CELLYTE Gel OPzV

STATIONARY Gel

BATTERIES

INSTALLATION and OPERATING

INSTRUCTIONS

Supplied Worldwide by :

SEC Industrial Battery

Last Revised June 2006

TABLE OF CONTENTS

SECTION CONTENT

4.2

5.0

PAGE SECTION CONTENT PAGE

1.0

1.1

GENERAL INFORMATION

Battery Characteristics

2.0

2.1

2.2

General Information

Sulphuric Acid

2.3 Gassing

3.0

3.1

3.2

Delivery Inspection

Hidden Damage

2

2

2

2

5.4

5.4.1

2

2

5.4.5

5.4.6

2

2

6.0

6.2.1

6.2.2

6.3

Electrical Connections

Cabling recommendations

Terminal

Connector

Battery to Charger Connection

Paralleling of Batteries

4

4

5

5

5

5

5

OPERATION 5

Float Voltage Requirements

Float Temp. Compensation

Maximum Charge Current

5

6

6

6

6

4.0 STORAGE 3

4.1 General

6

6

Short Term Storage 3

7.0

INSTALLATION PROCEDURES 3

3

STORAGE 6

5.1.1 Temperature

5.1.2

5.1.3

5.1.3.1

Temperature Variation

Ventilation

3 8.0

3

3

Battery Temperature Variation 3

8.1

8.2

MAINTENANCE & RECORDS 7

General Maintenance 7

General Records

8.2.1 Installation

7

7

5.1.3.2 Ventilation and Gassing 3

3

7

5.2 Unpacking

5.3 Installation

5.3.1

5.3.2

5.3.3

General

Location Layout

4

4

Horizontal Module Installation 4

5.3.4 Vertical Module Installation 4

4 9.1 General 7

7

10.0 Battery Maintenance Register 10

11.0 Technical Support 11

12.0 Battery Report 12

2

SECTION 1 - GENERAL INFORMATION

1.1 CELLYTE Gel OPzV Battery Characteristics

The CELLYTE Gel OPzV battery is a gelled Tubular positive plate sealed, valve-regulated lead-acid recombinant, low maintenance battery designed for stationary or cycling applications. This type of battery has no special ventilation or handling requirements.

Because the Gel electrolyte in the battery is immobilized, the batteries are considered dry and can be handled and shipped accordingly.

SECTION 2 - SAFETY INFORMATION

Lead acid batteries require care in installation and maintenance. Unsafe installation or maintenance procedures can cause severe injury or death.

Electrical shock or burns, acid burns and fire can result if proper safety precautions are not followed.

The following precautions apply to all battery installation and maintenance work. For more information read the following sections.

- Disconnect all power before attempting to install, remove or perform maintenance work on batteries.

When on-charge float voltages must be measured, be particularly careful because shorting a battery at this time can cause not only personal injury, but severe equipment failure as well.

- Do not tamper with any parts of the battery, including interconnect cables, vents, terminal bolts etc.

- Keep batteries clean and dry. Use ½ kg of baking soda in 4 litres of water to neutralize any possible acid. Do not use cleaners or solvents on any part of the battery. Do not allow excessive dust to accumulate on the battery or interconnect cabling.

- Keep battery inter connect cables clean, greased at the terminal post and tight. A loose connection can reduce battery standby time and cause cable fires.

WARNING Do not turn cells up side down or tilt to the front more than horizontal as this will ‘wet’ the vent with electrolyte which may be vented when the cell is charged.

The CELLYTE Gel OPzV battery is a lead acid battery and contains sulphuric acid in gelled diluted form.

Because the electrolyte is immobilized, in the event of a container rupture, no liquid acid will leak or run from the battery. However, if the internal components of the battery are touched or handled, contact with the acid will result.

2.3 Gassing

All VRLA lead acid batteries emit some gases during charging and float operation. Conventional flooded batteries release all the gases produced to the environment whereas gelled sealed, valve-regulated batteries re-combine most of the gases internally, releasing very little to the environment. Compared to a flooded battery of equal capacity, a CELLYTE Gel

OPzV battery releases a gas volume of 1% or less than the flooded battery. Because of this characteristic, no special ventilation is required under normal usage conditions.

