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OutBack Power EnergyCell 1100RE, Installation Manual And Owner'S Manual

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EnergyCell

®

 RE High Capacity Battery

Installation Guide and Owner’s Manual

Summary of Contents for EnergyCell 1100RE

Page 1: ...EnergyCell RE High Capacity Battery Installation Guide and Owner s Manual...

Page 2: ...ths 6months 6months 6months 6months Short Circuit Current A 4728 6748 7722 9267 12411 12337 16548 Internal Resistance micro 441 309 270 225 167 169 126 TerminalTorque Intercell Connects 88in lbs Hardw...

Page 3: ...DDm Publication No US DDm IM 003 November 2003 Installation Manual PowerSafe DDM Modular Battery Systems...

Page 4: ......

Page 5: ...DDm Installation Manual PowerSafe DDm Modular Battery Systems IMPORTANT Read safety information first See Safety Storage Operating and Maintenance Manual Publication No US DDm IM 003 November 2003...

Page 6: ...aintenance Failure to observe the precautions as presented may result in injury or loss of life Copyright 2003 by EnerSys Inc All rights reserved This document is proprietary to EnerSys Inc This docum...

Page 7: ...on 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...

Page 8: ...rounded 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 re...

Page 9: ...a fire The batteries may explode Caution Do not open or mutilate the batteries Released electrolyte is harmful to the eyes and skin and may also be toxic Warning This unit contains sealed lead acid ba...

Page 10: ...Page iv Publication No US DDm IM 003 www enersysinc com November 2003 IMPORTANT Read safety information first See Safety Storage Operating and Maintenance Manual...

Page 11: ...EM LAYOUT 5 Anchor Spacing 6 FRAME ASSEMBLY AND INSTALLATION 7 Base Beams 7 Vertical Channels 7 Horizontal Channels 8 Cell Support Shelves 10 BATTERY CELL INSTALLATION 11 Module Retainers 12 Electrica...

Page 12: ...ULTI STACK figure 2 or a MULTI STACK ZERO SEPARATION Figure 3 Systems are available in 24 48 and other voltage configurations These systems allow for assembly at remote locations See the ASSEMBLY DRAW...

Page 13: ...PowerSafe DDm Publication No US DDm IM 003 Page 3 November 2003 www enersysinc com MULTI STACK ZERO SEPARATION FIGURE 3 MULTI STACK FIGURE 2...

Page 14: ...a PowerSafe DDm Battery System TABLE 1 EQUIPMENT REQUIRED CHECK IF ON HAND Chalk Line Torpedo Level Plastic Torque Wrench 10 200 in lbs SAE Metric Torque Wrench 50 100 ft lbs SAE Metric Floor Anchors...

Page 15: ...ensions defined in Table 2 2 Locate the position of the floor anchors using the frame base beams 3 Mark floor with the position of the floor anchors L FRONT L L FRONT D D DISTANCE BETWEEN BASES VARIAB...

Page 16: ...4 6 31 43 79 8 41 26 104 8 62 68 159 2 L 2 94 L 7 5 85 27 22 98 58 4 33 69 85 6 44 27 112 4 67 22 170 7 L 2 94 L 7 5 85 33 27 48 69 8 40 43 102 7 53 26 135 3 80 71 205 0 L 2 94 L 7 5 100 21 18 48 46 9...

Page 17: ...s and anchor in place Do NOT torque anchor bolts until frame assembly is complete 2 Install ALL base beams before continuing Vertical Channels 1 Insert vertical channels into base beams See Figure 9 2...

Page 18: ...Lock Washer Hex Nut Second from bottom horizontal Serrated Hex Bolt M10x1 5 75mm Full Threads Rack Frame External Tooth Washer Flat Washer Lock Washer Hex Nut All other horizontals Serrated Hex Bolt M...

Page 19: ...uire full thread longer bolts at the vertical channel Bottom horizontal Serrated Hex Bolt M10x1 5 100mm Full Threads Rack Frame External Tooth Washer Flat Washer Lock Washer Hex Nut Second from bottom...

