varley red top varley red top 12v battery

varley red top varley red top 12v battery
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
VARLEY RED TOP
TM
12V BATTERY
OPERATION AND MAINTENANCE
INSTRUCTIONS
5501-0079 Issue 1
Page 1 of 9
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
CONTENTS
Section 1. IMPORTANT INFORMATION
Section 2. GENERAL GUIDELINES
Section 3. RECHARGING
3.1 General Considerations
3.2 Recharging Options
3.3 Battery Charging Voltages
3.4 Recharge times
3.5 Temperature Compensation
Section 4. TRANSPORTATION
Section 5. UNPACKING
Section 6. BATTERY CLEANLINESS
Section 7. INSTALLATION
Section 8. LOW VOLTAGE DISCONNECT
Section 9. MAINTENANCE & INSPECTION
Section 10. DISPOSAL
5501-0079 Issue 1
Page 2 of 9
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
SECTION 1. IMPORTANT INFORMATION
Please read this manual before unpacking and installing. The installation of Red Top batteries
should be undertaken by suitably qualified persons only. Failure to comply with these
instructions will render any warranties invalid.
CARE FOR YOUR SAFETY
Dispose at registered
waste handling facility
Battery must be recycled.
Protect eyes from electrolyte
Read instructions
Do not charge in sealed container
Handling
Keep flames away
Tools
Red Top Batteries are supplied in a
charged state and must be unpacked
carefully to avoid very high shortcircuit currents between terminals of
opposite polarity. Use care when
handling and moving batteries.
Appropriate lifting equipment must
be used where necessary.
In case of accidental
overcharge, flammable gas
can leak from the safety
vent. Discharge any
possible static electricity
from clothes by touching
an earth-connected part.
Use tools with insulated
handles. Do not place or drop
metal objects on the battery.
Remove rings, wristwatch and
articles of clothing with metal
parts that may come into contact
with the battery terminals.
Other safety precautions that need to be taken
No smoking, no naked flames
no sparks
Electrolyte is corrosive
Clean all acid splash in eyes or on skin with plenty of clean water. Then
seek medical help. Acid on clothing is to be washed with water.
5501-0079 Issue 1
Page 3 of 9
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
SECTION 2. GENERAL GUIDELINES AND INFORMATION
HEALTH AND SAFETY
Red Top Batteries are electrically live at all times. Care must be taken when handling the
batteries even when in a damaged or discharged condition.
Always ….
•
•
•
•
•
•
Remove all metal personal effects such as rings, metal watch bands, belt buckles
Switch off circuit before connecting or disconnecting battery
Use insulated tools
Keep sparks, flames and lighted cigarettes away from the battery
Remember – batteries are heavy; use appropriate handling techniques
Wear protective clothing (eg gloves, safety glasses etc)
Never….
•
•
•
•
•
Lift a battery by its terminals
Charge in a sealed container
Incinerate
Short circuit
Charge with a voltage greater than specified in this manual
Storage
•
•
•
If the battery cannot be installed immediately, it should be stored in a cool, clean and
dry environment
If the open circuit voltage drops to less than 12.5 volts, a recharge will be necessary.
The ambient temperature will affect the self discharge and therefore the time between
recharges
Batteries should not be kept in a discharged condition
5501-0079 Issue 1
Page 4 of 9
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
SECTION 3. RECHARGING
Red Top Batteries are Sealed Lead Acid (SLA) Batteries. They are capable of giving very
high current discharge and will provide a reliable source of power when used correctly. One
of the most important aspects of caring for your Red Top Battery is ensuring that it is
correctly recharged. This section provides an overview of the considerations when recharging
Red Top Batteries.
3.1 General Considerations
1. Red Top Batteries, like all lead acid batteries, must not be left in a discharged state,
otherwise irreversible damage may occur.
2. Red Top Batteries are designed for high power applications. Very deep discharges,
where the battery is discharged very slowly to a low voltage, are not recommended as
they may damage the battery.
3. Batteries must be fully recharged before they are stored.
4. It is not recommended to boost-charge Red Top Batteries.
3.2 Recharging options
Red Top Batteries can be recharged by the following methods:
1. Constant Voltage charging
2. Constant Current charging
3. Two or three stage charging
4. Taper charging
5. Other (Solar, wind etc.)
3.2.1 Constant Voltage Charging (i.e Alternator)
Constant Voltage Charging is the most efficient method of charging Red Top Batteries. To
obtain full recharge and maintain the capacity of the battery it is necessary to return a
minimum of 110% of the energy that has been removed during the last discharge. Correct
voltage setting and good voltage regulation of the charger are essential to maintain an
acceptable battery life. Fast recharge is possible with Red Top products although for
economic reasons batteries are usually recharged at the C/10 or C/5 rate.
3.2.2 Constant Current Charging
Constant current charging can be used with Red Top Batteries providing charging is
terminated before excessive overcharge occurs. Charge can be terminated by time or voltage
sensing but long term overcharge must be limited to C/500. Please contact our Customer
Support Staff for further assistance.
3.2.3 Two or Three Stage Constant Voltage Charging
To allow fast recharge but maximise standby life, switched voltage level charging can be
used. Charging should commence at the cyclic rate and switch down to the float charge
voltage after a preset time has elapsed. The time is established with reference to the charge
current limit (See table in Section 3.4).
3.2.4. Taper Charging
Although taper current chargers are the least expensive type of chargers, their lack of voltage
regulation can be detrimental to the life of any battery type. Half wave rectification should be
avoided because the high peak-to-average voltage ratio will reduce the service life of the
battery. It is recommended that charge rate at 15 volts/battery be between C/50 and C/100 to
prevent serious overcharging if the charger is left connected for extended periods.
