EnerSys PowerSafe Assembly, Installation, Operation & Maintenance Manual

Battery Safety, Storage, Installation,
Operation & Maintenance Manual
RE Flooded Lead-Acid Batteries
Publication No. US-RE-IOM-002 January 2012
This manual provides instructions regarding safety, storage, installation, operation and
maintenance. Failure to observe the precautions as presented may result in injury or loss of life.
This document is proprietary to EnerSys®. This document cannot be copied or reproduced in
whole or in part, nor can its contents be revealed in any manner or to any person except to meet
the purpose for which it was delivered, without the express written permission of EnerSys.
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GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in any of three ways:
Danger
Warning
Caution
The danger symbol is a lightning bolt mark enclosed in
a triangle. The danger symbol is used to indicate
imminently hazardous situations, locations and
conditions which, if not avoided, WILL result in death,
serious injury and/or severe property damage.
The warning symbol is an exclamation mark in a
triangle. The warning symbol is used to indicate
potentially hazardous situations and conditions, which,
if not avoided, COULD result in serious injury or death.
Severe property damage COULD also occur.
The caution symbol is an exclamation mark enclosed
in a triangle. The caution symbol is used to indicate
potentially hazardous situations and conditions, which,
if not avoided, may result in injury. Equipment damage
may also occur.
Other warning symbols may appear along with the Danger, Warning, and Caution symbol and
are used to specify special hazards. These warnings describe particular areas where special
care and/or procedures are required in order to prevent serious injury and possible death:
Electrical
warnings
Explosion
warnings
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The electrical warning symbol is a lightning bolt mark
enclosed in a triangle. The electrical warning symbol is
used to indicate high voltage locations and conditions,
which may cause serious injury or death if the proper
precautions are not observed.
The explosion warning symbol is an explosion mark
enclosed in a triangle. The explosion warning symbol is
used to indicate locations and conditions where
molten, exploding parts may cause serious injury or
death if the proper precautions are not observed.
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IMPORTANT SAFETY INSTRUCTIONS
DANGER
A battery can present a risk of electrical shock and high short circuit current.
The following precautions should be observed when working with batteries:
1. Verify that the Charging Power Supply to the battery is off and that all power is
disconnected from the power source.
2. Remove watches, rings or other metal objects.
3. Use tools with insulated handles to prevent inadvertent shorts.
4. Wear rubber gloves and boots.
5. Do not lay tools or metal parts on top of batteries.
6. Determine if the battery is inadvertently grounded. If inadvertently grounded, remove
source of ground. Contact with any part of a grounded battery can result in electrical
shock. The likelihood of such shock will be reduced if such grounds are removed during
installation and maintenance.
7. Verify circuit polarities before making connections.
8. Disconnect charging source and load before connecting or disconnecting terminals.
9. Vented lead-acid (VLA) batteries can contain an explosive mixture of hydrogen gas. Do
not smoke, cause a flame or spark in the immediate area of the batteries. This includes
static electricity from the body and other items that may come in contact with the battery.
10. Use proper lifting means when moving batteries and wear all appropriate safety clothing
and equipment.
11. Do not dispose of lead acid batteries except through channels in accordance with local,
state and federal regulations.
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Publication No. US-RE-IOM-002 January 2012
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for Flooded Lead-Acid Battery Systems that should
be followed during the installation and maintenance of the battery system.
Only a qualified EnerSys® service representative who is knowledgeable in batteries and the
required precautions should perform servicing of the batteries. Keep unauthorized personnel
away from batteries.
Caution
Misuse of this equipment could result in human injury and
equipment damage. In no event will EnerSys be responsible or
liable for either indirect or consequential damage or injury that may
result from the use of this equipment.
Caution
Do not dispose of the batteries in a fire. The batteries may
explode.
Caution
Do not mutilate the batteries. Released electrolyte is harmful to
the eyes and skin and may also be toxic.
Warning
Warning
This unit contains flooded lead acid batteries. Lack of preventative
maintenance could result in batteries exploding and emitting
gasses and/or flame. Annual preventative maintenance must be
performed per the guidelines set forth in this manual.
Failure to replace a battery before it becomes exhausted may
cause the case to crack, possibly releasing electrolyte from inside
the battery and resulting in secondary faults such as odor, smoke
and fire.
Warning
Installation and servicing of batteries should be performed by
personnel knowledgeable about batteries and the required
precautions. Keep unauthorized personnel away from the
batteries.
Warning
Proper maintenance to the battery system of this unit must be done
per the guidelines set forth in this manual. This is essential to the
safety and reliability of your power supply system.
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Publication No. US-RE-IOM-002 January 2012
iii
TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS .......................................................................................... i
1.0
1.1
1.2
1.3
GENERAL INFORMATION ........................................................................................ 1
Introduction ................................................................................................................. 1
1.1.1 Cell Design ...................................................................................................... 1
1.1.2 Range Summary .............................................................................................. 2
Precautions ................................................................................................................. 3
Service ........................................................................................................................ 3
2.0
2.1
2.2
2.3
SAFETY ...................................................................................................................... 4
General ....................................................................................................................... 4
Safety Equipment and Clothing ................................................................................... 4
Safety Precautions ...................................................................................................... 5
2.3.1 Sulfuric Acid Burns .......................................................................................... 5
2.3.2 Explosive Gases .............................................................................................. 6
2.3.3 Electrical Shocks and Burns ............................................................................ 6
3.0
3.1
3.2
3.3
INSPECTING BATTERY SHIPMENT ......................................................................... 8
General ....................................................................................................................... 8
Visible External Damage ............................................................................................. 8
Concealed Damage .................................................................................................... 9
4.0
4.1
4.2
4.3
BATTERY STORAGE BEFORE INSTALLATION ................................................... 10
General ..................................................................................................................... 10
Storage Interval ......................................................................................................... 11
Advance Preparation ................................................................................................. 11
5.0
5.1
5.2
5.3
INSTALLATION CONSIDERATIONS ...................................................................... 12
General ..................................................................................................................... 12
Considerations for Connecting the Battery System to Operating Equipment............ 14
Considerations for Parallel Installation ...................................................................... 14
6.0
6.1
6.2
6.3
UNPACKING AND HANDLING FOR INSTALLATION ............................................ 15
General ..................................................................................................................... 15
Recommended Installation Equipment and Supplies ................................................ 15
Cell/Battery Handling ................................................................................................ 16
6.3.1 Single Small Cell Handling (1RE) .................................................................. 16
6.3.2 Six Cell Unit Handling (6RE) ......................................................................... 16
7.0
7.1
7.2
SYSTEM INSTALLATION ........................................................................................ 17
System Layout .......................................................................................................... 17
Installation Considerations ........................................................................................ 18
7.2.1 Installation Precautions ................................................................................. 18
7.2.2 Arrangement .................................................................................................. 18