Because some gas is released from gelled sealed lead acid batteries, never charge or use batteries in

an unventilated space. This gas consists of mostly hydrogen gas and can explode if ignited in a confined area or space. Keep sparks, flame or any other ignition source (including smoking materials) away from batteries.

CAUTION: Hydrogen gas can explode and cause serious injuries and fire. Do not allow any flame or ignition source near batteries. Always allow some ventilation around operating batteries.

Contact SEC if there are any questions regarding gassing or ventilation.

Batteries store large amounts of electrical energy.

Even a discharged battery can deliver a high short circuit current. Keep all metallic objects away from the battery terminals. Multi-cell systems can attain lethal voltages. Remove watches and all jewelry before working on batteries. Cover all tools with vinyl electrical tape to minimize the possibility of shorting a battery during installation. Never lay tools or other metallic objects on batteries. Do not allow construction work over batteries to proceed unless the battery is protected by insulating rubber mats.

CAUTION: Shorting a battery can cause serious injury, fire or explosion. Do not attempt to work on a battery unless you are familiar with battery installation procedures and have adequate safety information and equipment. Read this manual thoroughly before attempting to install the battery.

If there are any questions about safety, contact

SEC before installing the batteries. Remember, safety is always the prime concern.

SECTION 3 - RECEIPT OF EQUIPMENT

3.1 Delivery Inspection

Immediately upon delivery, inspect the cells & rack for damage caused in transit. Damaged pallets could indicate rough, improper handling in transit. Describe in detail and take photographs if possible, note any damage on the delivery receipt before signature. If any damage is found, contact the carrier immediately, request an inspection and file a damage claim.

CAUTION: Sulphuric acid can cause burns and serious injury if it comes in contact with your skin or eyes. In the event of contact with sulphuric acid, flush thoroughly with water and neutralize any residual acid with baking soda (1 kg in 4 liter’s of water). Seek medical attention immediately. Do not handle batteries if the container has been ruptured except while wearing rubber gloves. Do not try to disassemble a cell.

Within 10 days of receipt, measure and record open circuit voltages (OCV's). If any damage is found, request an inspection by the carrier and file a hidden damage claim. Do not delay this step as it may result in a loss of right of reimbursement for hidden damages.

SECTION 4 - STORAGE

4.1 General

Do not store batteries outside, exposed to the elements. Store indoors in a cool, dry location. Do not store batteries in temperatures over 35ºC. The recommended storage temperature is 20

°

C or below.

Do not stack / top load pallets, or allow any other material to be stored on top of the pallets or possible battery damage may occur. Do not store where the possibility of metallic objects falling on the battery may occur.

4.2 Short Term Storage

CELLYTE Gel OPzV batteries are shipped fully charged from the factory. If the batteries are to be stored for 9 months or less at 20ºC or below before being put into service, nothing need be done at this time. If the batteries are to be stored longer than 9 months, at temperatures greater than 20ºC, or installation is delayed beyond expected time, a storage charge may be required. A storage charge is an equalizing charge applied to a battery that is stored in open circuit (not float charging) condition. See

Section 6.5 for details.

If the storage temperature is 20ºC or less, CELLYTE

Gel OPzV batteries must be charged at least every 9 months while in storage. For every 8ºC increase above 20ºC, the storage time between charges is cut in half. Therefore, at 28ºC the maximum storage time is 4.5 months. At 24ºC the maximum storage time would be 6 months.

Storage of batteries beyond the recommended temperatures or storage times, without charging, can result in permanent loss of capacity, cell shorting and loss of float life. It can also void the battery's

warranty. Keep careful records of battery time of arrival, storage time and when last charged.

SECTION 5 - GENERAL INSTALLATION PROCEDURES

CAUTION: Before attempting to install tubular plate

CELLYTE Gel OPzV batteries, study this section and the section on safety thoroughly. Failure to do so could result in personal injury and battery or equipment damage.

5.1.1 Temperature

Battery location is very important in determining life and performance of the battery. The ideal environment would be a dry, indoors, temperature regulated area.

The ideal operational temperature is 20ºC. Operation at temperatures below this will result in a loss of battery performance and may result in a larger, more costly battery being needed. Operation at temperatures above 20ºC will result in loss of battery operational life. For every 8ºC rise in battery temperature above 20ºC, the life of the battery will be cut in half. For example, the CELLYTE Gel OPzV battery is designed for an 18+ year float service life at

20ºC. If the battery were to be continuously operated at 28ºC, the life expectancy would be halved.