5501-0079 Issue 1
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DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
The normal recharge time for a taper charger can be assessed by reference to the charge
current available at charge voltage of 13.2V allowing for the return of 120% of discharged
capacity.
3.2.5 Other Charging Methods
For application engineering support on solar, vehicles systems or other charging methods
please refer to our Customer Support Staff.
3.3. Battery Charging Voltages
Voltage levels differ for float and cyclic applications. It is essential that the mode of
operation is understood so that the correct charging method can be applied. The normal range
of recharge voltages is as follows:
Float charge = 13.5 – 13.8V per battery at 25°C
Cyclic charge = 14.2 – 14.4V per battery at 25°C
The battery temperature affects the charge voltages. If the battery will be used at temperature
extremes for extended periods then it is advisable to apply temperature compensation to the
charging voltage. See Section 3.5 for more information.
3.4. Recharge Time
Red Top Batteries can be recharged to 90% capacity in less than one hour. No current limit is
necessary at either float or cyclic voltages. If a fast charge regime is used it is necessary to
allow a longer period of recharge (typically 6 to 10 hours) every 7-10 cycles. This permits
batteries to fully recharge and ensures a maximum cycle life.
The table below shows the correct charger voltage setting for both cyclic and float
applications.
Charge Voltage
13.6 VPC (Float)
14.4VPC (cyclic)
Charger Rating
90% Rech.
100% Rech.
90% Rech.
100% Rech.
(hours)
(hours)
(hours)
(hours)
2C
1
6
C
1.5
8
C/5
7
45
6
16
C/10
12
50
11
24
5501-0079 Issue 1
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DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
3.5 Temperature Compensation
If the battery is to be operated and recharged for extended periods at extremes of temperature
then compensation should be applied to the recharge voltage. This is a function of the
internal electro-chemistry of the battery. At very low temperatures, the battery voltage must
be increased. Conversely, at high temperatures the recharge voltage must be reduced to
prevent overcharge. Temperature compensation should be applied to the charging voltages as
shown in the graph below.
Temperature Compensation Graph for RED TOP Batteries
18
17
Float Charge
Cyclic Charge
Charge voltage (12V battery)
16
15
14
13
12
-40
-20
0
20
40
60
80
Temperature (°C)
For more information on temperature compensation please refer to our Customer Support
Staff.
SECTION 4. TRANSPORTATION
Red Top batteries are classed as “Non Hazardous” for transportation by air, sea or road. They
may therefore, be transported without restriction, without the use of Hazardous Goods
Precautions.
5501-0079 Issue 1
Page 7 of 9
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
SECTION 5. UNPACKING
On delivery, carefully examine the consignment for any obvious signs of transit damage and
then ensure that the goods are complete and agree with the material list, advice note or
invoice.
SECTION 6. BATTERY CLEANLINESS
Please ensure that the batteries are clean at all times. Cleaning should be carried out using a
damp soft cloth. Do not use solvents, paraffin, abrasive or proprietary cleaning fluids or
materials as this may cause permanent damage to the plastic battery cases.
SECTION 7. INSTALLATION
In adverse conditions, terminal grease, consisting of 20% lanolin in petroleum jelly, can be
used to protect the terminal against external corrosive substances. Whilst not harmful to the
battery, silicone grease should not be used as this can interfere with other electronic
components.
Ensure that the correct torque setting is applied to the terminal fasteners. Please note: Over
tightening may result in damage to the terminal. See the battery datasheet for the correct
terminal torque settings. Use an Insulated Torque Wrench to tighten the terminals.
When installed in a vehicle, the battery should be protected against excessive vibration with
suitable anti-vibration foam. For details of battery mounting brackets contact DMS
technologies at www.dmstech.co.uk.
SECTION 8. LOW VOLTAGE DISCONNECT
On-load battery voltage should not normally be allowed to fall below 10.0 Volts for discharge
times greater than 30 minutes. A low voltage disconnect must always be used where possible
to maintain the integrity of the battery system. This should completely isolate the battery
(including removing any control circuit load) until power is fully restored to the charging
equipment.
5501-0079 Issue 1
Page 8 of 9
DMS technologies
TM
VARLEY RED TOP
Operation and Maintenance
SECTION 9. MAINTENANCE AND INSPECTION
Red Top Batteries are Sealed Lead Acid Batteries and require no specific maintenance during
their lifetime. However, we recommend that the batteries are periodically inspected. The
optimum maintenance and inspection procedure will vary considerably according to the
application, number and critical nature of installations, along with other commercial
considerations.
What to Inspect
Method
Action
Check case for damage,
If a concern is found check
Appearance
cracks, splits, dents other the cause and replace the
impairment.
battery as necessary.
Check for contamination If contaminated isolate and
Cleanliness
by dust.
clean with a soft damp cloth.
Check for corrosion of
Perform cleaning &
General condition
the terminals, connecting corrosion prevention
cables and enclosure.
treatment.
SECTION 10. DISPOSAL
In accordance with the Waste Batteries Regulations Red Top Batteries must be recycled by an
approved battery treatment operator at their end of life.
DMS technologies operate a ‘Take back’ policy where waste batteries can be sent back to
DMS or your supplier for disposal. For more information on battery disposal see our website
at www.dmstech.co.uk/legislation
DO NOT INCINERATE END OF LIFE BATTERIES
5501-0079 Issue 1
Page 9 of 9
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