7.2.3 Spacing .......................................................................................................... 18
Battery Installation ..................................................................................................... 19
7.3
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7.4
Preparing and Installing Connections ........................................................................ 21
7.4.1 Terminal Posts ............................................................................................... 21
7.4.2 Intercell Connectors ....................................................................................... 21
7.4.3 Terminal Plates .............................................................................................. 22
8.0
8.1
INITIAL and/or FRESHENING CHARGE ................................................................. 24
External constant voltage charger or MPPT (Maximum Power Point Tracking) solar
charge controller: ....................................................................................................... 24
No external source or MPPT controller available for charging. ................................. 24
8.2
9.0
9.1
9.5
OPERATION ............................................................................................................. 25
MPPT Charge Regulators ......................................................................................... 25
9.1.1 ON/OFF Solar Charge Regulators ................................................................. 25
9.1.2 Low Voltage Disconnect ................................................................................ 25
Hydrometer Readings - Specific Gravity ................................................................... 26
Full-Charge Specific Gravity ...................................................................................... 26
Equalizing Charge ..................................................................................................... 28
9.4.1 Equalizing Charge Method ............................................................................ 28
Operating Temperature ............................................................................................. 29
10.0
BATTERY TAPS ....................................................................................................... 30
11.0
PILOT CELL ............................................................................................................. 30
12.0
12.1
MAINTENANCE ........................................................................................................ 31
Battery Cleaning ........................................................................................................ 31
12.1.1 Standard Cleaning ....................................................................................... 31
12.1.2 Corrosion Cleaning ...................................................................................... 31
12.1.3 Heavy Corrosion Cleaning ........................................................................... 32
12.1.4 Cleaning Flame Arrestors ............................................................................ 33
Maintenance Records ............................................................................................... 33
Corrective Actions ..................................................................................................... 35
Adding Water ............................................................................................................. 35
Quality of Water ......................................................................................................... 36
9.2
9.3
9.4
12.2
12.3
12.4
12.5
STORAGE BATTERY REPORT - Battery in Float Service
Sheet No. _________ ........ 37
APPENDIX .................................................................................................................................. 38
HYDROGEN EVOLUTION CALCULATION OF RE CELLS ...................................................... 38
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1.0
GENERAL INFORMATION
1.1
Introduction
The EnerSys® range of PowerSafe® RE batteries has been designed for use in renewable
energy applications. PowerSafe RE cells are designed for applications where the battery must
undergo repeated cycling with daily depths of discharge (“DOD”) of up to 80% DOD (such as
rural settlements, communications systems and lighting systems, etc.). The RE range’s abilities
allow them to excel in highly demanding stored energy applications:
•
•
•
•
•
1.1.1
Long cycle life
Overcharge ability
Cycling in state of discharge
Low rate of self-discharge
Large electrolyte reserve
Cell Design
PowerSafe RE cells are based on conventional, vented technology and designed for renewable
energy applications that require maximum cycle life with the highest level of reliability. They are
particularly suitable for use in solar energy installations, ensuring a continuity of electrical supply
during the hours of darkness or during periods of reduced sunshine. The entire RE range
utilizes tubular positive plates with EnerSys’ proprietery tube technology. Tubular positive plates
are widely used in batteries for particularly demanding applications. The current carrying lead
metal in tubular designs are entirely surrounded by active material – reducing the corrosion rate
and ensuring long life.
The RE range benefits from the square tubular plate when compared to both round tube and flat
plate battery designs. The PowerSafe RE battery’s square tubes provide more surface area on
the positive plate, exposing more positive plate active material to the electrolyte. The unique
tube construction also prevents shedding of the active material – a common failure mode in flat
plate designs that can lead to early failure due to sediment shorts. This combination of greater
positive surface area and reduced shedding allow for excellent cycling capacity.
Reduced maintenance is achieved through the use of additional electrolyte space above the
element, which means cells may only have to be watered every 6 months depending on
environmental conditions and duty cycle. Each cell is provided with a combination flame arrestor
and float level indicator which clearly indicates when the electrolyte level is low and water must
be added. The ample watering space and easily readable indicators help to reduce
maintenance costs and makes them an ideal solution for many remote or unmanned locations.
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1.1.2
Range Summary
The range is available in single cell (2 Volt) units or 6 cell (12 Volt) units. All cells feature bolt-on
connections at all terminals for ease of installation.
WARNING
The RE series is intended for nominal system voltages up to 48 Volts.
Exceeding this voltage is not recommended and can be extremely
hazardous. Contact your sales representive to inquire about custom
designed batteries for high voltage applications.
The single cell units (1RE range) feature a rugged plastic container featuring lift handles. Sizes
range from 207 Ah up to 2208 Ah at the 20 hour rate. They are ideal for remote locations where
lifting equipment is not available for installation. The plastic container also reduces maintenance
by helping mitigate ground shorts due to electrolyte spills. Any concern with container corrosion
is also removed. The cells can be installed on any acceptable floor or on customer supplied
racks.
The 6 cell units feature acid resistant epoxy-coated steel trays with lifting holes and mounting
flanges to bolt the batteries to the floor or into a rack. Sizes range from 384 Ah up to 2208 Ah at
the 20 hour rate. The 6 cell units are ideal for industrial applications where speed of installation
and modular design is a high priority. Lifting can be done with an overhead crane using specially
designed lifting straps available from EnerSys®. All intercell connections are made with welded
lead connectors so only terminal connections must be made. Terminal connections of each unit
are bolt-on, allowing easy cabling to the next unit or the DC bus.
SINGLE CELL (1RE)
Figure 1.1
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6 – CELL (6RE)
Figure 1.2
Publication No. US-RE-IOM-002 January 2012
1.2
Precautions
BEFORE UNPACKING, STORING, HANDLING, INSTALLING, OPERATING OR
PERFORMING MAINTENANCE ON THE FLOODED LEAD-ACID STATIONARY BATTERY
SYSTEM
READ
THE FOLLOWING
INFORMATION THOROUGHLY!
It is important to read, understand and strictly follow the instructions in this manual.
If the following precautions are not fully understood, or if local conditions are not covered,
contact your nearest EnerSys® sales/service representative for clarification, or call the corporate
office number listed on the back of this manual and ask for EnerSys Service.
Also, refer to all applicable federal, state and local regulations and industry standards.
YOU SHOULD BE TRAINED IN HANDLING, INSTALLING, OPERATING AND MAINTAINING
BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM.
1.3
Service
Should you require installation supervision, service, parts, accessories or maintenance,
EnerSys has a nationwide service organization to assist with your new battery purchase.
Please call your nearest EnerSys sales/service representative for more information, or, call the
corporate office number listed on the back of this manual and ask for EnerSys Service.
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Publication No. US-RE-IOM-002 January 2012
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2.0
SAFETY
2.1
General
All flooded, lead-acid batteries, may leak, release hydrogen gas or cause acid misting. Always
follow the generally accepted safety procedures for handling batteries. In addition, it is vitally
important that you observe the precautions recommended in this manual.
YOU SHOULD BE TRAINED IN HANDLING, INSTALLING, OPERATING AND
MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM.
You MUST understand the risk of working with batteries and BE PREPARED and
EQUIPPED to take the necessary safety precautions. If not, contact EnerSys® Service.
