floating Charge Method In this type of operation the battery is connected in parallel with a constant voltage charger and the critical load circuits The charger should be capable of maintaining the required constant voltage at battery terminals and also supply a normal connected load where applicable This sustains the battery in a fully charged condition and also makes it available to assume the emer gency power requirements in the event of an AC power interruption or charger failure 13 2 Float Charge Float Voltages Following are the float vol
43. pper module of the stack see Figure 4 Figure 4 Recommended Frame Ground Location 2 Once the location is determined it will be necessary to drill 2 holes for the frame ground conductor lug installer supplied Note hole size and spacing will be dependent on the lug 3 Using a grinder etc remove the paint from around the holes drilled in Step 2 Apply a thin film of NO OXID grease to the bare metal and attach the frame ground conductor lug 27 28 Exide Technologies The Industry Leader GNB Flooded ABS LYTE Elassic GNB Industrial Power a division of Exide Technologies is a global leader in stored electrical energy solutions for all major critical reserve power applications and needs Network power applications include communication data networks UPS systems for computers and control systems electrical power generation and distribution systems as well as a wide range of other industrial standby power applications With a strong manufacturing base in both North America and Europe and a truly global reach operations in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy your back up power needs locally as well as all over the world GNB Industrial Power A Division of Exide Technologies USA Tel 888 898 4GNB 4462 Canada Tel 800 268 2698 www exide com SECTION 92 80 2008 07 THON RELAY GEL el Sonnenschein Sorinter Based o
44. t relationship between percent ohmic change from baseline and battery capacity A change from baseline of 25 or less is in the normal noise or variability range Changes between 25 and 50 may call for addi tional scrutiny of the system An IEEE compliant discharge test is usually warranted on systems exhibiting more than a 50 change from baseline Consult a GNB representa tive for specific questions about ohmic data SECTION 14 EQUALIZING CHARGE 14 0 General Under normal operating conditions an equalizing charge is not required An equalizing charge is a special charge given a battery when non uniformity in voltage has devel oped between cells It is given to restore all cells to a fully charged condition Use a charging voltage higher than the normal float voltage and for a specified number of hours as determined by the voltage used Non uniformity of cells may result from low float voltage due to improper adjustment of the charger or a panel voltmeter which reads an incorrect higher output voltage Also vari ations in cell temperatures greater than 5 F 2 78 C in the series string at a given time due to environmental condi tions or module arrangement can cause low cells 14 1 Equalizing Frequency An equalizing charge should be given when any of the fol lowing conditions exist A The float voltage of any cell is less than 2 18 VPC B Arecharge of the battery is required in a minimum time period following an emerg
45. tage ranges recommended for the Absolyte Battery System Select any volts per cell VPC value within the range listed that will result in the series string having an average volts per cell equal to that value RECOMMENDED FLOAT RANGE 77 F 2 23 to 2 25 VPC NOTE Recommended float voltages are for 77 F For other temperatures a compensation factor of 003 V F 0055 V C per cell is recommended The minimum volt age is 2 20 VPC temperature correction does not apply below this voltage The maximum voltage is 2 35 VPC temperature correction does not apply above this voltage 19 TEMPERATURE CORRECTION V corrected V25 C T actual 25 C x 0055V C or V corrected V77 F T actual 77 F x 003V F See Appendix A for standard values Modern constant voltage output charging equipment is recommended for the floating charger method of opera tion of GNB Absolyte batteries This type of charger prop erly adjusted to the recommended float voltages and fol lowing recommended surveillance procedures will assist in obtaining consistent serviceability and optimum life After the battery has been given its initial charge refer to Section 12 the charger should be adjusted to provide the recommended float voltages at the battery terminals Do not use float voltages higher or lower than those rec ommended Reduced capacity or battery life will result Check and record battery terminal voltage on a regul
46. tices can increase the chances of thermal runaway As with good record keeping practices monitoring float current can prevent a minor excursion from becoming a major issue 13 7 AC Ripple AC ripple is noise or leftover AC waveform riding on the DC charge current to the battery that the rectifier did not remove It is usually more pronounced in UPS than tele com systems Proper maintenance of the UPS capacitors will reduce the amount of ripple going into the battery Establishment of absolute limits for AC ripple has always been problematic because the degree of damage it caus es depends on the wave shape peak to peak magnitude and frequency Accurate characterization of AC ripple requires an oscilloscope and even then only represents a picture of the ripple at that moment in time Whatever its exact characteristics AC ripple is always harm ful to batteries Depending on its particular properties ripple can result in overcharge undercharge and micro cycling that can prematurely age the battery The most common and damaging result of AC ripple is battery heating which can lead to thermal runaway AC ripple will decrease battery life and should be reduced as much as possible 20 13 8 Ohmic Measurements Impedance resistance and conductance testing is collectively known in the industry as ohmic measurements Each mea surement is derived using a manufacturer specific and propri etary algorithm and or frequency This means th
47. traps and four lifting shackles for lifting and placement of modules See Figure 4 HANDLING LIFTING STRAP PLACEMENT Figure 4 NOTE for Figure 4 1 Straps must be criss crossed 2 Observe lifting shackle orientation and proper channel hole use 3 See Figure 13 for handling modules in horizontal orientation 4 Never lift more than one module with straps and hooks HANDLING MODULE Figure 5 SECTION 7 SYSTEM ARRANGEMENTS 7 0 Module Arrangements Absolyte GX batteries may only be arranged horizontally Figure 6 shows some typical arrangements Absolyte GX 3 Stacks 4 High End to End Absolyte GX 2 Stacks 6 High Back to Back TYPICAL SYSTEM ARRANGEMENTS Figure 6 Modules are shipped without connectors installed The wiring diagram enclosed with shipment will show proper battery hook up Module stack height limitation depends on cell size and the seismic requirements of the application SECTION 8 SYSTEM ASSEMBLY 8 0 Module Assembly Identification Consult layout wiring diagram for total number and type of module assemblies in system Compare required module assemblies called for on layout wiring diagram with modules in shipment for completeness before continuing further The Absolyte GX has a standard module configuration of two cells per module Where application voltage requires a module may have only one cell in a two cell tray For example a 46 volt system will consist of eleven full mod
48. tures will result in accelerated rates of self discharge For every 18 10 temperature increase above 77 F 25 C the time interval for the initial charge and subsequent freshening charges should be halved Thus if a battery is stored at 95 F 35 the maximum storage interval between charges would be 3 months ref erence Appendix B Storage beyond these periods with out proper charge can result in excessive sulphation of plates and positive grid corrosion which is detrimental to battery performance and life Failure to charge accord ingly may void the battery s warranty NOTE Storage in temperatures above 25 C 77 F will result in loss of operating life Initial and freshening charge data should be saved and included with the battery historical records see Section 15 SECTION 5 INSTALLATION CONSIDERATIONS 5 0 General Prior to starting installation of the Absolyte GX Battery System a review of this section is strongly recommended Any modifications alterations or additions to an Absolyte GX system without the expressed written consent of GNB Engineering may void any warranties and or seismic qualifications Contact your GNB representative for additional information 5 1 Space Considerations It is important to know certain restrictions for the area where the battery is to be located First a designated aisle space should be provided to permit initial installation as well as for service
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