EnerSys PowerSafe Data Safe Operation & Maintenance Manual Download Page 9 | Manualshive

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www.enersys.com Publication No. US-FL-IOM-002 January 2007

Page

1

1.0 GENERAL

INFORMATION

1.1 Introduction

EnerSys flooded lead-acid batteries set the benchmark for reliability and durability in flooded
lead-acid batteries and battery systems.

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 Reserve Power 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 Reserve Power
Service.

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Summary of Contents for PowerSafe Data Safe

Page 1: ...Safety Storage Installation Operation Maintenance Manual Flooded Lead Acid Batteries C D E F and G Publication No US FL IOM 002 January 2007 ...

Page 2: ...tions 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 ...

Page 3: ...ndicate potentially hazardous situations and conditions which if not avoided may result in injury Equipment damage may also occur Caution 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 d...

Page 4: ...rounded 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...

Page 5: ...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 This unit contains flooded lead acid batteries Lack of preventative maintenance could result in batteries exploding and emitting gasses and or flame An authorized trained technician must perform annual preventative maintenance Warning Failure to replace a ...

Page 6: ...dvance Preparation 8 5 0 INSTALLATION CONSIDERATIONS 9 5 1 General 9 5 2 Considerations for Connecting the Battery System to Operating Equipment 11 5 3 Considerations for Parallel Installation 11 6 0 UNPACKING AND HANDLING FOR INSTALLATION 12 6 1 General 12 6 2 Recommended Installation Equipment and Supplies 12 6 3 Cell Jar Handling 13 6 3 1 Small Cell Handling C 13 6 3 2 Medium Cell Handling E an...

Page 7: ...ILOT CELL 35 12 0 MAINTENANCE 35 12 1 Battery Cleaning 35 12 1 1 Standard Cleaning 35 12 1 2 Corrosion Cleaning 36 12 1 3 Heavy Corrosion Cleaning 36 12 1 4 Cleaning Flame Arrestors 37 12 1 5 Replacing or Isolating a Cell 37 12 2 Maintenance Records 37 12 3 Corrective Actions 39 12 4 Adding Water 39 12 5 Quality of Water 40 Storage Battery Report Battery in Float Service 41 12 6 Filling and Chargi...

Page 8: ......

Page 9: ...ons 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 Reserve Power 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 ...

Page 10: ...E PREPARED and EQUIPPED to take the necessary safety precautions If not contact EnerSys Reserve Power 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 apron face protection face shield rubber gloves safety goggles emergency eye wash and shower if available fir...

Page 11: ...R 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 ...

Page 12: ...splatter Wear acid resistant 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...

Page 13: ...ound 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 ...

Page 14: ...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 o...

Page 15: ... 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 NOTE For export cells are usually shipped assembled moist charged with separate electrolyte Fill when ready to place in service not before Refer to Section 12 6 Filling and Charging Moist Charged Cells Check the received materials against the detailed pack...

Page 16: ... 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 factor...

Page 17: ...is recommended that the aisle space provided in front of all racks 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 Each cell should be accessible for the addition o...

Page 18: ...odes 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 rack or cabinet front to rear and side to side Capable of supporting the weight of the battery...

Page 19: ... 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 supplie...

Page 20: ...ng 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 CHECK IF ON HAND EQUIPMENT REQUIRED Forklift or Portable Lift Crane Chalk Line Torpedo Level Plastic Torque Wrench 10 200 in lbs Torque Wrench 50 100 ft lbs D...

Page 21: ... hoist or similar device use the lifting belt s and protective styrofoam shipping cover s provided DO NOT tamper with the seal nuts on the cell posts as this will void the warranty 6 3 1 Small Cell Handling C 1 Lift and move these batteries manually 2 Position hands under the bottom of the cell jar to lift it and place the cell unit in the desired location 6 3 2 Medium Cell Handling E and F Never ...