Page 20: ...position the vertical channels so that the front and rear horizontals fit tightly against the shelves See Figure 17 5 Torque ALL bolts connecting the horizontals to the verticals to 20 ft lbs 6 If yo...

Page 21: ...and use in steel modules 1 BEFORE installing the cells check the voltages The minimum acceptable cell voltage is 2 05 vpc If a cell has a voltage below 2 05 vpc call your nearest EnerSys sales service...

Page 22: ...M10x1 5 25mm Serrated Hex Bolt See Figure 22 2 Torque to 20 ft lbs Electrical Bonding Instructions 1 For each battery module install 1 M6 Self Tapping Screw through front lip of the battery module int...

Page 23: ...ystem connections must be made to the terminal plate and NEVER to the cell terminal Top termination is standard side termination is optional 1 Clean the terminal plate electrical contact areas with a...

Page 24: ...aintbrush 3 Bolt all inter cell connectors according to the ASSEMBLY DRAWING Assemble as the example shown in Figure 25 and below list Bolt M8 Lock Washer Flat Washer Inter cell Connector Battery Post...

Page 25: ...o the ASSEMBLY DRAWING 2 Clean the terminal bar contact area with a stiff bristle nonmetallic brush pad until the lead plated surface is bright Be careful not to remove the lead plating with excessive...

Page 26: ...an 2 15 times the number of cells in the system contact your EnerSys sales service representative or call the corporate office number listed on the back of this manual and ask for EnerSys Integrated S...

Page 27: ...t accidental contact with the live terminal plate Safety shields are designed to be removed for service or maintenance Safety Shields 1 Install ALL safety shield support posts into horizontals as show...

Page 28: ...Page 18 Publication No US DDm IM 003 www enersysinc com November 2003 NOTES...

Page 29: ......

Page 30: ...panying literature thoroughly for specific safety and installation information When ordering new batteries also remember to properly recycle your old lead batteries Federal and state regulations requi...

Page 31: ...Safety Storage Operating and Maintenance Manual VRLA Battery Systems mSeries DDm DDS DGX DDV and SC Publication No US VR OM 002 March 2008...

Page 32: ...Systems mSeries DDm DDS DGX DDV and SC Publication No US VR OM 002 March 2008 When working with any EnerSys Modular Battery System be sure to refer to the Installation Manual specified for that system...

Page 33: ...panying Installation Manual thoroughly Failure to observe the precautions as presented may result in injury or loss of life 2008 by EnerSys All rights reserved This document is proprietary to EnerSys...

Page 34: ...ially 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 and Caution symbol and are us...

Page 35: ...ded 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 remove...

Page 36: ...lode Do not open or mutilate the batteries Released electrolyte is harmful to the eyes and skin and may also be toxic This unit contains sealed lead acid batteries Lack of preventative maintenance cou...

Page 37: ...blication No US VR OM 002 March 2008 When working with any EnerSys Modular Battery System be sure to refer to the Installation Manual specified for that system and Rack Assembly Instructions included...

Page 38: ...Y STORAGE BEFORE INSTALLATION 9 4 1 General 9 4 2 Storage Location 9 4 3 Advance Preparation 10 5 0 INSTALLATION CONSIDERATIONS 11 5 1 General 11 5 2 Considerations for Connecting the Battery System t...

Page 39: ...orrosion Cleaning 23 11 1 3 Heavy Corrosion Cleaning 23 11 2 Test Procedures 24 11 2 1 Procedure for Battery Capacity Tests 24 11 3 Maintenance Records 26 12 0 TEMPORARY NON USE EXTENDED OUTAGE 29 12...

Page 40: ...management reduce the chances of thermal runaway Temperature compensation chargers are also recommended PowerSafe VRLA batteries typically do not require special battery rooms because excess hydro ge...

Page 41: ...ce 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 inform...

Page 42: ...RY 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 Reserve Power Service 2 1 Safety Equipment...

Page 43: ...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 IMMEDI...

Page 44: ...mes 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 vo...

Page 45: ...terminal of opposite polarity 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...

Page 46: ...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...

Page 47: ...als in the quantities specified For export the cells may be packed in wooden boxes which must be opened completely and carefully and the cells then handled as described hereafter See Section 6 for unp...

