Exide ABSOLYTE GX and Installation And Operating Manual Download Page 7

SECTION 3: DELIVERY INFORMATION

3.0

Receipt of Shipment

Immediately upon delivery, examine packaging for possible

damage caused in transit. Damaged packing material or

staining from leaking electrolyte could indicate rough han-

dling. Make a descriptive notation on the delivery receipt

before signing. If cell or unit damage is found, request an

inspection by the carrier and file a damage claim.

3.1

Concealed Damage

Within 10 days of receipt, examine all cells for concealed

damage. If damage is noted, immediately request an

inspection by the carrier and file a concealed damage

claim. Pay particular attention to packing material exhibiting

damage or electrolyte staining. Delay in notifying carrier

may result in loss of right to reimbursement for damages.

SECTION 4: STORAGE INFORMATION

4.0

Storage Prior to Installation

Do not remove shipping materials if a storage period is

planned, unless charging is required per Section 4.2.

4.1

Storage Location

If the battery is not to be installed at the time of receipt, it

is recommended that it be stored indoors in a cool (25°C,

77°F), clean, dry location.

4.2

Storage Interval

The storage interval from the date of battery shipment to

the date of installation and initial charge should not

exceed six (6) months. If extended storage is necessary,

the battery should be charged at regular intervals until

installation can be completed and float charging can be

initiated. When in extended storage, it is advised to mark

the battery pallets with the date of shipment and the date

of every charge. If the battery is stored at 77°F (25°C) or

below, the battery should be given its initial charge (refer

to Section 10) within 6 months of the date of shipment and

receive a freshening charge (perform per Section 10 Initial

Charge) at 6 month intervals thereafter. Storage at ele-

vated temperatures will result in accelerated rates of self

discharge. For every 18°F (10°C) temperature increase

above 77°F (25°C), the time interval for the initial charge

and subsequent freshening charges should be halved.

Thus, if a battery is stored at 95°F (35°C), the maximum

storage interval between charges would be 3 months (ref-

erence Appendix B). Storage beyond these periods with-

out proper charge can result in excessive sulphation of

plates and positive grid corrosion which is detrimental to

battery performance and life.

Failure to charge accord-

ingly may void the batteryʼs warranty.

NOTE: Storage in temperatures above 25°C (77°F)

will result in loss of operating life.

Initial and freshening charge data should be saved and

included with the battery historical records (see Section 15).

SECTION 5: INSTALLATION

CONSIDERATIONS

5.0

General

Prior to starting installation of the Absolyte GX

Battery System, a review of this section is

strongly recommended.

5.1

Space Considerations

It is important to know certain restrictions for the area

where the battery is to be located. First, a designated

aisle space should be provided to permit initial installation

as well as for service or surveillance. After installation,

any additional equipment installed after the battery should

not compromise access to the battery system.

A minimum aisle space of 36 inches from modules / 33

inches from clear covers should be available adjacent to

the battery system. See Figure 1 for typical space alloca-

tions required. Following the spacing requirements will

aid in maintenance of the battery and help maintain air

flow to battery surfaces to enhance heat dissipation.

NOTE:

When planning system space requirements, allow

at least 6 inches past system total length wherever a ter-

minal plate assembly is to be located (Figure 1A). Allow

4.5” minimum between back to back stacks (Figure 1B).

See Figure 1 for typical space allocations required. For

total length, width and height dimensions of connected

systems, consult layout/wiring diagram for the

particular system.

5.2

Battery Location & Ambient

Temperature Requirements

It is recommended that the battery unit be installed in a

clean, cool, dry location. Floors should be level.

A location having an ambient temperature of 24°C (75°F)

to 25°C (77°F) will result in optimum battery life and

performance. Temperatures below 25°C (77°F) reduce

battery charge efficiency and discharge performance.

Temperatures above 25°C (77°F) will result in a

7

Any modifications, alterations or additions to an

Absolyte GX system, without the expressed written

consent of GNB Engineering, may void any warranties

and/or seismic qualifications. Contact your GNB

representative for additional information.