Page 22: ...ook of the lifting device in both rings Always lift vertically and balance the cell See Figure 6 4 5 Remove the belt and cover after positioning the cell LIFTINGMEDIUM SIZE CELL Figure 6 2 LIFTINGMEDIUM SIZE CELL Figure 6 2 LIFTINGMEDIUM SIZE CELL Figure 6 2 LIFTINGMEDIUM SIZE CELL Figure 6 2 LIFTING MEDIUM SIZE CELL Figure 6 4 LIFTING MEDIUM SIZE CELL Figure 6 4 LIFTING MEDIUM SIZE CELL Figure 6 ...

Page 23: ...d styrofoam insert covering the posts and intercell connectors This insert should remain in place for lifting the cells As the cell is lifted the belts will tighten against the shipping top The belts will cut into the styrofoam This is desirable because the indentations created will help to keep the belts positioned and the cell stable 1 Remove the packaging from around the cells units and remove ...

Page 24: ...TING LARGE SIZE CELL Figure 6 6 5 Pull this loop end of the belt from under the cell and out through the slot Disengage the wire hook from the loop and again insert the hook through a different slot between the bottom of the jar and the shipping base See Figure 6 7 LIFTING LARGE SIZE CELL Figure 6 7 6 Engage the other belt loop with the wire hook and pull it out through the slot on the same side A...

Page 25: ...they are parallel with each other The space between the belts should be the same as the distance between the belt notches on the edge of the styrofoam Correct belt spacing is important because it permits removal of the belt after the cell unit has been placed on the rack rails 8 Lift cell into position and remove belt Exercise extreme care when initially lifting cells and when lowering them into f...

Page 26: ...rack components locate the position of the floor anchors Floor anchors are the responsibility of the owner Follow the installation instructions of the anchor manufacturer 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 The Battery Rack must be securely anchored to the ...

Page 27: ...ical 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 Reserve Power Service 7 2 2 Arrangement Arra...

Page 28: ...reme caution when initially lifting cells and when lowering them into final position on the rack 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 4 Position the first cell jar on the bottom shelf centered across the rails After placement remove the lifting belt if used from the hook and pull the belt from unde...

Page 29: ...eviously installed unit See Figure 7 3 Be certain to allow proper spacing between cells jars as outlined in Section 7 2 2 Observe proper polarity orientation Exercise extreme care when positioning cells Bumping or scraping a cell against the adjacent cell unit or rack member may damage the jar material Do NOT use any kind of tool to pry cells into position CELL JAR PLACEMENT Figure 7 3 7 Remove th...

Page 30: ...cells unless flame arrestors are in place Once installed DO NOT REMOVE the flame arrestors They are provided with a filling funnel for adding water and measuring the electrolyte temperature Do not permit the lectrolyte level to drop below the bottom of the tube on the flame arrestor Allowing too low a level defeats the flame arrestor function 10 Number the cells starting from the positive terminal...

Page 31: ...h pad until a clean bright surface is obtained Do NOT expose copper 4 Apply a light coat of NO OX ID grease 7 4 2 Intercell Connectors The connections are made by bolting the plated copper intercell connectors to the cell posts of opposite polarity on adjacent cells When more than one intercell connector for each cell is furnished bolt the connectors on opposite sides of the cell posts 1 Clean the...

Page 32: ...agram for CX DX DXC EA EC ES FTA FTC GC GT GU Certain intercell connectors such as those for all G cells are furnished with the bolt holes located off center Install these connectors so that the bottom edge of the connector does not interfere with the post ledge Figure 7 6b and the detail Stamped flat washers may have one sharp edge Install with this edge away from the plated copper intercell conn...

Page 33: ...Torque Value Inch Pounds Newton Meter Retorque Value Inch Pounds Newton Meter 1 4 20 70 75 8 0 8 5 60 65 7 0 7 5 5 16 18 120 125 13 6 14 1 110 115 12 5 13 0 1 2 13 130 135 14 7 15 3 120 125 13 6 14 1 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 6 Apply a light coat of he...