2.2
Safety Equipment and Clothing
When working with any battery system, be sure you have the necessary tools and safety
equipment, including but not limited to:
insulated tools
rubber gloves
fire extinguisher
•
•
•
•
•
•
rubber apron
safety goggles
acid spill cleanup kit
•
•
face protection / face shield
emergency eye wash and
shower, if available
ALWAYS:
•
•
remove all jewelry (i.e., rings, watches, chains, etc.)
keep sparks, flames and smoking materials away from the battery
NEVER lay tools or other metallic objects on the battery/cell.
Using the correct tools and wearing proper safety equipment will help prevent injury should an
accident occur.
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2.3
2.3.1
Safety Precautions
Sulfuric Acid Burns
Batteries are safe when operated and handled properly. However, they do contain sulfuric acid,
which can cause burns and other serious injuries.
Always wear protective clothing AND use the correct safety tools.
In case of SKIN CONTACT with sulfuric acid, IMMEDIATELY
1. REMOVE contaminated CLOTHING
2. FLUSH the area THOROUGHLY with WATER
3. Get MEDICAL ATTENTION, if required.
In case of EYE CONTACT with sulfuric acid, IMMEDIATELY
1. FLUSH THOROUGHLY for at least 15 minutes with
large amounts of WATER.
2. Get MEDICAL ATTENTION.
In case of sulfuric acid CONTACT WITH CLOTHING OR
MATERIAL, IMMEDIATELY
1. REMOVE CONTAMINATED CLOTHING
2. Apply a solution of sodium bicarbonate solution (1.0 lb/1.0
gal or 0.5 kg/5.0 liters of water) on the clothing or material.
3. Apply the solution until bubbling stops, then rinse with clean
water.
NOTE:
In case of a sulfuric acid SPILL, bicarbonate of soda or an emergency spill kit
should be within the battery room in accordance with OSHA regulation
1910.178g2.
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2.3.2
Explosive Gases
Batteries can generate gases which, when released, can explode, causing blindness and other
serious personal injury.
•
Always wear protective clothing and use the correct safety tools.
•
Eliminate any potential of sparks, flames or arcing.
•
Provide adequate ventilation. See Appendix.
IN CASE OF FIRE: To extinguish a fire in a battery room containing lead acid batteries, use
CO2, foam, or dry chemical extinguishing media. Do NOT discharge the extinguisher directly
onto the battery. The resulting thermal shock may cause cracking of the battery case/cover.
SPECIAL PROCEDURES:
If batteries are on charge, shut off power. Use positive pressure, self-contained breathing
apparatus. Water applied to electrolyte generates heat and causes it to splatter. Wear acidresistant clothing.
TOXIC FUMES:
Burning plastic may cause toxic fumes. Leave area as soon as possible if toxic fumes are
present. Wear breathing apparatus if required to remain in the area.
2.3.3
Electrical Shocks and Burns
Multi-cell battery systems can attain high voltage and/or currents. Do NOT
touch uninsulated batteries, connectors or terminals. To prevent serious
electrical burns and shock, use EXTREME CAUTION when working
with the system.
•
Always wear protective clothing and use nonconductive or insulated tools when
working with ANY battery system.
•
Remove all jewelry that could produce a short circuit.
BEFORE working on the system:
1. Disconnect ALL loads and power sources to the battery. Use appropriate lockout/tagout
procedures.
2. If working on an assembled battery system, sectionalize (interrupt the battery in sections)
into safe working voltage levels.
3. Check the battery system grounding. Grounding of the battery system is NOT
recommended. However, rack grounding is recommended.
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Publication No. US-RE-IOM-002 January 2012
IF BATTERY SYSTEM IS GROUNDED (system is intentionally grounded by connecting a
battery terminal to ground):
1. a shock hazard exists between all other terminals and
ground (i.e., dirt and acid on top of battery cell touching
rack).
2.
if an unintentional ground develops within the already
grounded system, a short circuit may occur and cause
explosion or fire.
IF BATTERY SYSTEM IS UNGROUNDED (system is NOT grounded):
1. if an unintentional ground develops within the system, an
increased shock hazard exists between the terminals and
ground.
2. if a second unintentional ground develops within the already
unintentionally grounded system, a short circuit may occur
and cause explosion or fire.
Therefore, should you be required to work on a grounded battery system, make absolutely sure
you use the correct safety precautions, equipment and clothing.
IMPORTANT!!
If you have ANY question concerning safety when working with the battery system, contact your
local EnerSys sales/service representative to clarify any of the noted safety precautions, or, call
the corporate office number listed on the back of this manual and ask for EnerSys® Service.
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Publication No. US-RE-IOM-002 January 2012
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3.0
INSPECTING BATTERY SHIPMENT
3.1
General
Precautions have been taken to pack the cells/battery units for shipment to ensure its safe
arrival. However, upon receipt, you should inspect for evidence of damage that may have
occurred during transit.
WARNING
During inspections, take precautions against electrical shock.
You are handling LIVE batteries.
3.2
Visible External Damage
IMMEDIATELY upon delivery (while the carrier representative is still on-site), inventory all
materials against the Bill of Lading and inspect for visible external damage.
Check material quantities received against the Bill of Lading, including the number of battery
pallets and the number of accessory boxes.
Note any:
•
•
damage to packing material.
wetness or stains, indicating electrolyte leakage.
If damage is noted:
1. Make a descriptive notation on the delivery receipt before signing.
2. Request an inspection by the carrier.
3. File a damage report.
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Publication No. US-RE-IOM-002 January 2012
3.3
Concealed Damage
Within 15 days of receipt (or as soon as practical), unpack the cells and check for
concealed damage. Remember, you are handling a LIVE battery. Take
precautions against a shock hazard. Follow all safety precautions as noted in
Section 2.0.
Examine the electrolyte level to ensure that none has been spilled. If electrolyte has been lost in
transit and the level is less than 1/2 inch (12 mm) below the top of the plates, add Battery Grade
sulfuric acid electrolyte of the nominal operating specific gravity indicated on the cell nameplate,
and bring to the low level line on open circuit.
If the electrolyte level is more than 1/2 inch (12 mm) below the top of the plates, request an
inspection by a representative of the carrier and file a claim for concealed damage.
Check the received materials against the detailed packing list to verify receipt of all materials in
the quantities specified.
DELAY IN NOTIFYING THE CARRIER MAY RESULT IN LOSS OF YOUR RIGHT TO
REIMBURSEMENT FOR DAMAGES. Refer to the Bill of Lading, if, when performing the parts
inventory, you are unsure about the appearance of a part.
If you have questions concerning potential damages, contact your local EnerSys® sales/service
representative, or, call the corporate office number listed on the back of this manual and ask for
EnerSys Service.
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4.0
BATTERY STORAGE BEFORE INSTALLATION
4.1
General
Batteries should be unpacked, installed and charged as soon as possible after receipt.
However, if this is impractical, follow the instructions below for storing the battery before
installation.
Store the battery at a dry, clean and preferably cool and frost-free location. Temperature limits
for storage are -20°C (-68 °F) to +45°C (113 °F), Humidity < 90% RH. Self discharge will occur
when a battery is left at rest (without charge) and periodic freshening charge is required. Failure
to charge batteries at the required intervals may result in irreversible damage.