5.1.2 Temperature Variation

Maintaining temperature balance across the string is very important for maximum battery life. The difference between the maximum and minimum cell temperature in a series string can be no more than

3ºC. Excessive temperature variation will result in the need for equalization and may result in loss of battery operational life.

Sources of battery temperature variation can be placement of the battery system near a heat source such as radiators, power equipment, windows or heating vents. Air conditioning vents can also cause temperature variations. It is recommended that the battery location be designed, engineered and monitored to minimize temperature variations.

5.1.3 Ventilation

Proper ventilation of CELLYTE Gel OPzV batteries is important for two reasons:

1) to minimize battery temperature variation

and

2) to minimize build up of potentially explosive

5.1.3.1 Ventilation and Battery Temperature Variation

Recombinant batteries such as CELLYTE Gel OPzV give off a small amount of heat during charging and float operations. Proper ventilation is important to remove this heat and to prevent temperature differences from arising in the string. Sufficient air circulation should be present to prevent temperature layering effects. In an improperly designed room, there can easily be a 5ºC difference in temperature between the floor and the ceiling. If this difference exists in a series string, it will result in a need for equalization and in reduced battery life.

5.1.3.2 Ventilation and Gassing

As noted, VRLA batteries emit small amounts of gas during normal charging and floating. The gas composition, while on float, is approximately 80% by volume hydrogen with the remainder being oxygen.

CAUTION: Hydrogen gas can be explosive. Never install batteries in an air-tight space. Ventilation must be provided to remove this hydrogen gas.

Allow about 1 litre per hour per cell of air exchange to prevent hydrogen accumulation.

NOTE: In virtually all cases, the amount of air circulation required for battery cooling and temperature variation maintenance will far exceed the amount of air circulation required to prevent gas buildup. However, ensure some air exchange is present in the ventilation.

5.1.4 Floor Loading

Before installing the cells/batteries, it should be ascertained that the floor has the capability to support the weight of the battery and related equipment. The total system weight will be the sum of the cells plus about 5% for the inter connectors and battery rack. It

is the responsibility of the installer to ensure adequate floor load carrying capabilities.

5.1.5 Seismic Considerations.

When specified CELLYTE Gel OPzV battery racks are capable of withstanding seismic events of UBC Zone 4 magnitude in horizontal stacks of up to 8 tiers and when properly installed. When seismic capability is desired, suitable floor anchoring should be provided.

Proper floor anchoring is the responsibility of the installer. Ensure that the anchor bolts used are of

4

sufficient strength to withstand the maximum seismic load foreseeable.

5.2 Unpacking

CELLYTE Gel OPzV batteries cells/racks are shipped on pallets. All the accessories needed for installation and use are packed in boxes and secured to the pallet. Unpack all items carefully and note the quantities received.

5.3 Installation

5.3.1 General

CELLYTE Gel OPzV cells up to 1500 ah (ETG 1700) can be installed in the vertical and horizontal position.

The horizontally positioned cells may be stacked up to

8 tiers high. Where possible, racks are configured to provide the termination at the top of the battery while providing the shortest possible connections. When a system requires fewer cells than are needed to completely fill the rack, the extra spaces will be filled with a dummy cell(s). When possible, the tiers with the dummy cells will be at the top of the rack.

CELLYTE Gel OPzV cells when mounted in the vertical position may be placed end-to-end or side-byside or a combination of the two. Note that standard

vertical configuration will be supplied unless

specified differently at time of order. Also note that cells ETG 2300, 2900 & 3500 can only be mounted vertically. The racks can be designed to meet seismic zone 0 to 4 qualifications.

NOTE: Handle cells and rack carefully. Do not try to lift the rack when the cells are in place because damage to the cells may result.

5.3.2 Location Layout

Locate and mark on the floor the position of the battery system/rack. Locate and mark the position of the floor anchor bolts. Determine the polarity location of the battery system and mark accordingly. Ensure that sufficient space is available in front or above for cell handling and placement. Do not locate the battery system near a source of heat or in direct sunlight.

