® S P A C E S A V E R® SYSTEMS Interlock 45, 75, 95 & 125 AH Non-Interlock 45, 75 & 95 AH ™ ™ Installation and Operation Manual California Proposition 65 Warning: Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
TABLE OF CONTENTS Safety Precautions Protective Equipment ......................................3 Procedures ......................................................3 Record Keeping Voltages, Temperatures & Ohmic Readings ..........................................6 Receiving & Storage Receiving Inspection........................................3 Unpacking ........................................................3 Storage ............................................................
SAFETY PRECAUTIONS DANGER Although all valve-regulated batteries have the electrolyte immobilized within the cell, the electrical hazard associated with batteries still exists. Work performed on these batteries should be done with the tools and the protective equipment listed below. Valve-regulated battery installations should be supervised by personnel familiar with batteries and battery safety precautions. HIGH VOLTAGE... RISK OF SHOCK. DO NOT TOUCH UNINSULATED TERMINALS OR CONNECTORS. SHIELD EYES.
Connector Assembly (con’t) INSTALLATION (con’t) 125 ± 5 inch pounds (14.1 ± .5 Nm.) The installation and direction of the post bolts is important! (Refer to Fig. 4-1, 4-2 and 4-3 pg. 11 and 12; Fig. 4-4, pg. 4. For proper direction when inserting into posts.) The 125 AH battery is supplied with a 2CU connector package as standard. (Refer to Fig.5-1A, pg. 13 for special connector orientation for side terminal & stack to stack connections.) 3.
Final Assembly Check Procedure Top Protective Shield Assembly 1. For future identification of all cells, number individual cells in sequence, beginning with number one (1) at the positive end of the battery. The last cell of the battery is located at the negative output terminal. 2. Read and record the voltages of the individual cells to assure that they are connected properly.
Voltages, Temperatures & Ohmic Readings (con’t) SYSTEM OPERATIONS Charger Voltage 5. Ambient temperatures 6. Terminal connections should be checked to verify that the installer did torque all connections properly (125 ± 5 in.-lbs.). Micro-ohm readings should be taken across every connection. (Refer to Fig. 6-2, pg. 6) Refer to meter manufacturer’s instructions for proper placement of probes.
Annual Inspection (con’t) CELL REMOVAL PROCEDURE 5. Record the ambient temperatures. 6. Record individual cell ohmic readings. 7. Record all interunit and terminal connection resistances. Micro-ohm readings should be taken during this inspection. If any reading differs by more than 20% from initial readings taken, retorque the connection. Recheck the micro-ohm reading. If the reading remains high, clean the contact surface according to installation portion of this manual.
SHIPPING BOX TOP TERMINAL BRACKET SUPPORT CHANNEL ACCESSORY PACKAGE SEE PARTS LIST FOR COMPONENTS CLEAR FRONT SHIELD PACKAGE SHIPPING BOX PALLET FRONT PROTECTIVE WAFFLE BOARD MOUNTING PLATE & 3/8 X 1 3/4" GRADE 5 BOLT ASSEMBLY, REMOVE AND DISCARD MODULES STACK 4 HIGH MAX. MODULES ARE STACKED IN REVERSE ORDER FROM LAYOUT. REMOVE ONE MODULE AT A TIME. Fig. 2-1 2 REQUIRED FOR LIFTING DETAIL OF STRAP ASSEMBLY Fig.
Interlock™ System Leveling When leveling Unigy II Interlock™ battery systems that are installed with a 1-piece base support, it is critical to note that the back channel is 3/16" shorter than the front channel. If a level is placed across the front and rear channels, a 3/16" shim should be placed on top of the rear channel in order to level properly. Fig. 3-1A TORQUE TO 50 in. lbs. (5.
LIFT STRAP 3/8-16 X 1-1/4" BOLT FLAT WASHER LOCK WASHER TORQUE TO 50 in. lbs. (5.6 Nm) LOWER MODULE NESTS INTO UPPER MODULE - FASTENED WITH 3/8" HARDWARE BOTTOM MODULE 3/8-16 X 1-1/4" BOLT FLAT WASHER LOCK WASHER MODULE SUPPORT Fig. 3-3 NOTES: 1. HARDWARE REQUIRED TO MEET ZONE 4 CERTIFICATION (45, 75 & 95AH INTERLOCK™) 2. TORQUE REQUIREMENT: 50 FT. LBS. (67.8 Nm) HEX NUT ZONE 4 ONE PIECE MOUNTING SUPPORT LOCK WASHER FLAT WASHER FLAT WASHER 3/8-16 X 1" BOLT Fig.
2 & 4 CELL MODULES 75 A.H. 95 A.H. 95 A.H. X Y X Y X Y X Y 11.72 16.16 20.66 25.16 29.66 34.17 ––– ––– 10.64 10.64 10.64 10.64 10.64 10.64 10.64 10.64 11.72 16.16 20.66 25.16 29.66 34.17 19.07 21.32 17.74 17.74 17.74 17.74 17.74 17.74 17.74 17.74 ––– 16.16 20.66 25.16 29.66 34.17 19.07 21.32 ––– 20.34 20.34 20.34 20.34 20.34 20.34 20.34 ––– 9.86 12.86 15.86 18.86 21.86 11.80 13.30 ––– 20.34 20.34 20.34 20.34 20.34 20.34 20.34 NO. OF PLATES NO.
Fig. 4-2 RECOMMENDED BOLT DIRECTION 5-15 PLATE 17-27 PLATE 29-33 PLATE NOTES: INSULATED TORQUE WRENCH SHOULD BE PLACED ON BOLT HEAD TO ENSURE MAXIMUM CLEARANCE. Fig.