Batteries that were previously in service or previously installed must be fully charged before
storing for long periods of time.
Self discharge will increase:
•
With natural aging of the cell
•
Following faulty use such as excessive over-discharge, bad maintenance, or by the
addition of non-demineralized water
•
Temperature rise
Do NOT stack pallets. DAMAGE MAY OCCUR AND THE WARRANTY WILL BE VOIDED.
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4.2
Storage Interval
PowerSafe® RE batteries must be given a freshening charge at maximum storage times shown
in the table below, or when open circuit voltage (“OCV”) approaches 2.06 VPC, whichever
occurs first. Under higher temperature conditions, greater charging frequency is required. Use
date of battery shipment to determine freshening charge requirements.
TABLE 4.1
Average storage
Maximum
Ambient temperature
storage time
20°C
6 months
25°C
5 months
30°C
4 months
40°C
2 months
Storage times exceeding the above may result in plate sulfation, which may adversely affect
electrical performance and expected life.
Give the battery a freshening charge before the end of the recommended storage interval. See
Section 8 for charging information.
Repeat the freshening charge for each additional storage interval until the battery is installed.
Maximum total storage time before installation is two years from date of shipment from the
factory to the customer. Freshening charges are required a minimum of every three to six
months during the storage time period, as noted above.
4.3
Advance Preparation
If freshening time interval is likely to be exceeded in storage, make advance preparation to have
an adequate charger available and adjacent to an appropriate AC supply voltage. Positioning of
the cells to accept the temporary intercell connectors is another consideration of advance
planning.
Make every effort to get the battery installed and connected to the charger before the expiration
of the storage period, thereby avoiding the additional labor cost of preliminary freshening
charges.
WARNING
FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S WARRANTY.
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BEFORE INSTALLATION
READ THIS SECTION THOROUGHLY.
5.0
INSTALLATION CONSIDERATIONS
5.1
General
®
If you have any questions concerning the installation considerations, contact your EnerSys
sales/service representative. The diagrams shown are general representations and may not
depict all models and options.
®
When planning the system space requirements for the PowerSafe RE batteries, consider the
following:
•
space
•
ventilation
•
environment
•
battery system configuration
•
temperature
•
floor loading
•
distance from operating equipment
Use Table 5.1 to ensure that all requirements for installation location are considered.
TABLE 5.1
CONSIDERATION
Space
RECOMMENDATION
It is recommended that the aisle space provided in front of all trays be a
minimum of 36 inches (915 mm). The designer must verify the
requirements for aisle space in all applicable local codes or regulations.
A minimum of 9 inches (230 mm) is desirable above the tops of the cell
posts of the top row of cells to permit access for maintenance or cell
removal.
Environment
Temperature
Each cell should be accessible for the addition of water and for taking
individual cell voltage and hydrometer readings.
Clean, cool and dry. The location should be selected to keep water, oil, and
dirt away from all cells.
The recommended operating temperature range is between 5-113°F
(-15°C - +45°C), Humidity >90%.
Elevated temperatures reduce operating life. Lower temperatures reduce
battery performance.
Minimize temperature variations between the cells.
• To avoid temperature variation between the cells, do NOT locate
the battery near HVAC ducts or exhausts, heat sources
(i.e., equipment that generates heat) or direct sunlight.
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Publication No. US-RE-IOM-002 January 2012
Table 5.1 (continued)
CONSIDERATION
Ventilation
RECOMMENDATION
Adequate ventilation must be provided, so as to prevent hydrogen gas
from exceeding a 2% concentration as shown in IEEE 484-1987.
Hydrogen accumulation must be limited to less than 2% of the total
volume of the battery area.
Ventilation must be adequate to ensure that pockets of trapped
hydrogen gas do not develop, particularly at the ceiling.
See Appendix for additional information
Grounding
It is recommended that the steel trays be grounded in accordance with
NEC and/or local codes.
Codes
Building codes and fire codes may require a spill containment system
for battery installations. Please consult local building codes. EnerSys®
offers spill containment systems. Contact your EnerSys sales/service
representative for more information.
Floor
Reasonably level. Shim up to 1/4 inch (6 mm) maximum to level battery
front to rear and side to side. Capable of supporting the weight of the
battery as well as any auxiliary equipment.
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5.2
Considerations for Connecting the Battery System to Operating
Equipment
The battery has been sized based on a specific load (amps or KW) for a specific run time to a
specific end voltage. Consult with the system/equipment supplier to determine these
parameters, because battery performance is based on these values, as measured at the battery
terminals.
Therefore, ensure that the load cables:
•
between the battery and its load are the shortest routing possible to the terminal,
allowing sufficient additional cable (about 6 inches/15 cm) for connect/disconnect.
•
are the proper size to minimize the voltage drop between the battery output terminals
and the load.
To select the proper cable size:
1.
Determine the cable size necessary to carry the design load.
2.
Calculate the voltage drop of the cable between the battery terminal plate and the
operating equipment.
3.
Increase cable size to achieve the allowable voltage drop.
Cable selection should create no greater voltage drop than allowed between the battery system
and the operating equipment as determined by the equipment/system supplier. Excessive
voltage drop will reduce the desired support time of the battery system.
5.3
Considerations for Parallel Installation
If it is necessary to connect the battery system in parallel to obtain sufficient capacity, cable
connections to each of the parallel strings are important.
To obtain:
• proper load sharing on the discharge,
•
satisfactory recharge, and
•
the same float voltage for each string.
cables from the batteries to the load must be:
• as short as possible,
•
•
of equal lengths to the load (do not exceed cable ampacity), and
of sufficient ampacity.
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Publication No. US-RE-IOM-002 January 2012
6.0
UNPACKING AND HANDLING FOR INSTALLATION
6.1
General
Batteries are shipped assembled, charged, and filled with the electrolyte.
All accessories for installation and use are supplied as optional prepackaged kits. Accessories
may be in the same container as the cell, or separate containers depending on the item. Cells
may be packed in wooden boxes, which must be opened completely and carefully. The cells are
then handled as described in Section 6.3.
6.2
Recommended Installation Equipment and Supplies
Before working with the battery system, be sure that you have the proper protective clothing,
safety equipment and insulated tools as specified in Section 2.0. Additional equipment for the
installation of the battery system is listed in Table 6.1.
TABLE 6.1
EQUIPMENT REQUIRED
Forklift or Portable Lift Crane
Chalk Line
Torpedo Level (Plastic)
Torque Wrench (10-200 in-lbs)
Drift Pins
Floor Shims (User-supplied)
Insulated 3/8 inch Drive Ratchet Wrench with Minimum 3" Extension
With 3/8 inch thru 11/16 inch Sockets
Insulated Box Wrenches (3/8 inch to 11/16 inch)
Screwdrivers
Wipes, Paper or Cloth
Plastic Bristle Brush or Nonmetallic Cleaning Pad
Tape Measure (Nonmetallic)
Safety Equipment and Clothing
Small Paint Brush
NO-OX-ID Grease
CHECK IF
ON HAND
Be sure you have all the proper protective clothing and safety tools
and equipment on hand before starting the installation.