5.3.3 Horizontal Cell Installation

Using the rack layout supplied assemble the steel rack, fit all the bolts but leave the bolts loose. With the wiring diagram supplied, identify the polarity of the cells to be placed in the bottom tier. Then, noting the cell polarity, slide each cell carefully into the steel rack. Repeat this procedure for the cells in each tier.

When all the cells are in place, tighten the bolts to 130 in-lbs (15 N-m).

If the system consists of multiple stacks of racks, the racks are positioned directly next to each other. The vertical sections are bolted together between stacks using the connecting studs provided.

5.3.4 Vertical Module Installation

When the cells are to be installed in the vertical position, the rack must be first fully assembled. Then the cells must be individually (carefully) lowered into the rack. It is highly recommended to attach the rack / battery system to the floor using suitable floor anchor bolts. Rack for cells installed in a vertical position may be designed to meet seismic Zone 0 to 4.

WARNING Do not turn cells upside down or tilt to the front more than horizontal as this will ‘wet’ the vent with electrolyte which may be vented when

the cell is charged.

5

Proper battery electrical connections are very important for the best battery performance. Improper battery connections can cause a loss of standby time or even a battery fire. Follow the electrical connection instructions carefully and review Section 2.4 thoroughly before working on the battery. Make sure, before connection, that all terminals and interconnects are cleaned and are covered with the No-Oxide grease provided.

CAUTION: Remove all rings and watches before installing the intercell inter connectors on the cells. Ensure that all tools are insulated with vinyl electrical tape to prevent shorting. Do not reach or lean across batteries. Remember, hazardous voltages may be present. Be aware of what you are touching at all times.

5.4.1 Cabling Recommendations

Battery ratings are specified at the terminals of the battery. The cabling used to connect the battery terminals to the load has a voltage drop (when the battery is discharging) that is dependent on cable length and conductor diameter/size. The longer the cable run, the greater the voltage drop.

The smaller the cable wire diameter, the greater the voltage drop.

Therefore, to get the best performance from the battery short, heavy duty cables are recommended.

Do not size the cables based on current carrying

capacity only. A general rule of thumb is to allow no more than a 30 mv or less of voltage drop per meter of cable run. As an example, if it is 10 meter’s from the battery to the load, the cable should be sized to allow no more than 2 x 10 x .030 = 0.6 volt drop.

In order to help select cable sizes for load connections, the following table should be consulted :

CABLE PROPERTIES AT 20ºC

U.S. CABLE AREA MAX AMPS

SIZE mm² 30mv DROP/M

8 AWG

6

8.4

13.3

15

23

4

2

1

0

00

000

0000

21.2

33.6

42.4

53.5

67.4

85.0

107.2

37

59

74

93

117

148

187

221

309

353

442

Use 1.74 amps/mm² for other cable sizes.

5.4.2 Terminal Preparation

If corroded gently clean the contact surface of the terminals with a brass bristle brush or a Scotch Brite pad. Immediately after this cleaning, apply a thin layer of No-Ox-Id "A" or NCP-2 antioxidant grease to the contact areas. A petroleum jelly such as "Vaseline" may also be used.

5.4.3 Connector Installation

The CELLYTE Gel OPzV batteries are supplied with intercell cables sized for the specified discharge time.

If stored for some time the insulated cables may need to be cleaned at the contact points prior to installation.

If the interconnect cables need to be cleaned, carefully use a Scotch-Brite pad or a soft brass bristle brush to clean the lug to bright metal. Lightly grease the contact surfaces of the cable lug before installation.

Following the supplied wiring diagram, install the intercell interconnects connecting positive to negative terminals. Carefully using the supplied 10 M bolts and tighten the insulated bolts finger tight.

CAUTION: Use extreme care not to short the battery connections. CELLYTE Gel OPzV batteries are capable of very high short circuit currents containing a very high energy level.

Before the final tightening of the intercell connections, visually check that the connections are properly made and in the proper sequence. See Section 5.4.4 for the proper procedure for checking string voltage. When proper connection has been verified, torque all intercell connections to 130 in-lbs (15 N-m).

When installing the battery load cabling, attach the load cabling to the wall or the cable tray so that the weight of the cable is not on the battery terminal plate.

