EnerSys PowerSafe Assembly, Installation, Operation & Maintenance Manual Download Page 1

Page: 1 / 46

Battery Safety,

Storage, Installation,

Operation & Maintenance Manual

RE Flooded Lead-Acid Batteries

Publication No. US-RE-IOM-002 January 2012

Summary of Contents for PowerSafe

Page 1: ...Battery Safety Storage Installation Operation Maintenance Manual RE Flooded Lead Acid Batteries Publication No US RE IOM 002 January 2012...

Page 2: ...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 perso...

Page 3: ...ed 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...

Page 4: ...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 main...

Page 5: ...ries may explode Caution Do not mutilate the batteries Released electrolyte is harmful to the eyes and skin and may also be toxic Warning This unit contains flooded lead acid batteries Lack of prevent...

Page 6: ...mage 9 4 0 BATTERY STORAGE BEFORE INSTALLATION 10 4 1 General 10 4 2 Storage Interval 11 4 3 Advance Preparation 11 5 0 INSTALLATION CONSIDERATIONS 12 5 1 General 12 5 2 Considerations for Connecting...

Page 7: ...harge Regulators 25 9 1 2 Low Voltage Disconnect 25 9 2 Hydrometer Readings Specific Gravity 26 9 3 Full Charge Specific Gravity 26 9 4 Equalizing Charge 28 9 4 1 Equalizing Charge Method 28 9 5 Opera...

Page 8: ...ar 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 corro...

Page 9: ...nits 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...

Page 10: ...ve 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 sta...

Page 11: ...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 necess...

Page 12: ...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 sul...

Page 13: ...o 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 th...

Page 14: ...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 sho...

Page 15: ...entative 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...

Page 16: ...ated 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...

Page 17: ...8 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 interval...

Page 18: ...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 y...

Page 19: ...e 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...

Page 20: ...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 Buildin...

Page 21: ...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 ach...

Page 22: ...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...

Page 23: ...r 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...

Page 24: ...ed 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 4 Batterie...

Page 25: ...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 ge...

Page 26: ...nal 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 st...

Page 27: ...arrestors DO NOT attempt to charge 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 Add water to the...

Page 28: ...rnished 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...

Page 29: ...eas 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 W...

Page 30: ...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 S...

Page 31: ...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 fo...

Page 32: ...ing 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 9 1...

Page 33: ...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 Ful...

Page 34: ...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 readin...

Page 35: ...ll 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 voltag...

Page 36: ...le below and chart below for expected life given by the two variables TABLE 9 3 DAILY DEPTH DISCHARGE C20 No of Cycles 10 20 30 40 50 60 70 80 20 8891 4764 3164 2312 1852 1530 1319 1163 25 8717 4671 3...

Page 37: ...ndition 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...

Page 38: ...he 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...

Page 39: ...on 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 Exercis...

Page 40: ...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 necessar...

Page 41: ...he 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...

Page 42: ...trolyte 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 norm...

Page 43: ...purity 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 cl...

Page 44: ...DATE INITIALS OF READER BATT TERM VOLTS CHARGER ACID LEVEL PILOT CELL HYDRO METER READINGS TEMPERATURES DATE VOLTS AMPS PILOT CELL ROOM CELL VOLTS HYD RDG VOLTS HYD RDG VOLTS HYD RDG VOLTS HYD RDG VOL...

Page 45: ...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 1RE...

Page 46: ...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 com...

Search results

Summary of Contents for PowerSafe

Reviews:

Related manuals for PowerSafe

Brands by name

Popular brands

EnerSys PowerSafe, Assembly, Installation, Operation & Maintenance Manual

Search results

Summary of Contents for PowerSafe

Reviews:

Related manuals for PowerSafe

Brands by name

Popular brands