Page 34: ...al 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 A typical terminal plate is illustrated in Figure 7 7 2 With a small paintbrush apply a light coating of heated NO OX ID grease to contact areas 3 Install the terminal connectors to cell posts Tighten all connections acc...

Page 35: ...e connections Support cables so that the cell post does not bear the load 8 Before activating the charger 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 06 times the number of cells in the string for 1 215 nominal specific gravity...

Page 36: ...cted to the DC bus the use of lower voltage is accceptable See Table 8 1 Should the charge current cause electrolyte to flood out onto the cover reduce the charge voltage at once Least desirable is to put the battery on at the float voltage particularly for calcium alloy cells Equalize charging at 2 33 volts per cell is the minimum acceptable procedure for 1 215 calcium alloy cells 1 Determine the...

Page 37: ...24 36 44 Table 8 1 applies for cell temperatures between 60o to 90o F 16o to 32o C For cell temperatures 40o to 59o F 5o to 15o C use twice the number of hours For cell temperatures 39o F 4o C or below use four times the number of hours On C D E F and G cells you may insert the thermometer in the funnel of the pilot cell s flame arrestor and leave it there by adjusting the rubber washer to the cor...

Page 38: ...r required in the event of an AC power interruption or charger failure The table below lists the recommended average float volts per cell for nominal specific gravities used in stationary service TABLE 9 1 RECOMMENDED AVERAGE FLOAT VOLTS PER CELL FOR NOMINAL SPECIFIC GRAVITIES Average Float Volts per Cell Nominal Specific Gravity Suffix Antimony Calcium 1 250 1 215 B None 2 17 2 21 2 15 2 20 2 21 ...

Page 39: ... cap of the flame arrestor All the corner holes are sealed with plugs Keep these plugs tightly closed and do NOT open them to withdraw acid sample Using the long stemmed hydrometer Cat 81332 will result in sampling of the electrolyte at a point one third down from the top of the plate The long stem of the hydrometer must be cut to 7 3 4 inches 200 mm for E cells to 9 inches 230 mm for D and F cell...

Page 40: ... 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 ...

Page 41: ...tant voltage charging is the method for giving an equalizing charge Determine the equalizing voltage based on the maximum voltage allowed by the system equipment connected to the DC bus The charge table shown in Table 9 3 lists the minimum hours of equalizing charge to be given after the charging current has stabilized no further current reduction for 24 hrs TABLE 9 3 MINIMUM HOURS OF CHARGE AFTER...

Page 42: ...y while low temperatures decrease capacity but may not affect life expectancy Table 9 5 shows the relationship between average temperature and battery life TABLE 9 5 RELATIONSHIP OF TEMPERATURE TO BATTERY LIFE of 8 Hr Capacity Antimony Flat Plate Calcium Flat Plate Approx number of cycles at 80 discharge 300 50 Average operating Temp o F Life Expectancy in Full Float Application years 107 109 6 5 ...

Page 43: ...adings 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 12 0 MAINTENANCE EnerSys also recommends to follow IEEE Std 450 for the battery maintenance in addition to the following 12 1 Battery Cleaning Observe the battery for cleanliness at regular intervals Keep cell terminals ...

Page 44: ...ing 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 Arrange to maintain continuity of the circuit if required 2 Unbolt and remove connectors 3 Apply a solution of bicarbonate of soda and w...

Page 45: ...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 m...

Page 46: ...rly In addition to the monthly items also obtain and record the following For antimony cells specific gravity of each cell optional for calcium cells Voltage of each cell Total battery voltage Temperature of one cell on each row on each rack Randomly select and check 10 of intercell connection resistances AnnuaIIy In addition to the quarterly items also do the following Perform detailed visual ins...