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6.3
Cell/Battery Handling
To prevent damage to the cells and personal injury when moving/handling the batteries, follow
the procedures in this section. For ease of explanation, lifting/handling instructions are grouped
into two categories depending on the size of the units:
See Section 6.3.1 — single small cell handling (1RE)
See Section 6.3.2 — six cell unit handling (6RE)
DO NOT lift any cell by the terminal posts as this will void the warranty. RE cell terminals
are not designed to support the cell weight. When lifting large cells/units with crane, hoist or
similar device, use the lifting straps provided.
6.3.1
Single Small Cell Handling (1RE)
1.
Lift and move these batteries manually. For cells heavier than 50 lbs, 2 people should be
used to move and position cells.
2.
Optionally, a strap can be placed under the container and run through the handles for
lifting with a crane. Contact your EnerSys sales/service representative for correct lifting
strap and lifting instructions.
6.3.2
Six Cell Unit Handling (6RE)
When lifting 6 cells units in steel trays, use the supplied lifting straps with steel hooks to lift the
unit by the eyelets at the top of the steel tray.
1.
For sizes with 2 lifting eyes, use one strap.
2.
For sizes with 4 lifting eyes, use two straps. Connect each strap to eyelets at each end
of the battery. Put both straps through the crane hook for lifting.
Multicell Lifting
Figure 6.1
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7.0
SYSTEM INSTALLATION
7.1
System Layout
Lay out the battery system before installation. Consult Section 5.0 for installation considerations.
1.
Locate the system position in the area designated as determined in Section 5.0.
2.
Mark the floor with system outline dimensions.
3. The floor must be level. Shimming up to 1/4 inch (6 mm) may be required to have the
Battery System fully level.
NOTE: The floor must be capable of supporting the weight of the Battery.
4. Batteries should be kept in the original shipping containers until installed. However, if you
must remove the batteries before installation, see the procedures in Section 6.3,
“Cell/Battery Handling.”
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7.2
Installation Considerations
7.2.1
Installation Precautions
1.
Install the system in a well-ventilated location; allow at least 4 inches (10 cm) on all sides
for air ventilation and maintenance.
2.
Install the unit in a stable, level and upright position which is free of vibration.
3.
Install the unit where the ambient temperature is within the correct operating range.
4.
Do not install the Battery System in areas that are subject to high humidity.
5.
Do not allow direct sunlight to shine on the system.
6.
Do not install the Battery System in areas that are subject to contamination, such as high
levels of airborne dust, metal particles or flammable gasses.
7.
Avoid installation near sources of electrical noise and always make sure that the unit
ground is intact to prevent electrical shock and to help reduce electrical noise.
8.
Do not install where water, or any other foreign object or substances may get inside the
Battery System.
NOTE: Contact your nearest EnerSys® sales/service representative
when paralleling Battery Systems, to ensure compatibility of
mating different batteries. Or, call the corporate office
number listed on the back of this manual and ask for
EnerSys Service.
7.2.2
Arrangement
Arrange the cells so that the positive terminal of one cell/battery will be adjacent to the negative
terminal of the next cell/battery throughout the battery.
Take care when positioning cells to ensure that main battery terminals are not close together.
7.2.3
Spacing
Maintain proper spacing between cells/batteries to provide thermal management and ensure
proper fit of hardware connections. Position cells/jars such that a ¼ inch (6mm) is maintained
between adjoining units.
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7.3
Battery Installation
To install an EnerSys® battery system, follow the procedures below:
1. Clear area where battery will be placed, allow space for installation maneuvering.
2. Employ the appropriate lifting/handling method for the cells to be installed (as described in
Section 6.3).
Exercise extreme caution when initially lifting cells and when lowering them into final
position. To prevent one end of the unit from “kicking out,” assign one person to steady the
unit on a level plane during the entire lifting procedure.
3. After placement, carefully remove the lifting strap (if used) from the hook and pull the belt
from under the module.
WARNING
Do not allow steel crane parts or steel hooks of lifting straps to
come into contact with cell posts at any time. Allowing steel
lifting parts to contact cell terminals may results in a short.
WARNING
Allowing the cell/unit to drop quickly may damage the
internal cell components.
WARNING
Improper lifting may result in damage to the module or
personal injury.
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4. Lift the next cell/battery to be installed and place it next to
the previously installed unit. See Figure 7.1. Be certain to
allow proper spacing between cells/jars as outlined in
Section 7.2.2. Observe proper polarity orientation.
5. Repeat Procedures 5 thru 7 until all units are installed.
See Figure 7.2.
Do NOT use any kind of tool to pry cells into
position.
6. As soon as cells are unpacked and installed in position,
remove the shipping vent plugs and immediately install
the flame arrestors. DO NOT attempt to charge cells
unless flame arrestors are in place.
SINGLE CELL (1RE)
CONNECTIONS
Figure 7.1
Once installed, DO NOT REMOVE the flame arrestors.
They are provided with a filling funnel for adding water.
Add water to the cells immediately after the indicator falls
to the low level. Do not permit the electrolyte level to
drop below the bottom of the tube on the flame arrestor.
Allowing too low a level defeats the flame arrestor
function.
7. Number the cells starting from the positive terminal of the
battery for maintenance purposes. Pressure-sensitive
adhesive labels are available from EnerSys®. Before
applying the cell numbers, clean surfaces according to
Procedure 3 in Section 12.1.1.
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MULTI CELL UNITS (6RE)
CONNECTIONS
Figure 7.2
Publication No. US-RE-IOM-002 January 2012
7.4
Preparing and Installing Connections
The cells are now positioned and ready to be connected.
Before preparing and making the connections,
heat NO-OX-ID grease in hot water as necessary
to soften for application with a paintbrush.
7.4.1
Terminal Posts
All terminal posts of the cells are greased at the factory to prevent oxidation.
1.
Inspect each terminal post. If discoloration or tarnishing is noted, neutralize the post with
sodium bicarbonate and water solution (Section 12.1.2, Procedure 2). Dry thoroughly.
2.
Clean the contact surface with a stiff-bristle nonmetallic brush/pad until a clean, bright
surface is obtained.
3.
Apply a light coat of NO-OX-ID grease.
7.4.2
Intercell Connectors
1.
The connections are made by bolting the supplied connectors/cable assemblies to the cell
posts of opposite polarity on adjacent cells or batteries. When more than one cable for
each cell is furnished, bolt the cable to the posts in the identical position on each battery.
2.
With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the contact
surface of the terminal post.
3.
Place cable lug directly on lead terminal surface. Use supplied ¼-20 bolts and washers to
fasten cable to terminals. Secure all connections finger-tight to allow for some adjustment
of position.
4.
After all connections are completed, torque all stainless steel connector bolts to 70-75
inch-lbs (8.0-8.5 Nm).
5.
Apply a light coat of heated NO-OX-ID grease to the bolted connection with a small
paintbrush in the area of the terminal post only. Ensure the entire cable lug and stainless
steel bolt are coated.