Summary of Contents for ABSOLYTE GX and

Page 1: ...Installation and Operating Instructions For ABSOLYTE GX Batteries SECTION 92 80 2008 07 ...

Page 2: ...r to Installation 7 4 1 Storage Location 7 4 2 Storage Interval 7 SECTION 5 INSTALLATION CONSIDERATIONS 7 5 0 General 7 5 1 Space Considerations 7 5 2 Battery Location Ambient Temperature Requirements 7 5 3 Temperature Variations 9 5 4 Ventilation 9 5 5 Floor Loading 9 5 6 Floor Anchoring 9 5 7 Connecting Cables Battery System to Operating Equipment 9 5 7 1 Paralleling 9 5 8 Stacking Limitations 1...

Page 3: ... 14 SECTION 9 ELECTRICAL CONNECTIONS 14 9 0 Post Preparation 14 9 1 Connections System Terminals 15 9 2 Connections InterMODULE 15 9 3 Connections InterSTACK 15 9 4 Torquing 15 9 5 Connections Check 15 SECTION 10 IDENTIFICATION LABELS 15 10 0 Surfaces 15 10 1 Cell Numerals 15 10 2 System Polarity Labels 17 10 3 Warning Label 17 10 4 Battery Nameplate 17 SECTION 11 PROTECTIVE MODULE COVERS 17 11 0 ...

Page 4: ...Measurements 20 SECTION 14 EQUALIZING CHARGE 20 14 0 General 20 14 1 Equalizing Frequency 21 14 2 Equalizing Charge Method 21 SECTION 15 RECORDKEEPING 21 15 0 Pilot Cell 21 15 1 Voltmeter Calibration 21 15 2 Records 21 SECTION 16 TAP CONNECTIONS 22 16 0 Tap Connections 22 SECTION 17 TEMPORARY NON USE 22 17 0 Temporary Non Use 22 SECTION 18 UNIT CLEANING 22 18 0 Unit Cleaning 22 SECTION 19 CONNECTI...

Page 5: ...ig 14 Hardware Installation Sequence 14 Fig 15 Installing Hardware 14 Fig 16 Completed Horizontal Stack 14 Fig 17 Positioning Horizontal Base Modules 14 Fig 18 Tie Plate Assemblies 15 Fig 19 Stack Connections 16 Fig 20 Terminal Plate Kit Materials Assembly 18 Fig 21 Protective Cover Materials Assembly 23 Fig 22 Sample Record Form LIST OF TABLES PAGE TABLE DESCRIPTION 9 A Temperature Effects on Lif...

Page 6: ...ecautions These installation and operating instructions should be understood and followed Assure that you have the necessary equipment for the work including insulated tools rubber gloves rub ber aprons safety goggles and face protection 2 3 1 Static Discharge Precautions for Batteries When maintaining a connected battery string care must be taken to prevent build up of static charge This danger i...

Page 7: ...B Storage beyond these periods with out proper charge can result in excessive sulphation of plates and positive grid corrosion which is detrimental to battery performance and life Failure to charge accord ingly may void the batteryʼs warranty NOTE Storage in temperatures above 25 C 77 F will result in loss of operating life Initial and freshening charge data should be saved and included with the b...

Page 8: ...8 ...

Page 9: ...well as any auxiliary equipment The total battery weight will depend on the cell size num ber of cells as well as module configuration involved Consult layout wiring diagram for the battery system weight Prior to installation a determination should be made that the floor integrity is adequate to accommodate the battery system 5 6 Floor Anchoring Where seismic conditions are anticipated floor ancho...

Page 10: ...e top adjacent channels See Figure 2 6 1 Accessories NOTE Check accessory package against packing list to assure completeness Do not proceed with instal lation until all accessory parts are available Accessories are packed separately and will include the following Layout wiring diagram Installation and operating instructions Lifting straps and lifting shackles Bottom Supports I beams Hardware bag ...

