RS-2046 Product Manual

RS-2046 Product Manual
RS-2046
Installation and Operating Procedures
For
C&D Technologies TRUE Front Access TEL Series Batteries
FOLLOW MANUFACTURER’S PUBLISHED INSTRUCTIONS WHEN
INSTALLING, CHARGING AND SERVICING BATTERIES.
For additional information: www.cdtechno.com
Technical-Warranty Assistance, contact:
C&D Technologies, Inc.
1400 Union Meeting Road / PO Box 3053 / Blue Bell, PA 19422-0858
800-543-8630 or 215-619-2700
Fax 215-619-7899
Before handling cells or storing cell for future installation take time to read this manual. It contains
information that could avoid irreparable damage to the battery and/or void product warranty.
I. Purpose
The purpose of this manual is to inform installers how to receive, install and maintain C&D Technologies
front access batteries.
Safety
Installation and servicing of batteries should be performed or supervised by personnel knowledgeable
of lead acid batteries standard safety practices i.e., personal and equipment safety precautions.
Installation Tools and Materials Required
Safety Glasses – not provided
Insulated gloves (1 pair) – not provided
Digital Voltmeter – not provided
Terminal Prep Supplies – not provided
100FS/160F/180F Bus Bar (included 1 per unit)
PB00540 Bolt ¼ 20 (included 2 per unit)
Insulated 7/16” socket wrench – not provided
Inch Pound Torque Wrench (110 in lb) – not provided
Battery Numbers – not provided
TEL Series Front Access batteries
160FW Bus Bar – (included 1 per unit)
PB01706 Washer 1/4” (included 2 per unit)
Battery Description
The Valve Regulated Lead Acid (VRLA) battery is a minimal maintenance system utilizing an
oxygen recombination cycle to minimize gassing and eliminate electrolyte maintenance. The dilute
sulfuric acid electrolyte is immobilized by absorbent glass mat (AGM) separators. Each of the 2 VDC
cells (6 cells per unit) in each unit has a unique self resealing one way valve to relieve any excess
pressure generated during overcharging conditions. Four six cell units make up a 24 cell 48VDC
battery, two six cell units in series for 12 cell 24VDC applications.
ll. Safety Concerns
(Please reference C&D Material Safety Data Sheet document L-84 for additional information.)
• Electrical Hazards
Battery systems present a risk of electrical shock and high short circuit current. Remove any
metal objects (e.g. watches and rings), use properly insulated tools, wear eye protection and rubber
gloves. Observe circuit polarities, use a voltmeter to check potentials before making connections
and do not make or break live circuits.
• Disposal
Lead Acid Batteries are to be recycled. Batteries contain lead and immobilized dilute sulfuric
acid. Dispose of in accordance with Federal, State and local regulations. Do not dispose of in a
landfill, lake or other unauthorized location. For assistance contact C&D at www.standbypower.com
• Chemical Hazards
Any liquid emission from a battery may be electrolyte which contains dilute sulfuric acid this is
harmful to the skin and eyes, is electrically conductive and is corrosive. If electrolyte contacts
the skin, wash immediately and thoroughly. If electrolyte enters the eyes, promptly flush eyes with
water and seek medical attention. Neutralize spilled electrolyte with a solution of 1 lb. bicarbonate
of soda (baking soda) to 1 gallon of water.
• Fire, Explosion and Heat Hazards
Batteries can contain an explosive mixture of hydrogen gas which can vent under overcharging
conditions. Do not smoke or cause sparks in the vicinity of the battery. Do not install and charge
batteries in a sealed container. Mount the individual batteries with a minimum of 0.5'' between
units. If contained, assure the container or cabinet and room have adequate ventilation to prevent
accumulation of potentially explosive vented gas. Refer to the current issue of the National
Electric Code (NEC).
• Caution
Do not attempt to remove battery vents or add water as this presents a safety hazard and voids the
warranty. Wash hands after any contact with the battery lead terminals.