WARNING
Make sure that all bolted battery connections are torqued to the
recommended values. The increased resistance of a loose
connection can generate heat and become a fire hazard.
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7.4.3
Terminal Plates
Terminal plates can be supplied as an option with the battery system to provide a system
connection point (except for 2 post cells).
1.
Clean the electrical contact areas of the terminal plate, terminal connectors, and cell/jar
posts with a stiff-bristle nonmetallic brush/pad until the surface is bright. Be careful not to
remove the plating with excessive brushing.
2.
With a small paintbrush, apply a light coating of heated NO-OX-ID grease to contact
areas.
3.
With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the electrical
contact areas of the terminal plate.
TERMINAL PLATE INSTALLATION
Figure 7.3
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Publication No. US-RE-IOM-002 January 2012
4.
Install the terminal plate to the terminal connectors using the torque values of 70-75 inchlbs (8.0-8.5 Nm).
5.
Connect the positive lead from the charge controller to the positive terminal plate of the
battery and the negative lead from the charge controller to the negative terminal plate of
the battery.
6.
Connectors to battery terminal plates should be flexible since rigid terminal connectors
may transmit vibrations or strain to cell posts that could result in loose connections.
Support cables so that the cell post does not bear the load.
7.
Before activating the system:
a.
Inspect the cell connections of the system to ensure that all cells are connected
correctly, POSITIVE (+) to NEGATIVE (-),
b.
Measure the voltage across the system terminals. Voltage of the battery should
equal approximately 2.10 times the number of cells in the string.
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8.0
INITIAL and/or FRESHENING CHARGE
Batteries lose some initial charge during shipment and storage. Depending on storage time, a
battery may require a freshening charge. See Section 4.0 for battery storage times.
Before switching on the charger or controller, ensure that shipping vent plugs are
removed and flame arrestors are installed.
Initial charge is extremely important as it will condition the battery service life. So the battery
must be fully recharged to ensure that it is in an optimum state of charge. Initial charge
conditions depend on the type of equipment available per below:
8.1 External constant voltage charger or MPPT (Maximum Power Point
Tracking) solar charge controller:
1. Charge at a constant voltage of 2.40 VPC at 77°F, corrected for temperature, for a minimum
of 48hrs. Current should be limited to 0.14C20.
2. End-of-charge is when all cell voltages and electrolyte specific gravities (corrected to 25°C)
cease to rise for three consecutive hourly readings. Continue charging until the specific
gravity of electrolyte for all cells rise to nominal specific gravity at maximum level.
3. Add demineralized water if cells to not reach maximum level. Allow an additional 6 hours of
charge for stirring of the electrolyte.
8.2
No external source or MPPT controller available for charging.
1. Connect the battery to the solar panel regulator and leave at rest for 1 to 2 weeks. For this
charge, set the regulator to the following values:
Low charge-restart
voltage
High charge-disconnect
voltage
TABLE 8.1
Temp (°C)
0 to 20°C
20 to 40°C
0 to 20°C
20 to 40°C
Voltage
2.30V
2.30V
2.50V
2.45V
2. Add demineralized water if cells to not reach maximum level. Allow an additional 3 days of
charge for stirring of the electrolyte if water is added.
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Publication No. US-RE-IOM-002 January 2012
9.0
OPERATION
9.1
MPPT Charge Regulators
Recommended Inverter Settings:
Bulk (Absorb) Voltage: 2.40 VPC
Float Voltage: 2.25 VPC
Equalize Voltage: 2.67 VPC
Rebulk or Recharge Voltage: 2.08 VPC
Equalize charge should be done every 6 months for a minimum of 1 hour, maximum of 3 hours.
If possible, add water during the last 30 minutes of equalize charge. This helps ensure good
mixing of the electrolyte when the water is added.
9.1.1
ON/OFF Solar Charge Regulators
In order to ensure optimum recharge, the following setting charge disconnect and restart
voltages can be applied:
TABLE 9.1
TEMPERATURE
-20 to 0°C
0 to 20°C
9.1.2
20 to 35°C
> 35°C
Low charge-restart
voltage (Vpc)
2.35V
2.30V
2.30V
2.25V
High charge-disconnect
voltage (Vpc)
2.50V
2.45V
2.40V
2.35V
Low Voltage Disconnect
As a rule, installations will be equipped with a regulator whose voltage threshold values will
protect against deep discharge:
Low voltage alarm
Disconnect
voltage
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TABLE 9.2
DISCHARGE TIME
10h
1.92V
1.80V
120h
1.92V
240h
1.95V
1.85V
1.90V
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9.2
Hydrometer Readings - Specific Gravity
Specific gravity is a measurement of the density or weight of the electrolyte compared with
water (1.000). Specific gravity decreases on discharge and rises again on charge as a result of
the electrochemical reaction within the cell.
Because both the cell temperature and the electrolyte level affect the specific gravity reading,
they should be recorded at the same time as the gravity reading.
Do not take gravity readings immediately after adding water to the cells. Complete mixing
usually takes several days for antimony cells in typical operation.
To take a specific gravity reading, use the level indicator’s center funnel. Access this funnel
flipping over the flame arrestor top.
A long stemmed hydrometer can be purchased form EnerSys® for measurements (Cat. 81332).
The long stem of the hydrometer can be cut down so it reaches the separator protector when
the hydrometer is fully inserted.
9.3
Full-Charge Specific Gravity
With the cells fully charged and the electrolyte level ¼ from the bottom of the vent well (max
level) the specific gravity of the electrolyte at 77o F (25o C) should read 1.255 ±.005. The full
charge specific gravity will increase as water evaporates and the electrolyte level goes down.
These gravity limits are adjusted at the factory and will not require any further adjusting during
the life of the battery unless electrolyte is actually lost from a cell. If electrolyte should
accidentally be lost, it should be replaced with electrolyte of the same specific gravity as that in
the adjacent cells.
When taking hydrometer readings, hold the hydrometer stem in an upright position so that the
hydrometer floats freely and does not touch at either the top or the sides (See Figure 9.1).
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Publication No. US-RE-IOM-002 January 2012
1.215
1.255
FLOAT
FLOAT
Hydrometer
Cat. 81332
Figure 9.1
STEM
STEM
Periodically clean the hydrometer barrel and float with soap and water for ease of reading and
improved accuracy.
Specific gravity readings should be corrected for temperature. For every 3o F (1.67o C) of
temperature above 77o F (258o C), add one point (.001) to the hydrometer reading. For every 3o F
(1.67o C) of temperature below 77o F (25o C), subtract one point (.001) from the hydrometer
reading.
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9.4
Equalizing Charge
An equalizing charge is a special charge given to a battery when nonuniformity in voltage has
developed between cells. It is given to restore all cells to a fully charged condition.
Nonuniformity of cells may result from:
•
repeated deep discharge or idleness in a discharged state.
•
failure to fully recharge the battery on a regular basis (partial state of charge
operation).
•
selection of too low a float voltage.
