EnergyCell® RE High Capacity Battery Installation Guide and Owner’s Manual
Purpose This document provides the EnergyCell RE High Capacity Installation Guide and Operation Manual. Scope This document applies to all models of the EnergyCell RE High Capacity series. The reference table below shows the Outback part number cross referenced with the manufacturer part number. When using this document for installation and service operations, please refer to the manufacturer part number when referencing critical information.
DDm Installation Manual PowerSafe DDM Modular Battery Systems Publication No.
DDm Installation Manual PowerSafe DDm Modular Battery Systems IMPORTANT! Read safety information first See Safety, Storage, Operating and Maintenance Manual Publication No.
The installation manual is for reference only. To maximize safety and performance, read the accompanying Safety, Storage, Operating and Maintenance Manual thoroughly. It provides full instructions regarding safety, storage, operation and maintenance. 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.
PowerSafe DDm GENERAL SAFETY INSTRUCTIONS Warnings in this manual appear in any of three ways: The danger symbol is a lightning bolt mark enclosed in a triangle. The danger symbol is used to indicate imminently hazardous situations, locations and conditions which, if not avoided, WILL result in death, serious injury and/or severe property damage. Danger The warning symbol is an exclamation mark in a triangle.
IMPORTANT SAFETY INSTRUCTIONS A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working with batteries. 1. Verify that the Uninterruptible Power Supply (UPS) is off and that the power cord is disconnected from the power source. 2. Remove watches, rings or other metal objects. 3. Use tools with insulated handles to prevent inadvertent shorts. 4. Wear rubber gloves and boots. 5.
PowerSafe DDm IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for PowerSafe DDm Lead-Acid Battery Systems that should be followed during the installation and maintenance of the battery system. Only a qualified EnerSys Inc. service representative who is knowledgeable in batteries and the required precautions should perform servicing of the batteries. Keep unauthorized personnel away from batteries.
IMPORTANT! Read safety information first See Safety, Storage, Operating and Maintenance Manual Page iv www.enersysinc.com Publication No.
PowerSafe DDm TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS ........................................................................................... i GENERAL INFORMATION...........................................................................................................2 RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES .............................................4 SYSTEM LAYOUT .......................................................................................................................
GENERAL INFORMATION PowerSafe DDm battery systems are modular units that can be installed in a SINGLE STACK (figure 1), a MULTI-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 DRAWING to determine the configuration for your installation. Before installation: Verify items received versus Bill of Lading. Verify parts against system Bill of Materials.
PowerSafe DDm MULTI-STACK FIGURE 2 MULTI-STACK ZERO SEPARATION FIGURE 3 Publication No. US-DDm-IM-003 November 2003 Page 3 www.enersysinc.
RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES Before working with the battery system, be sure that you have the proper protective clothing, safety equipment and insulated tools as specified in the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery Systems. The following is a recommended list of equipment required for installation of a PowerSafe DDm Battery System.
PowerSafe DDm SYSTEM LAYOUT Before installing the battery system, lay out available floor space including aisles for installation, maintenance and possible cell replacement. Consult the local installation considerations as determined in Section 5 of the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery Systems. Recommended clearance between these racks and any objects (including walls and equipment) is 4 inches (102 mm).
Anchor Spacing TABLE 2 Base Beam Anchor Spacing Cell Model 50-09 50-13 50-17 85-13 85-15 85-21 85-25 85-27 85-33 100-21 100-25 100-27 100-33 125-25 125-27 125-33 2 Cells Wide L (in) 9.04 12.04 15.49 12.04 13.54 18.48 21.48 22.98 27.48 18.48 21.48 22.98 27.48 22.09 23.59 28.09 L (cm) 23.0 30.6 39.3 30.6 34.4 46.9 54.6 58.4 69.8 46.9 54.6 58.4 69.8 56.1 59.9 71.3 3 Cells Wide L (in) N/A N/A 22.48 N/A N/A 26.93 31.43 33.69 40.43 26.93 31.43 33.69 40.43 31.88 34.14 40.88 L (cm) N/A N/A 57.1 N/A N/A 68.4 79.
PowerSafe DDm FRAME ASSEMBLY AND INSTALLATION To assemble and install the frame for the PowerSafe DDm battery system, follow the procedure below using the system layout determined in the “System Layout” section. Base Beams 1. LEVEL with customer-supplied floor shims, 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.
Horizontal Channels NOTE: There may be two types of horizontal channels with your shipment: 1) Rear – have four weld nuts 2) Front – have more than four weld nuts The front horizontals are universal and, in most configurations, are substituted for the rear horizontals. Front horizontals are to be installed with the flange positioned with the holes facing up. Starting at the bottom of the REAR verticals: INSTALL REAR HORIZONTAL CHANNELS FIGURE 11A 1.
PowerSafe DDm Starting at the bottom of the FRONT verticals: 1. Insert FRONT horizontal channels into the vertical channels. Center the horizontals between the verticals. See figures 13A & 13B. 2. Bolt horizontal channels to vertical channels. Refer to below list for hardware order and Figure 14. NOTE: The bottom two horizontals require full thread longer bolts at the vertical channel. Bottom horizontal: – Serrated Hex Bolt (M10x1.