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lll. Receiving Instructions
Upon receipt, inspect the batteries for physical damage to the containers and terminals. If found, a claim
must be filed with the carrier within 10 days. Also check the packing slip to make sure all material has
arrived. The batteries are shipped fully charged. Their Open Circuit Voltage (OCV) should not be below
12.48 volts per 12 volt unit.
lV. Storage Instructions
Store batteries in a clean, dry, cool area away from radiant heat sources. Recharge batteries in storage
every 6 months or before their OCV declines to 12.48 VDC. Follow instructions as outlined in section VI
Freshening Charge.
V. Installation Instructions-Required Installation Tools & Room
Equipment
At a minimum, the following tools and equipment are required to install VRLA batteries. A digital
voltmeter, insulated 7/16” socket wrench, inch pound torque wrench (110 in. lb.), rubber gloves, safety
glasses for normal maintenance, full face shield for load testing, optional plastic apron, potable eyewash,
spill kit and fire extinguisher (Class C).
Optional test equipment, depending on the type of checkout to be performed includes; micro-ohm meter,
ohmic test set, 100 amp momentary load test set or system load bank.
Typically for Telecom applications, four individual batteries are connected in series to form a higher
voltage string of batteries (e.g. 4 each 12 volt batteries connected in series form a 48VDC battery
system). Refer to Figure 1 for a 48 VDC series connected battery string using 12 volt front access
batteries.
Two or more strings may be connected in parallel to increase the total capacity of the
system (e.g. two strings of 48 volt 75 ampere-hour batteries connected in parallel make a 48 volts
150 Amp hour battery. Refer to Figure 2 for parallel connected front access batteries.
Warranty Date Code
C&D’s front access batteries date code is located on the front panel of the battery as a four digit
number, MMYY (e.g., 1107 means November 2007).
Series -48VDC connection of individual front access batteries
Front access batteries are heavy, typically over 100 pounds each. Make sure the proper lifting and
moving arrangements to safely handle this weight have been considered before traveling to the site.
Note: Disconnect the battery string(s) (A or B) being installed from the DC source by turning
the circuit breaker off, if so equipped as noted in Figure 1.
Step 1. Beginning with the lowest shelf, string A, place each the individual front access batteries on
the shelf (4 per shelf) with approximately 1/2 inch spacing between the individual units. All the
batteries should be placed with terminals to the front of the rack / shelf. Remove and save terminal
protectors (see Figures 2 & 3).
Step 2. C&D recommends, prior to connection of inter-unit bus bars and/or cables, the battery
terminals and all contact surfaces should be cleaned, lightly brushed with a brass bristle brush or
scotch brite type pad and lightly coated with protective No-Ox-Id terminal grease.
Step 3a. Starting at the battery on the right, which is to be the positive (+) output, label it as number 1
and then label the adjacent batteries (right to left) in ascending numerical order 2, 3 & 4 (see Figures 1 ,
2 & 3).
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Step 3b. If more than one 48 VDC string is within the enclosure, number the additional batteries the same way.
Identify the bottom string as string A with the string above as string B and so on (see Figure 2).
Step 4. Properly insulate the String A power supply negative (-) cable lug (cable coming from circuit breaker
shown in Figure 1, if a circuit breaker is used) that will eventually be connected to battery 4’s negative (-)
terminal.
Step 5. Connect String A’s power supply positive (+) cable onto battery number 1’s positive (+) terminal using
the provided bolt and washer. Tighten bolt washer assembly hand tight.
Step 6. Using the provided bus bar and hardware (bolt and washer), connect between battery 1’s negative (-)
terminal to battery 2’s positive (+) terminal. Tighten bolt washer assembly hand tight.