Page 11: ...s must be criss crossed 2 Observe lifting shackle orientation and proper channel hole use 3 See Figure 13 for handling modules in horizontal orientation 4 Never lift more than one module with straps and hooks HANDLING MODULE Figure 5 SECTION 7 SYSTEM ARRANGEMENTS 7 0 Module Arrangements Absolyte GX batteries may only be arranged horizontally Figure 6 shows some typical arrangements TYPICAL SYSTEM ...

Page 12: ...e module I beam assembly may now be removed from the pallet using methods outlined in Section 6 5 See Figures 4 and 5 Remaining modules may be removed in a similar manner 8 1 3 Tip Over Procedure In order to stack modules in the horizontal position refer to Figures 9 through 11 to perform the tip over procedure The module I Beam assembly tip over should be per formed first This procedure can be pe...

Page 13: ...to stack connectors cannot be installed A Using Section 6 5 and 8 1 3 and the layout wiring diagram position the next module on top of first so that channels of each mate with one another Use drift pins to align channel holes Make sure channel ends and sides of the upper and lower modules are flush Remove lifting straps and install M10 serrated flange bolts and nuts in open holes finger tight Use ...

Page 14: ... are 3 x 1 x 1 8 with two 9 16 holes Use one tie plate at each interface to connect the module channels of adjacent stacks See Figure 18 TIE PLATE ASSEMBLIES HORIZONTAL STACKS Figure 18 Position plates on the module channels and secure with hardware as shown Where stacks have different heights for example a 3 high stack adjacent to 4 high stack install plates on shorter stack top module and adjace...

Page 15: ...X ID A grease to these areas NOTE Apply a minimum amount of grease to cover the surface As a rule If you can see it it s too much Where multiple connectors are required across any single connection brighten both sides of connectors along the entire length Grease these areas as well It is recom mended when installing connectors on horizontal arrangements that the upper bolts be installed first to r...

Page 16: ...R SYSTEM 1 PLATE TOP TERMINAL 2 2 BRACKET TERMINAL SUPPORT 2 3 LOCK WASHER M10 8 4 FLAT WASHER M10 16 5 NUT M10 X 8D 8 6 BOLT M10 X 40 8 7 COVER FRONT 2 8 COVER BACK 2 9 NUT M6 X 8D 4 10 BOLT M6 X 25 VARIES 11 WASHER M6 VARIES Terminal Plate Kit Materials Assembly Figure 20 ...

Page 17: ...the battery and may void the warranty 12 1 Constant Voltage Method Constant voltage is the only charging method allowed Most modern chargers are of the constant voltage type Determine the maximum voltage that may be applied to the system equipment This voltage divided by the num ber of cells connected in series will establish the maxi mum volts per cell VPC that is available Table C lists recommen...

Page 18: ...s at bottom of cover to bottom standoff legs and slide in place Locate holes at top of cover and install to top standoff legs Standoff legs need not be removed to access cells simply remove protective cover Module Clear Cover Materials and Assembly Figure 21 ITEM DESCRIPTION QTY PER SYSTEM 1 Cover 1 2 Standoff Leg 4 3 Standoff Key 4 BILL OF MATERIALS MODULE CLEAR COVER MATERIALS ...

Page 19: ... actual 77 F x 003V F See Appendix A for standard values Modern constant voltage output charging equipment is recommended for the floating charger method of opera tion of GNB Absolyte batteries This type of charger prop erly adjusted to the recommended float voltages and fol lowing recommended surveillance procedures will assist in obtaining consistent serviceability and optimum life After the bat...

Page 20: ...s collectively known in the industry as ohmic measurements Each mea surement is derived using a manufacturer specific and propri etary algorithm and or frequency This means that one type of measurement cannot be converted or related easily to another Reference ohmic values are of dubious value because so many factors can affect the way the readings are made and displayed by the devices Connector c...