If using a stiff cable, pre-bend the cable so no "spring" force is placed on the terminal plate. Failure to support the cable weight could result in unnecessary load being placed on the terminal support plate and the steel rack.

5.4.4 Voltage Checks

Visually check that all connections are properly made

(positive to negative) and are tight. Measure string

voltage, check that this is about 2.15 x No. of cells.

CAUTION: High voltage may be present.

The total string voltage should be approximately 2.12 to 2.15 volts multiplied by the number of cells in the string. If the measured string voltage is not close to the calculated value, recheck the battery connections to ensure proper polarity sequence and measure the individual cell voltages. Calculate the average cell voltage and use this value to recalculate the string voltage. If the recalculated and measured string

voltages do not match reasonably well, contact your SEC representative for further instructions.

5.4.5 Battery to Charger Connection

Ensure that the charger is disconnected from the power line. If a battery disconnect is installed, open it.

Note: The positive terminal of the battery bank

should be connected to the positive terminal of

the charger and the negative terminal of the

battery bank should be connected to the negative

terminal of the charger.

5.4.6 Paralleling of Batteries

When greater capacity is desired than available from a single cell or string, paralleling of batteries becomes necessary. Batteries must be properly paralleled in order to get the best system performance and longest battery life. The battery strings must be treated as equally as possible. This means equal length cabling to a common collection point for the load cables, uniform temperature between the strings and equal strings of batteries. Do not parallel flooded

6

batteries with valve-regulated batteries if the

charge voltages differ between the batteries.

Ask SEC for advice on paralleling flooded and VR batteries.

To check the proper paralleling of the strings, connect the strings in the final form and place a load on the battery. Measure the load cable voltage drops. The voltage drops should match within 5%.

SECTION 6 - OPERATION

The initial charge on the battery is essentially an equalization charge of the battery. Always perform this charge of the battery when it is first installed. Failure

to do so could result in uneven float voltages and

low initial capacity.

The equalization, or initial charge voltage in this case, for the CELLYTE Gel OPzV battery is 2.4 volts per cell at 20ºC or 2.38 at 25

°

C. Calculate the initial charge voltage for your installation, based on the number of cells in the string. Turn on the charger and raise the charger output voltage (using the equalization control) to the calculated value. Leave the string charging at this level for 12 hours, maximum of 24 hours.(The

battery is fully charged when the string voltage has not changed for 3 hours.) At the end of this time, reduce the charger output voltage to the float voltage 2.23 vpc at 20ºC. See Section 6.2.1

Just prior to reducing the string voltage to the float voltage, measure and record the individual cell voltages.

If the charger output voltage cannot be raised to the calculated initial charge voltage or the load cannot tolerate a charge voltage this high, raise the charger output voltage to the maximum permissible level.

Measure the charger output voltage and calculate the voltage per cell. Use the following as a guideline:

Max. Voltage Charge Time

Obtained (Hrs) Min/Max.

2.32 - 2.35 vpc 12 / 24

2.29 - 2.31 vpc 24 / 48

At voltages below 2.29 vpc, adequate equalization will not be obtained. Contact your SEC representative for additional details on procedures to equalize a battery under these conditions.

If the ambient temperature is not in the range of 20-

25ºC, the initial charge voltage will have to be

temperature compensated. the charge voltage is changed as the function of the battery temperature. The temperature correction factor

(TCF) for CELLYTE Gel OPzV batteries is -0.004 volts

/ cell / ºC from a 20ºC baseline temperature. This means that as the battery temperature rises (falls) above (beneath) 20ºC, the charge voltage must be reduced (raised) the TCF amount for every degree of change. The formula to calculate the temperature corrected voltage is :

TCV= chg. voltage (20ºC) - [T -20ºC] x (-0.004 v/c)

As an example, if the initial charge were going to be performed at 30ºC the temperature corrected charge voltage would be :

TCV = 2.40 - (30-20) x (-0.004 v/c) = 2.36 volts/cell

The float voltage is sometimes known as the continuous charge voltage. It is very important that it be calculated and set properly for maximum battery life and performance. The purpose of the float voltage is to provide enough float voltage and current to the battery to compensate for self-discharge and maintain the battery in a fully charged condition of readiness.

Failure to properly follow float voltage

recommendations can result in loss of warranty and premature battery failure.