Step 7. Using the provided bus bar and hardware (bolt and washer), connect between battery 2’s negative (-)
terminal to battery 3’s positive (+) terminal. Before inserting the washer and bolt onto battery 2’s negative (-)
terminal, place the power supply’s thermal probe on top of the bus bar (if applicable noted on Figure 1). Once
lined up insert the washer and bolt onto battery 2’s negative (-) terminal as well as battery 3’s positive (+)
terminal. Tighten bolt washer assembly hand tight.
Step 8. Using the provided bus bar and hardware (bolt and washer), connect between battery 3’s negative (-)
terminal to battery 4’s positive (+) terminal. DO NOT connect the power supply negative cable to battery 4’s
negative (-) terminal.
Step 9. Torque all the bolt washer assemblies as per the inch-pound specifications in Table 1 (except the
remaining negative (-) power supply cable).
Step 10. Carefully remove the earlier applied insulation from the power supply negative (-) cable lug. Do not
let the power supply negative (-) cable touch any terminals or any conductive surface.
Step 11. Switch the string A circuit breaker to the “on” position, assuming a positive (-) leg circuit breaker as
noted in Figure 1 (if applicable).
Step 12. To make sure the battery is connected properly, place the voltmeter’s positive (+) probe on battery 4’s
positive (+) terminal and the voltmeter’s negative (-) probe to the power supplies negative (-) lug. Check to
make sure the polarity is correct (not negative). If the value is negative (-), then the system was not wired
properly and must be corrected before it is hooked up to the power supply.
Step 13. If step 12’s value was negative (-), do not connect the negative (-) cable lug to battery 4’s negative (-)
terminal, again wrap and insulate the enclosures negative (-) cable’s lug. Switch String A circuit breaker to the
“off” position (if applicable).
Step 14. Connect the power supply negative (-) cable lug to Battery 4’s negative (-) terminal and torque to the
specification in table 1.
Step 15. Switch string A’s circuit breaker to the “on” position (if applicable).
Step 16. Replace the previously removed terminal protectors.
Step 17. Repeat the above steps on String B, String C, etc.
Series +24VDC connection of individual front access batteries
Front access batteries are heavy, typically over 100 pounds each. Make sure the proper lifting and
moving arrangements to safely handle this weight have been considered before traveling to the site.
Note: Disconnect (isolate) the battery string(s) being installed from the DC source by turning
the circuit breaker off, if so equipped as noted in Figure 4.
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Step 1. Beginning with the lowest shelf containing string A & B, place each of the individual front
access batteries on the shelf (4 per shelf) with approximately 1/2 inch spacing between the individual
units. All the batteries should be placed with terminals to the front of the rack / shelf. Remove and
save terminal protectors (see Figures 5 & 6). Place a safety shield in the center of the tray
between adjacent 24 volt battery strings.
Step 2. C&D recommends, prior to connection of inter-unit bus bars and/or cables, the battery
terminals and all contact surfaces should be cleaned, lightly brushed with a brass bristle brush or
scotch brite type pad and lightly coated with protective No-Ox-Id terminal grease.
Step 3a. Starting at the battery on the far right of the tray, which is to be the positive (+) output, label
it as number 1 and then label the adjacent battery to the left as battery number two, string A. Repeat
the numbering procedure for the adjacent string (next two batteries to the left), string B. (see Figures 4,
5 & 6).
Step 3b. If more than two 24 VDC strings is within the enclosure, number these batteries the same way.
Identify the bottom tray as string A and B with the strings above as string C and D and so on (see Figure 5).
Step 4. Properly insulate the String A power supply negative (-) cable lug that will eventually be connected to
battery 2A’s negative (-) terminal.
Step 5. Connect String A’s power supply positive (+) cable onto battery number 2A’s positive (+) terminal
using the provided bolt and washer for 24 volt DC systems (cable coming from circuit breaker shown in Figure
4). Tighten bolt washer assembly hand tight.
Step 6. Using the provided bus bar and hardware (bolt and washer), connect between battery 1A’s negative (-)
terminal to battery 2A’s positive (+) terminal. Tighten bolt washer assembly hand tight.