Page 48: ...STORAGE TIME 32 F 0 C to 50 F 10 C 9 months 51 F 11 C to 77 F 25 C 6 months 78 F 26 C to 92 F 33 C 3 months If storage time exceeds the storage time recommended in Table 4 1 give the battery a freshe...

Page 49: ...sitioning of the cells to accept temporary intercell connectors is another consideration of advance planning Keep cells on styrofoam pads until the cells are installed on the rack when applicable Make...

Page 50: ...floor anchoring Table 5 1 will assist you to ensure that all requirements for installation location are considered Space Aisle space should be in accordance with the National Electric Code NEC Articl...

Page 51: ...c Electronic Equipment equipment unless it generates heat CONSIDERATION RECOMMENDATION TABLE 5 1 continued 12 www enersys com Publication No US VR OM 002 March 2008 5 2 Considerations for Connecting t...

Page 52: ...m 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 t...

Page 53: ...sure relief valves or vent covers as this will void the warranty Attempted removal may also damage the vent and prevent proper functioning of the battery 6 2 Accessories CHECK accessory package with P...

Page 54: ...nd equipment on hand before starting the installation TABLE 6 2 EQUIPMENT RECOMMENDED Forklift or Portable Lift Crane Chalk Line Torpedo Level Plastic Torque Wrench 10 200 in lbs Torque Wrench 50 100...

Page 55: ...al charge voltages per cell and charge time for the initial charge Select the HIGHEST voltage the system allows for the initial charge without exceeding 2 35 volts per cell TABLE 7 1 CELL VOLTS Initia...

Page 56: ...Place the battery on charge recharge following a discharge Read the ammeter The charging current will be a combination of the load current plus the current necessary to charge the battery 2 The batte...

Page 57: ...in Table 8 1 If a temperature compensated charger is not used manual adjustments must be made according to Table 8 1 TABLE 8 1 AVERAGE AMBIENT TEMPERATURE RECOMMENDED FLOAT VOLTAGE F C VOLTS PER CELL...

Page 58: ...wise reduced battery life or reduced capacity will result 3 Check and record battery terminal voltage monthly for accurate calibration 4 If the VOLTS PER CELL average voltage is above or below the ran...

Page 59: ...the problem review the location instructions in Section 5 0 to ensure proper location of the battery system An equalizing charge should be given when the float voltage of any cell is less than 2 17 v...

Page 60: ...lize charge time The times listed are the number of hours to charge the battery system AFTER the charge current has been stabilized for three hours Stabilization occurs when the current level remains...

Page 61: ...negative post of the pilot cell Read and record the pilot cell voltage on a monthly basis between regularly scheduled individual cell readings 11 0 MAINTENANCE Batteries lose some initial charge duri...

Page 62: ...lize the corrosion as described in Section 11 1 2 3 Clean the contact surfaces by rubbing the surface of post or terminal and lead plated contact surfaces with a stiff bristle nonmetallic brush pad Li...

Page 63: ...period The test discharge current is equal to the rated discharge current divided by the K Factor see Table 11 1 for the initial battery temperature 5 With the variable load bank having an ammeter in...

Page 64: ...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...

Page 65: ...ohms terminal connection resistance ohms ambient temperature in the immediate battery environment F or C Any connection resistance that exceeds the base value by more than 20 should be corrected by th...

Page 66: ...BATTERY MAINTENANCE REPORT DDm DDS DDV DGX mSeries and SC...

Page 67: ...BATTERY MAINTENANCE REPORT DDm DDS DDV DGX mSeries and SC...

Page 68: ...arge according to Section 8 3 1 2 After the charge open the connections at the battery terminals to remove load from the battery 3 Throughout the extended non use period give the battery an equalizing...

Page 69: ...30 www enersys com Publication No US VR OM 002 March 2008 NOTES...

Page 70: ...ttery 2 Do not remove pressure relief valves 3 Do not lift any cells by the terminal posts 4 Do not tamper with seal nuts on the cell post 5 Do not remove lead coating from post or connectors and expo...

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