•
variations in cell temperatures in the series at a given time, due to environmental
conditions or module arrangement. The maximum cell-to-cell temperature difference is
5˚F (3˚C). If cell temperature is the problem, review the location instructions in Section
5.0 to ensure proper location of the battery system.
9.4.1
Equalizing Charge Method
MPPT Charge controllers use constant voltage charging as the method for giving an equalizing
charge.
Use the voltage setting given in section 9.1 for correct equalize charge setting.
Equalize charge should be done every 6 months for a minimum of 1 hour, maximum of 3 hours.
If possible, add water during the last 30 minutes of equalize charge. This helps ensure good
mixing of the electrolyte when the water is added. Water tends to float on top of the electrolyte
for awhile, but the gassing action of equalize charge will mix the water into the electrolyte.
Alternatively, if an outside charging source is available, the batteries may be constant current
equalized at 4.5%, in amps, of the battery’s nominal amp hour rating (C20).
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9.5
Operating Temperature
Under normal operating conditions, the battery lifetime largely depends on the temperature and
depths of discharge. High temperature increases realized capacity but decreases life
expectancy, while low temperatures decrease capacity, but may not affect life expectancy. See
table below and chart below for expected life given by the two variables.
Daily Weighted
Average
Temperature
No. of Cycles
20
25
30
35
40
45
10%
8891
8717
7514
6478
5584
4814
TABLE 9.3
DAILY DEPTH DISCHARGE @ C20
20%
30%
40%
50%
4764
3164
2312
1852
4671
3102
2266
1816
4026
2674
1954
1566
3471
2305
1684
1350
2992
1987
1452
1163
2580
1713
1252
1003
60%
1530
1500
1293
1115
961
828
70%
1319
1293
1115
961
828
714
80%
1163
1140
983
848
731
630
Batteries for renewable energy applications
Derating factor for number of cycles vs. average cell temperature
Temperature in °C
Figure 9.2
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10.0 BATTERY TAPS
Connections made to a battery for tapping a certain group of cells to provide a voltage other
than the total battery voltage is NOT recommended and can void the warranty. Tapping results
in an imbalance of the system during charging and discharging, causing unsatisfactory
operation.
11.0 PILOT CELL
One cell in a battery is usually selected as a pilot cell. It becomes an indicator of the general
condition of the entire battery with regard to voltage, gravity and temperature. Pilot cell readings
serve as an interim indicator between regularly scheduled voltage and gravity readings of the
complete battery. A cell near the middle of the battery layout is usually the best selection, as it
will have the most representative temperature. This cell should be used for the charge controller
temperature probe for voltage correction.
Because a small amount of electrolyte may be lost in taking hydrometer readings, you should
select a different cell as the pilot cell annually.
Read and record the pilot cell voltage on a monthly basis between regularly scheduled
individual cell readings.
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12.0 MAINTENANCE
12.1 Battery Cleaning
Observe the battery for cleanliness at regular intervals. Keep cell terminals and connectors free
of corrosion. Terminal corrosion may adversely affect the performance of the battery, and it
could present a safety hazard.
12.1.1
Standard Cleaning
To perform a standard cleaning of the battery, follow the procedure below:
1. Disconnect the battery.
2. Wipe off any accumulation of dust on the cell covers with a cloth dampened with clean
water.
3. If the cell covers or jars are damp with spilled electrolyte, wipe with a cloth dampened with a
solution of sodium bicarbonate and cold water, mixed in the proportions of 1.0 lb/1.0 gal (0.5
kg/5.0 liter) of water. Follow this by wiping with a cloth dampened in clear water and then
wipe dry with a clean cloth.
Do NOT use any type of oil, solvent, detergent, petroleum-based
solvent or ammonia solution to clean the jars or covers. These
materials will cause permanent damage to the battery jar and cover
and will void the warranty.
12.1.2
Corrosion Cleaning
To clean mild corrosion from cell posts, follow the procedure below:
1. Disconnect the battery.
2. Remove corrosion by wiping with a cloth dampened with bicarbonate of soda solution [mix 1
gallon (4l) of water with 1 lb. (500g) of bicarbonate of soda]. Follow with a cloth dampened
with clear water.
3. Dry with a clean cloth.
4. With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the entire bolted
connection.
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12.1.3
Heavy Corrosion Cleaning
If the routine cleaning of bolted connections has been neglected, heavy post
corrosion may occur. The performance of the battery under load could be adversely
affected, and this condition could present a safety hazard.
To perform the heavy corrosion cleaning, follow the procedure below:
1. Unbolt and remove connectors.
2. Apply a solution of bicarbonate of soda and water to the cell posts and connectors/cable
lugs to neutralize the corrosion (as described in Section 12.1.2, Procedure 2).
3. Clean the contact surfaces by rubbing the surface of the post or terminal and plated contact
surfaces with a stiff-bristle nonmetallic brush/pad. Exercise care so you do NOT remove
the plating on the connectors, terminal plates or lugs, exposing copper.
4. Recoat the contact surfaces with a thin application of the NO-OX-ID grease, heated to a
liquid form and applied with a small paintbrush.
5. Reinstall and tighten connections to appropriate retorque value (see section 7.4). DO NOT
use any type of oil, solvent, detergent, petroleum-based solvent or ammonia solution
to clean the jars or covers. These materials may cause permanent damage to the
battery jar and cover and will void the warranty.
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12.1.4
Cleaning Flame Arrestors
When cells are overfilled with electrolyte (above the high level line) or are excessively
overcharged, the diffuser material of the flame arrestor may become partially clogged from
electrolyte spray. Replace all flame arrestors having clogged pores or clean the arrestors as
follows.
Immerse the flame arrestor several times in a plastic bucket filled with fresh water. After each
immersion, eject the water by vigorous shaking or with an air blast. Following the immersion of
15 flame arrestors, dump and refill the bucket with clean water.
Do not use any cleaning or neutralizing agents in the cleaning water, since any dry residue may
clog the pores of the diffuser materials.
12.2 Maintenance Records
A complete recorded history of the battery operation is essential for obtaining satisfactory
performance. Good records will show when corrective action is required to eliminate possible
charging, maintenance or environmental problems.
Should you have ANY questions concerning how to perform the required maintenance, contact
your nearest EnerSys sales/service representative or call the corporate office number listed on
the back of this manual and ask for EnerSys® Service.
Accumulate and permanently record the following data for review by supervisory personnel so
that any necessary remedial action may be taken:
The initial records are those readings taken after the battery has been in regular float service for
3 months (90 days). These should include the battery terminal float voltage and specific gravity
reading of each cell corrected to 77o F (25o C), all cell voltages, the electrolyte level,
temperature of one cell on each row of each rack, and cell-to-cell and terminal connection detail
resistance readings. It is important that these readings be retained for future comparison.
The frequency and types of readings recorded are usually governed by the standard operating
procedures and policies of the user. Adequate battery records are an invaluable aid as a check
on maintenance procedures, environmental problems, system failures and corrective actions
taken in the past.