Step 7. DO NOT connect the power supply positive cable to battery 2A’s negative (-) terminal.
Step 8. Torque all the bolt washer assemblies as per the inch-pound specifications in Table 1 (except the
remaining negative (-) power supply cable).
Step 9. Carefully remove the earlier applied insulation from the power supply negative (-) cable lug. Do not let
the power supply negative (-) cable touch any terminals or any conductive surface.
Step 10. Switch the string A circuit breaker to the on position, assuming a positive (+) leg circuit breaker as
noted in Figure 4 (if applicable).
Step 11. To make sure the battery is connected properly, place the voltmeter’s negative probe on battery 2A’s
negative (-) terminal and the voltmeter’s positive probe to the power supplies negative (-) lug. Check to make
sure the polarity is correct (not negative). If the value is negative (-), then the system was not wired properly
and must be corrected before it is hooked up to the power supply.
Step 12. If step 12’s value was positive (+), do not connect the negative (-) cable lug to battery 2A’s negative () terminal, again wrap and insulate the enclosures negative (-) cable’s lug. Switch String A circuit breaker to
the off position (if applicable).
Step 13. If using a thermal probe, before inserting the washer and bolt onto battery 2A’s negative (-) terminal,
place the power supply’s thermal probe on top of the negative power supply lug (if applicable noted on Figure
4).
Step 14. Connect the power supply negative (-) cable lug to Battery 2A’s negative (-) terminal tightening the
bolt washer assembly hand tight. Torque to the specification in table 1.
Step 15. Switch string A’s circuit breaker to the on position (if applicable).
Step 16. Replace the previously removed terminal protectors.
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Step 17. Repeat the above steps on String B, String C, String D, String E, etc.
Parallel Connection of individual strings of batteries
C&D recommends each of the individual battery strings be cabled separately to a common junction
point or box. Each string should also contain a separate fuse or disconnect switch to facilitate
maintenance, see Figure 2 & 5. The parallel connections should be completed only when the charger
and load are not connected to the battery output circuit. The battery strings should not be ''daisy
chained'' in parallel.
Vl. Freshening Charge
When the batteries have been in storage or transit for an extended period, over 6 months or if OCV’s
are below 12.48 volts or when the number of cells in series is greater than 24, it is recommended the
battery system be given a freshening charge at 2.4 volts average per cell for 24 hours. This will
assure higher initial performance and will reduce the time period required for the cells to achieve
proper voltage balance between the individual units. Normally freshening charges are only necessary at
installation.
Vll. Float Charging
Following the freshening charge (if necessary) the battery system should be placed on “float“ charge
at between 2.25 v/c and 2.30 v/c average (approximately 13.5 to 13.8 volts/unit average for 12 volt
units at 77°F).
Vlll. Periodic Maintenance
These VRLA batteries are maintenance free with respect to the electrolyte. However, the charging
voltage, temperature, performance and connection resistances must be periodically monitored and any
necessary corrective actions taken if irregular values are observed to assure reliable standby power
when required.
Quarterly Inspection
•
•
•
•
Measure and record the system total float charging voltage at the battery terminals
Record the charger on charge output current and voltage
Record the ambient temperature and condition of ventilation equipment
Visually inspect the batteries and rack for; general appearance, cleanliness or any irregularity.
Semiannual Inspection
•
•
•
Repeat the quarterly checks
Record the on charge voltage of each unit
Optionally perform and record Ohmic checks for trending purposes
Yearly and Initial Inspection
•
•
Repeat the semiannual checks
Inspect all connections to ensure integrity.
Item
TEL12-105FS
TEL12-160FW
TEL12-160F
TEL12-180F
Bolt Size
¼-20 ¾ inch long
¼-20 ½ inch long
¼-20 ½ inch long
¼-20 ½ inch long
Wrench Size
7/16
7/16
7/16
7/16
Table 1
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Initial Torque
110 inch pounds
110 inch pounds
110 inch pounds
110 inch pounds
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