6.2.1 Float Voltage Requirement

The allowable float voltage range for CELLYTE Gel

OPzV batteries is 2.22 to 2.24 volts/cell at 20ºC. The recommended float voltage setting is 2.23 volts/cell at

20

°

C or 2.21 volts/cell at 25

°

C.

6.2.2 Float Voltage Temperature Compensation

The float voltage temperature compensation factor is -

0.004 volts / cell / ºC from a 20ºC baseline (the same as the equalization TCF). For temperatures around

20ºC, use the following table :

°C

5

10

15

20

volts / cell

2.290

2.270

2.250

2.230 <<<Baseline

25

30

2.210

2.190

35 2.170

For temperatures outside of this range see Section 6.1 for the equation used for calculation of the temperature corrected float voltage.

6.3 Maximum Charge Current

The maximum charge current is limited to prevent the possibility of charging the batteries at a higher rate than they can efficiently accept. Greater than recommended maximum charge currents can result in excessive battery heating and gassing and a shortened battery life.

The maximum normal charge current is the C/5 rate in amps, for a 500 AH C/5 rated battery this is

100 amps. If a very rapid recharge is desired,

please contact SEC for more instructions.

6.4 Recharge

Recharge VRLA Gel batteries immediately or as soon as possible after a discharge. Do not wait more than

24 hours to initiate the recharge after the batteries have been discharged. Failure to follow this

recommendation could result in a permanent loss

of capacity due to plate sulphation.

The approximate recharge time can be calculated as follows:

---------------------- x F = number of hours to charge

Available charge current where F = 3 if the batteries are charged at the float voltage and F = 2 if an equalization voltage is needed.

The equalization charge voltage of the CELLYTE Gel

OPzV battery is 2.40 to 2.38 volts per cell at 20

°

C to

25

°

C. While equalization is not required by the

CELLYTE Gel OPzV battery under normal operating conditions, it is possible to operate the battery in

such a way that equalization would be needed.

These conditions would include:

-Temperature variation in the string greater than 3ºC

-Low float voltage

-Low operational temperature without temperature compensation

-Frequent deep discharges

-Rapid recharge required

-Long delay in recharging the battery after a discharge

-Unevenly paralleled string balance

Equalization should be performed on an 'as needed' basis. The standard equalization would be 12 / 24 hours at a constant voltage of 2.40 VPC at 20

°

C or

2.38 VPC at 25ºC. For equalization at voltages and temperatures other than the above, see Section 6.1 for methods to compensate.

Section 7 - STORAGE

When installed CELLYTE Gel OPzV batteries will not be used (floated) for a period of time, the following procedure should be followed:

1. Equalize charge the battery (refer to Section 6.5).

2. Disconnect the battery from all loads. Do not allow any loads, no matter how small, to remain connected.

3. Equalize charge the battery every 9 months when the storage temperature is 20ºC or less. For every 8ºC rise in storage temperature, reduce the equalization interval by half.

4. Perform a full equalization charge on the battery prior to returning to service.

During the storage time, particularly if it is extended, it is recommended to continue to monitor and record battery voltage levels. Measure and record the battery open circuit voltage just before equalization and then record the on-charge voltage and current just prior to completing the charge. Refer to Section 4.0 for more information.

Section 8.0 - MAINTENANCE AND RECORD KEEPING

Maintenance and record keeping is critical to battery life and warranty continuance. Proper maintenance will ensure that the batteries are being correctly used and will be available when needed. Proper record keeping will ensure that, if there is a problem with a battery, the customer can demonstrate the batteries were correctly used and so maintain the warranty.

General maintenance of the battery means keeping the battery and surrounding area clean and dry. Since

CELLYTE Gel OPzV batteries are of low maintenance design, there is no addition of water or specific gravity checks needed for the life of the battery. The only required maintenance action is an annual retorque of the battery connections to 130 in-lbs, (15 N-m).

Review Section 2.4 on Electrical Shock before performing this action.

CAUTION: Only use insulated tools.

Do not use any solvents or strong cleaners on or around the batteries. A dry brush may be used to remove any dust accumulations. If required, a solution of 1 kg of baking soda in 4 litres of water may be used as a multipurpose cleaner if more stubborn stains or dirt accumulations are present.