Fig. 5-1 BOLT THROUGH TERMINAL CONNECTOR INTO TERMINAL AS SHOWN TO CLEAR SHIELD CLIP DETAIL A SCALE 0.30 : 1 DOUBLE STACK CONNECTOR ON ONE SIDE OF TERMINAL TO CLEAR SHIELD CLIP. BOLT THROUGH COPPER CONNECTOR INTO TERMINAL (AS SHOWN). DETAIL B SCALE 0.30 : 1 Fig. 5-1A 13 NOTES: 1. REFERENCE I & O MANUAL FOR COMPLETE CONNECTOR ASSEMBLY 2. 2CU PACKAGE ONLY 3. BATTERY SYSTEM RATED TO 2 HOUR DISCHARGE 695 AMPS TO 1.
Fig. 5-2 Fig.
3/8-16 X 1 1/4" BOLT LOCK WASHER FLAT WASHER SHIELD ASSEMBLY SLIDES ONTO TERMINAL BRACKET SLIDE CLIP INTO TOP CHANNEL FROM CUT OUT ON BACK OF CHANNEL. (APPLY CLIPS AT BOTH ENDS OF CHANNEL.
CUT OUT TOP PROTECTIVE SHIELD FOR TERMINAL LOCATION SHIELD SLIDES INTO AND SNAPS ONTO THE CLIP INSERT CLIP END INTO HOLES ON MODULE SLIDE TOP PROTECTIVE SHIELD ONTO FRONT SHIELD ON TOP MODULES ONLY DETAIL OF ASSEMBLED SHIELD (2) END CLIPS AND (1) FRONT SHIELD PER ASSEMBLY Fig. 5-4 .56Ø HOLE TYPE .56Ø X 1.19 LG. SLOT TYPE 5 THROUGH 15 PLATE POST 17 AND 19 PLATE POST .34Ø X 1.00 LG. SLOT TYPE HOLES & SLOTS 21 THROUGH 33 PLATE POST 29 THROUGH 33 PLATE POST (125 AH PRODUCT LINE ONLY) NOTES: .
SIDE TERMINATION Fig.
APPENDIX A – Material Safety Data Sheet – VALVE REGULATED LEAD-ACID BATTERY – “BATTERY NON-SPILLABLE 49 CFR 173.159 (d)” SECTION I Manufacturer’s Name: East Penn Manufacturing Co., Inc., Deka Road, Lyon Station, PA 19536 Telephone Number for Information: (610) 682-6361 Date: March 4, 2005 Emergency Telephone Number: CHEMTREC: 1-800-424-9300 Trade Name: Gel; Absorbed Electrolyte, Trade Name: Sealed Valve Regulated Non-Spillable Battery In Washington D.C. or outside continental U.S.
APPENDIX A (continued) SECTION VI HEALTH HAZARD DATA Route(s) of Entry: Not applicable under normal use. Carcinogenicity: Sulfuric Acid: The International Agency for Research on Cancer (IARC) has classified “strong inorganic acid mist containing sulfuric acid” as a Category 1 carcinogen, a substance that is carcinogenic to humans. This classification does not apply to liquid forms of sulfuric acid contained within a battery.
APPENDIX B – Material Safety Data Sheet – LEAD ACID BATTERY WET, FILLED WITH ACID SECTION I Manufacturer’s Name: East Penn Manufacturing Co., Inc., Deka Road, Lyon Station, PA 19536 Telephone Number for Information: (610) 682-6361 Date: March 16, 2005 Emergency Telephone Number: CHEMTREC: 1-800-424-9300 Trade Name: Electric Storage battery, SLI or Industrial battery In Washington D.C. or outside continental U.S.
APPENDIX B (continued) SECTION VI HEALTH HAZARD DATA (continued) Carcinogenicity: Sulfuric Acid: The International Agency for Research on Cancer (IARC) has classified “strong inorganic acid mist containing sulfuric acid” as a Category 1 carcinogen, a substance that is carcinogenic to humans. This classification does not apply to liquid forms of sulfuric acid contained within a battery. Inorganic acid mist (sulfuric acid mist) is not generated under normal use of this product.
APPENDIX C BATTERY MAINTENANCE REPORT Date ______________________ Company ____________________________________________________________________________________________ Address______________________________________________________________________________________________ Battery Location and/or Number ____________________________________________________________________________ No. of Cells ________ Type ________________________________ Date Mfg.
APPENDIX D Unigy II SPACESAVER System Acid Volumes & Weights ® Cell Size 45-5 45-7 45-9 45-11 45-13 45-15 75-5 75-7 75-9 75-11 75-13 75-15 75-17 75-19 75-21 75-23 75-25 75-27 75-29 75-31 75-33 95-7 95-9 95-11 95-13 95-15 95-17 95-19 95-21 95-23 95-25 95-27 95-29 95-31 95-33 125-33 125LG-33 Acid Wt gm Acid Vol cc 1,814 2,542 3,276 4,004 4,732 5,460 2,984 4,258 5,480 6,695 7,911 9,133 10,348 11,375 12,786 14,001 15,223 16,436 17,654 18,870 20,092 4,780 6,080 7,440 8,780 10,170 11,467 12,330 14,380 15,350
“POWERED FOR PERFORMANCE”® DISTRIBUTED BY: Lyon Station, PA 19536-0147 • Phone: 610-682-6361 • Fax: 610-682-4781 Order Department Hotline: 610-682-4231 www.eastpennunigy.com • E-mail: sales@eastpennunigy.com E.P.M. Form No. 1112 Rev. 11/07 © 2007 by EPM Printed in U.S.A. All data subject to change without notice. No part of this document may be copied or reproduced, electronically or mechanically, without written permission from the company.