Page 47: ... as to maintain the electrolyte level at the mid point between the high and low level lines marked on the jar while on float Cells are equipped with flame arrestors with a filling funnel Add water through the filling funnel by removing the dust cap but without removing the flame arrestors from the cell covers The best time to add water to the stationary lead acid battery is when the recharge or eq...

Page 48: ...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 wat...

Page 49: ...S ACI D LEV EL PILOT CELL HYDRO METER READING S PILO T CEL L ROO M CELL VOL TS HYD RDG VOL TS HYD RDG VOL TS HYD RDG VOL TS HYD RDG VOL TS 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 Notes Quarterly ADDING WATER when required Add water after completing hydrometer read...

Page 50: ...arted within 12 hours of the initial fill Before charging install the flame arrestors and then lock in place with one quarter turn clockwise Then install the dust cap when provided on each arrestor The preferable way to charge antimony alloy cells is a constant voltage averaging 2 50 volts per cell For calcium alloy cells the voltage needs to be 2 70 volts per cell Charge for the time shown in Tab...

Page 51: ...gravity may not be available In this case adjust the level with electrolyte instead of water Measure the specific gravity and keep adjusting the level with electrolyte until a normal specific gravity reading is achieved TABLE 12 2 ELECTROLYTE QUALITY DILUTE SULFURIC ACID H2SO4 MAXIMUM IMPURITIES By Weight 1 250 1 300 Sp Gr 1 170 1 215 Sp Gr Organic Matter Platinum Pt Sulfurous Acid SO2 Iron Fe Cop...

Page 52: ...test discharge current is equal to the rated discharge current divided by the K Factor see Table 13 1 for the initial battery electrolyte temperature See IEEE 450 2002 for reference 5 With the variable load bank having an ammeter in series and a voltmeter across the battery terminals connect the load simultaneously starting the timing device Maintain the correct current while periodically reading ...

Page 53: ...22 8 23 4 23 9 24 5 25 0 25 6 26 1 26 7 27 2 27 8 28 3 28 9 29 4 30 0 30 6 31 1 31 6 32 2 32 8 33 4 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 1 098 1 092 1 086 1 080 1 072 1 064 1 056 1 048 1 040 1 034 1 029 1 023 1 017 1 011 1 006 1 000 0 994 0 987 0 980 0 976 0 972 0 968 0 964 0 960 0 956 0 952 0 948 0 944 0 940 0 938 0 936 ...

Page 54: ...re it is nearing end of life or equalize charge at 2 33 VPC Float Current demand of fully charged stationary lead acid cells Milliamperes per 100 Ah 8 hr rate Charge Voltage Antimony Calcium NEW OLD 2 15 vpc 15 60 2 17 vpc 19 80 4 2 20 vpc 26 105 6 2 23 vpc 37 150 8 2 25 vpc 45 185 11 2 27 vpc 60 230 12 2 33 vpc 120 450 24 2 37 vpc 195 700 38 2 41 vpc 300 1100 58 NOTE The above values apply when t...

Page 55: ...MPLE 60 cell GT 41 3730 AH near end of life on equalize at 2 33 VPC at 92o F 33o C electrolyte temperature FC 450 from table x 2 for 92o F 33o C 900 milliamperes C 900 x 3730 x 0 000267 cu ft 7 56 x 10 6 cu m x 60 1000 100 Hydrogen 0 538 cu ft 0 0152 cu m per minute Assume a room size of 16 000 cu ft 452 5 cu m that is allowed a 2 concentration of hydrogen or 320 cu ft 9 06 cu m At the above hydro...

Page 56: ...2007 Subject to revisions without prior notice E O E Do Not clean cell with anything other than water bicarbonate of soda 7 Do Not over torque connections 8 Do Not store EnerSys Lead Antimony batteries for over three months without charge 9 EnerSys Lead Calcium for over six months without charge at normal temperatures These are only a few of the precautions Please read this manual thoroughly for c...

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