7

8.2.1 Installation Records

When the battery is received, record such things as :

- Date of receipt,

- Condition of the modules,

- Open circuit voltages (if measured)

- Date of installation

- Original P.O. number

- Installer (s) name

- Equalization time and voltage

- Any unusual storage conditions.

8.2.2 Maintenance Records

At least twice per year, record the following :

- Cell float voltage

- Any unusual charges or discharges - 6 months.

Keep the above records in a safe place for review by maintenance personnel. Remember, these records

are mandatory for any warranty claim on the battery.

Section 9 - CAPACITY TESTING

9.1 General

Discharge testing of the battery is performed to determine the battery capacity. There are two reasons for performing this test:

(1) A ratings test discharge. The intention here is to determine the percentage of battery capacity as compared to the rated capacity. This is typically a 3, 8 or 10 hour discharge test.

(2) A service test discharge. This test is to determine the battery standby time under the actual load conditions of intended battery usage.

The ratings test discharge is usually performed using a suitably designed and sized load bank to provide a constant current load to the battery. The test is performed for the specified period of time to an endpoint voltage per cell (usually 1.75 or 1.80 VPC) with the ampere hour capacity of the battery calculated by multiplying the load current by the number of hours of run time. The actual AH capacity can be compared to the rated AH capacity to determine percentage capacity. This type of test is usually used as an acceptance test of the battery.

The service test is usually performed by placing the actual load on the battery and determining the actual time the battery will support the load. This test is done, in the case of a UPS, by switching into a test mode where the battery becomes the primary power source and the normal AC line becomes the back-up.

If the load is not critical, the AC input can simply be shut off to simulate a loss of power event and total system operation can be verified as well. A load bank can be used if the normal battery load is well defined.

The battery test procedure for either test is :

(1) Ensure the battery is fully charged before capacity testing and that all connections are clean and tight.

An equalization charge is highly recommended before performing a capacity test and is mandatory if the

battery has not been on continuous float for at least one week or if there is any questions about the battery's state of charge.

8

(2) Prepare the load bank or test load system. Ensure all temporary cable connections are heavy duty, secure and connected to the proper polarity, and have sufficient current carrying capacity.

(3) Determine the battery temperature by measuring and recording the temperature of every 6 th

cells. Average the readings to determine average battery temperature. Measure the cell temperature in the middle of the rack (preferably) or the inner wall of the cell.

(4) If a ratings test is being performed, the load current or power must be temperature corrected if the battery temperature is significantly different from 20ºC. The formula for calculating corrected load is :

Temperature corrected load = load at 20ºC x CF, where CF is the C/10 capacity correction factor for temperature. The following table should be used :

Temperature Float

ºC) Factor (CF) voltage

0 0.87 2.310

5 0.91 2.295

10 0.94 2.270

15 0.97 2.250

20 1.00 2.230

25 1.03 2,210

30 1.05 2.190

35 1.07 2.170

If the service test is being performed, no temperature correction is necessary.

(5) Just prior to starting the discharge test, measure and record the individual cell voltages, the string voltage and float current (if available).This can be accurately measured using the SEC recommended shunt. Which can be supplied as an optional extra with the battery.

(6) Remove or disconnect the charger from the

battery string.

(7) Connect the load to the battery and start a timer.

Monitor the string voltage and record the lowest voltage reached and the time reached.

(8) Record the load current, string and individual cell voltages on a regular basis. A minimum of three sets of readings should be taken. The time interval between sets of readings will vary based on the expected test time. For example, take readings every hour for the first 5 hours of an 10 hour rating test. For the following 4 hours take readings every ½ hour. For the last hour, take readings every 15 minutes. For a

15 minute UPS discharge, readings every 5 minutes is desirable.

(9) Continue the discharge until the string voltage drops below the end-point voltage per cell times the number of cells in the string.

For example: 1.75 VPC x 60 cells = 105.0 Volts is the stop discharge voltage. Do not be concerned if the voltage of some cells falls a little below 1.75 on a new battery these cells will be restored to full capacity when the battery is recharged.

(10) Stop the timer and remove the load from the battery.

(11) Immediately recharge the battery using the existing charger or an external charger. An equalize voltage of

2.4 vpc at 20ºC may be used to reduce charge time.