Page 21: ...secutive hours D When the current has stabilized proceed to step 2 A Continue the charge for the time listed in Table E depend ing on the charger voltage setting The time is IN ADDITION to the time spent charging in Step 1 Example charge for 12 hours if the charger voltage is set to 2 35 VPC TABLE E EQUALIZE CHARGE 77 F CELL VOLTS TIME HOURS 2 30 24 2 33 18 2 35 12 B Record cell voltages hourly du...

Page 22: ...t tery to the charger and the load give an equalizing charge and return the battery to float operation SECTION 18 UNIT CLEANING 18 0 Unit Cleaning Periodically clean cell covers with a dry 2 paintbrush to remove accumulated dust If any cell parts appear to be damp with electrolyte or show signs of corrosion contact your local GNB representative SECTION 19 MAINTENANCE 19 0 Connections Battery termi...

Page 23: ... 117 87 57 116 56 86 115 85 55 114 54 84 113 83 53 112 52 82 111 81 51 110 50 80 109 79 49 108 48 78 107 77 47 106 46 76 105 75 45 104 44 74 103 73 43 102 42 72 101 71 41 100 40 70 99 69 39 98 38 68 97 67 37 96 36 66 95 65 35 94 34 64 93 33 63 32 92 62 91 61 Conn Resist 23 24 25 26 27 28 19 20 21 22 15 16 17 18 11 12 13 14 7 8 9 10 31 5 6 Cell DATE INSTALL DATE BATTERY LOCATION NUMBER SYSTEM VOLTA...

Page 24: ... 140 170 229 139 169 199 228 198 138 168 227 137 167 197 226 196 136 166 225 135 165 195 224 194 134 164 223 133 163 193 COMPANY SERIAL NUMBER ADDRESS BATTERY LOCATION NUMBER DATE TYPE MANUF DATE INSTALL DATE SYSTEM VOLTAGE TEMPERATURE Cell Conn Cell Conn Cell Conn Cell Conn No Volts Resist No Volts Resist No Volts Resist No Volts Resist 121 151 181 211 122 152 182 212 123 153 213 124 154 184 214 ...

Page 25: ... 2 28 2 29 2 30 73 2 24 2 25 2 26 2 27 2 28 22 2 25 2 26 2 27 2 28 2 29 74 2 24 2 25 2 26 2 27 2 28 23 2 25 2 26 2 27 2 28 2 29 75 2 24 2 25 2 26 2 27 2 28 24 2 24 2 25 2 26 2 27 2 28 76 2 23 2 24 2 25 2 26 2 27 25 2 23 2 24 2 25 2 26 2 27 77 2 23 2 24 2 25 2 26 2 27 26 2 23 2 24 2 25 2 26 2 27 78 2 23 2 24 2 25 2 26 2 27 27 2 22 2 23 2 24 2 25 2 26 79 2 22 2 23 2 24 2 25 2 26 28 2 22 2 23 2 24 2 ...

Page 26: ...15 40 2 4 92 3 11 41 1 29 93 3 7 42 1 25 94 3 4 43 1 22 95 3 0 44 1 18 96 2 27 45 1 15 97 2 23 98 2 20 99 2 17 100 2 14 101 2 11 102 2 9 103 2 6 104 2 4 105 2 1 106 1 29 107 1 27 108 1 25 109 1 23 110 1 21 111 1 19 112 1 17 113 1 15 APPENDIX B MAXIMUM STORAGE INTERVAL BETWEEN FRESHENING CHARGES VERSUS AVERAGE STORAGE TEMPERATURE Average Ambient Storage Temperature F Average Ambient Storage Tempera...

Page 27: ... the module see Figure 1 Be sure to securely tighten the bolts such that the paint is penetrated see Figure 2 3 Attach each end of cable assembly to a beam clamp using 1 1 4 20 x 0 75 in bolt per end see Figure 3 Tighten hardware securely 4 Repeat Steps 2 and 3 for the second horizontal support I beam CONNECTING TO THE CBN 1 The recommended location for attaching the frame ground is the back C cha...

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