While specific gravity readings are a good indication of the health of a cell, other readings can
be used to indicate relative health. However, it is highly recommended that a supplemental full
set of readings on each cell (including specific gravity) be taken approximately two years after
service initilization to verify that the floating conditions of the battery are appropriate.
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The following schedule is recommended for good maintenance and records. Readings should
be taken when battery is in float state of charge.
Monthly
•
General appearance and cleanliness
•
Charger output amps and volts
•
Electrolyte levels
•
Cracks in cells or leakage of electrolyte
•
Evidence of corrosion at terminals or connectors
•
Ambient temperature and condition of ventilating equipment
•
Pilot cell voltage, specific gravity and electrolyte temperature
•
Evidence of voltage leaks to ground
Quarterly
In addition to the monthly items also obtain and record the following:
•
•
•
•
Specific gravity of each cell
Voltage of each cell
Total battery voltage
Temperature of one cell on each row on each rack
AnnuaIIy
In addition to the quarterly items, also do the following:
•
•
Check all bolted connections to see if retorquing is required. Tighten all bolted
connections to specifiications given in section 7.4.
Check integrity of rack, if applicable.
THE ABOVE FREQUENCY OF RECORD TAKING IS THE ABSOLUTE MINIMUM TO
PROTECT THE WARRANTY. This data will be required for any warranty claim made on the
battery. For system protection and to suit local conditions/requirements, more frequent readings
(quarterly) are desirable. A sample record chart is provided. Make a copy of the chart to use for
your permanent records.
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12.3 Corrective Actions
Low electrolyte levels should be corrected by following the procedures given in Section 12.4
below.
If charger output voltage is not within the recommended voltage range, make adjustments. Then
determine the cause of the shift and correct the problem.
Keep cells clean, terminal posts and connectors corrosion-free, and grounds eliminated by
following the procedures in Section 12.1.
When cell temperatures deviate more than 5o F (3o C), from each other during an inspection,
determine the cause and correct the problem.
12.4 Adding Water
Cells on charge normally show a very gradual lowering of the electrolyte level over a period of
time, due to a loss of water from the electrolyte. Hydrogen and oxygen gasses are liberated by
electrolysis as a result of charging current. Cells also lose water from normal evaporation at a
rate relative to the cell temperature and the humidity. At regular intervals this water loss must be
replaced with distilled, deionized or approved water.
Only add water to the battery when the battery is at full state of charge or during equalize
charge. In this condition the electrolyte should be brought up ¼” from the bottom of the vent
well. Watering the battery when it is not fully charged may cause an overflow when the battery
does reach a fully charged state.
In cold climate with unheated battery rooms, water should be added only when the battery
temperature is 50o F (10o C), or above.
Never add any special types of powders, solutions or jellies to the batteries.
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12.5 Quality of Water
Only distilled, deionized or other approved water (Deionizer Cat. 94866, Watering Gun Cat.
92755) should be added to the battery.
Approved water is water that has been analyzed by a qualified laboratory and found safe for use
with lead-acid storage batteries. Local municipal water supplies in the U.S.A. & Canada are
usually satisfactory. Obtain an analysis from the local municipality to be sure the results comply
with the impurity levels in Table 12.1.
Before drawing water from a tap or spigot, run the water for several minutes to clear metallic
impurities from the pipes.
Do not store the water in a metal container. Use a clean container made of glass, rubber or
plastic. The container should not have stored anything but water in the past.
The following table shows the maximum allowable impurities:
TABLE 12.1 — BATTERY WATER QUALITY
MAXIMUM IMPURITIES
Requirements
Maximum Allowable Limits
Parts Per Million (P.P.M.)
350.0
200.0
150.0
4.0
25.0
4.0
10.0
10.0
0.07
40.0
Total Solids*
Fixed Solids*
Organic and Volatile*
Iron
Chloride
Ammonium (NH4)
Nitrates (NO2)
Nitrates (NO3)
Manganese
Calcium and Magnesium
* ASTM Spec. D-1888 Method A or equal
Page 36
www.enersys.com
Publication No. US-RE-IOM-002 January 2012
STORAGE BATTERY REPORT - Battery in Float Service
Company
_______________________________
Sheet No. _________
Batt. Type ___________
Date Installed
_______________
Location
_______________________________
Pilot Cell No. __________
Battery No.
_______________________________
Full Charge Gravity (Range)
Monthly
DATE &
INITIALS
OF
READER
CHARGER
BATT.
TERM
VOLTS
VOLTS
AMPS
ACID
LEVEL
_______________
Quarterly
PILOT CELL
HYDRO
METER
READINGS
TEMPERATURES
PILOT
CELL
Notes
Quarterly
ADDING WATER
(when required)
Add water after completing hydrometer readings.
Date
Quantity
_____________
______________ Qts.
Annually
Connector Bolts
Retorqued
Acceptance Test Results — Date
Performance Test Results — Date
www.enersys.com
(rotate as needed)
ROOM
DATE
CELL
VOLTS
HYD.
RDG
VOLTS
HYD.
RDG
VOLTS
HYD.
RDG
VOLTS
HYD.
RDG
VOLTS
HYD.
RDG
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
Publication No. US-RE-IOM-002 January 2012 Page 37
APPENDIX
HYDROGEN EVOLUTION CALCULATION OF RE CELLS
Every battery gives of hydrogen and oxygen during recharge. Most of the gassing occurs after
the 80% point has been reached. The concentration of the gasses is proportional to the current
being delivered to the battery.
To calculate the hydrogen produced, use the following formula, and ventilate the area as
required. Hydrogen must be ventilated in order to avoid an explosion. Hydrogen concentrations
of 4% or greater will cause an explosion.
Cubic Feet per Minute (cfm) of Hydrogen = 0.000013 x (nominal Ah capacity) x (number of
cells)
For example, an installation with 24 cells of 1RE85-21 would be:
0.000013 x (960 Ah) x (24 cells) = 0.30 cfm of Hydrogen
The National Fire Protection Association (NFPA) allows up to 1% concentration. Make sure the
ventilation system can remove the hydrogen before it reaches concentrations of 1% within the
battery area.
NOTE: The above values apply when the electrolyte temperature is 77o F (25o C). The cfm
values will double for every 15o F (8o C) of temperature rise. If the temperature drops, the cfm
values will be halved for every 15o F (8o C) decrease.
Page 38
www.enersys.com
Publication No. US-RE-IOM-002 January 2012
PRECAUTIONS*
1.
Do Not bring any heat or flame source near battery.
USE EDGE OF MODULE
WHEN POSITIONING BATTERY
DO NOT PUSH ON CENTER
TO POSITION BATTERY
2.
Do Not lift any cells by the terminal posts.
3.
Do Not remove coating from post or connectors and expose any bare copper.
4.
Do Not clean cell with anything other than water/bicarbonate of soda.
5.
Do Not over torque connections.
6.
Do Not exceed EnerSys recommended storage intervals without refreshing charge.
* These are only a few of the precautions. Please read this manual thoroughly for
complete details.
WARNING
Do Not use any lubricant other than EnerSys® Pro-Slide or Dow
Corning Silicon Compound #111 to lubricate rails to facilitate
sliding of batteries.