(12) Record the discharge time and calculate percentage capacity if a ratings test was performed.

(13) Keep a copy of all the test data with the battery records.

DISCHARGE TEST NOTES:

(1) When batteries are new, the battery may deliver only

95% of rated capacity. Full capacity will be obtained after 3-6 months in float service or after 10 cycles.

(2) String voltage should be measured at the battery terminals, not at the load connections.

(3) Accurate meters are essential for correct test results.

Ensure all meters, shunts, etc., have been properly calibrated not more than 6 months before use.

(4) If a long duration test is being performed, the terminal to terminal voltage drop across the intercell connections should be measured and recorded. This will serve as a reference for any needed terminal maintenance work and will assist in verifying the battery integrity.

(5) A float voltage check after the test and recharge is desirable, but not required information.

9

Date

SEC BATTERY MAINTENANCE REGISTER

Maintenance Description

SEC

Industrial Battery Co.

10

SEC

Industrial Battery Co.

SECTION 10 - TECHNICAL SUPPORT

SEC is always ready to assist you in your installation and operation of SEC batteries. If you have any questions on any portion of this manual, please do not hesitate to call or fax any of our offices listed below and request assistance.

USA OFFICE

SEC Industrial Battery Co. Inc

1643 Holicong Road

Box 849 Buchkingham

PA 18912 USA

Tel.: 1-215-654 9334

Fax.: 1-215-654 9871 [email protected]

EUROPE & AFRICA OFFICE

SEC Industrial Battery Co. Ltd.

Thorney Weir House,

Iver, Bucks, SLO 9AQ,

United Kingdom.

Tel.: 44-01895-431543

Fax.: 44-01895-431880

[email protected]

Website at: WWW.secbattery.com [email protected]

MIDDLE EAST OFFICE

SEC Industrial Battery Division,

P.O. Box 32225,

Kingdom of Bahrain

Tel.: 97317-721322

Fax.: 97317-740743 [email protected]

FAR EAST OFFICE

SEC Industrial Battery Co. Ltd.,

Unit 6, 6/F., Hewlett Centre,

54 Hoi Yuen Road, Kwun Tong.

Kowloon, Hong Kong.

Tel.: 852-304 4382

Fax.: 852-304 4013

[email protected]

SEC CORBY OFFICE

SEC Industrial Battery Co.Ltd.

Unit 16 Alexander Court, Fleming Road,

Earlstrees Industrial Estate,

Corby, Northants, NN17 4SW

Tel: 01536 264123

Fax:01536 264126

[email protected]

11

Installed by:

Operating Company:

Address/Location:

Battery Information

Type of Battery:

Installation Date:

Battery Charge Current:

Charging Equipment:

Battery Charger Information

Make

Model

SEC BATTERY REPORT

Representative:

Date:

No. of Cells/String:

No. of Strings/Battery:

Battery Code:

Ambient Temperature:

Type

Year of manufacture

Time:

String Float Voltage:

Float Voltage/ Cell:

Float Current:

Cell Temperature:

Current rating

Charging voltage

21

22

23

24

25

17

18

19

20

11

12

13

14

15

16

7

8

9

10

Cell/

Unit

No.

1

Open

Circuit

Voltage

2

3

4

5

6

46

47

48

49

50

42

43

44

45

36

37

38

39

40

41

Float

Charge

Voltage

Cell/

Unit

No.

26

Open

Circuit

Voltage

INDIVIDUAL CELL READINGS

Float

Charge

Voltage

Cell/

Unit

No.

Open

Circuit

Voltage

Float

Charge

Voltage

Cell/

Unit

No.

Open

Circuit

Voltage

51 76

27 52 77

28

29

30

31

53

54

55

56

78

79

80

81

32

33

34

35

57

58

59

60

82

83

84

85

Float

Charge

Voltage

Cell/

Unit

No.

101

102

Open

Circuit

Voltage

Float

Charge

Voltage

103

104

105

106

107

108

109

110

71

72

73

74

75

67

68

69

70

61

62

63

64

65

66

96

97

98

99

100

92

93

94

95

86

87

88

89

90

91

121

122

123

124

125

117

118

119

120

111

112

113

114

115

116

Remarks and Recommendations:

SEC

Industrial Battery Co.

Signed:

SEC

Industrial Battery Co.