Cell Support Shelves Starting at the bottom of the rack: 1. Place shelves over FRONT and REAR horizontals. See Figure 15. 2. Align holes of shelf with holes of horizontal channels. Bolt the shelf to the REAR horizontal using (2) M10x1.5 – 25mm Serrated Hex Bolts in the two OUTSIDE holes of the shelf. See Figure 16. 3. Torque these bolts to 20 ft-lbs. 4. After ALL shelves for the rack are in place, position the vertical channels so that the front and rear horizontals fit tightly against the shelves.
PowerSafe DDm BATTERY CELL INSTALLATION DDm battery cells are designed for shipment and use in steel modules. USE CAUTION WHEN HANDLING THE DDm MODULES After a cell has been inserted into a module at the factory, a loose fit could develop because of recombination. The cell could slip very easily from the module if the module/cell is turned so that the open end of the module is lower than the closed end of the module. Serious personal injury could result if the cell slides unintentionally from the module.
NOTE: The larger modules are too heavy to lift onto the shelves manually. To avoid personal injury use appropriate lifting devices when lifting modules onto the shelves. 4. Slide the module back into a safe position. Remove the shipping retainer. 5. Slide module completely into position so the lip of the module touches the front of the shelf. 6. Place another cell onto the shelf next to the previously placed battery sleeve. Refer to the Assembly Drawing for the cell polarity configuration. See Figure 19.
PowerSafe DDm CONNECTIONS The cells are now positioned and ready to be connected. The cells must be connected according to the polarities on the ASSEMBLY DRAWING and the following instructions. Before preparing and making connections, heat NO-OX-ID grease in hot water as necessary to soften for application with a paintbrush. Terminal Plates Terminal plates are provided with the battery system to provide a system connections point.
Inter-Cell Connectors The connections are made by bolting the supplied lead-plated copper inter-cell and intermodule connectors to the cell posts of opposite polarity on adjacent cells. See ASSEMBLY DRAWING for details. 1. Clean the contact surface of the inter-cell connector using a stiff-bristle nonmetallic brush/pad. Be careful not to remove the lead plating with excessive brushing. 2.
PowerSafe DDm Terminal Bars Terminal bars are supplied with the battery system to provide a cell terminal-to-terminal plate connection. 1. Inspect the system to be assured that all cells are connected correctly – POSITIVE to NEGATIVE and according to 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 brushing. 3.
INITIAL SYSTEM READINGS Measure the DC system voltage across the system terminals. Voltage should equal approximately 2.15 times the number of cells in the system (See Table 3). If the voltage is lower than 2.15 times the number of cells in the system, inspect the system to be assured that all cells are connected correctly — POSITIVE to NEGATIVE and according to the ASSEMBLY DRAWING. TABLE 3 APPROXIMATE VOLTAGE Number of Cells 12 24 (2.15 x number of cells) 25.8 51.
PowerSafe DDm SAFETY SHIELDS AND COVERS Safety shields and covers are provided to help prevent accidental contact with connections after installation and during operations. Safety shields and covers should remain in place at all times during normal operation of the system. Terminal plate covers are provided as necessary to prevent accidental contact with the “live” terminal plate. Safety shields are designed to be removed for service or maintenance. Safety Shields 1.
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PRECAUTIONS* 1. Do Not bring any heat or flame source near battery. 2. Do Not remove pressure relief valves. USE EDGE OF MODULE WHEN POSITIONING BATTERY 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 expose any bare copper. 6. Do Not allow cell temperature to exceed 105oF during charging. 7. Do Not clean cell with anything other than water/bicarbonate of soda. 8.
Safety, Storage, Operating and Maintenance Manual VRLA Battery Systems mSeries, DDm, DDS, DGX, DDV and SC Publication No.
Safety, Storage, Operating and Maintenance Manual VRLA Battery Systems mSeries, DDm, DDS, DGX, DDV and SC 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 in the rack shipment. Publication No.
This manual provides full instructions regarding safety, storage, operation, and maintenance for EnerSys® valve-regulated lead acid batteries, as well as certain installation considerations. To maximize safety and performance, read the accompanying 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.
GENERAL SAFETY INSTRUCTIONS Warnings in this manual appear in any of three ways: Danger The danger symbol is a lightning bolt mark enclosed in a triangle. The danger symbol is used to indicate imminently hazardous situations, locations and conditions which, if not avoided, WILL result in death, serious injury and/or severe property damage. Warning The warning symbol is an exclamation mark in a triangle.
IMPORTANT SAFETY INSTRUCTIONS DANGER A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working with batteries. 1. Verify that the Uninterruptible Power Supply (UPS) is off and that power cord is disconnected from the power source. 2. Remove watches, rings or other metal objects. 3. Use tools with insulated handles to prevent inadvertant shorts. 4. Wear rubber gloves and boots. 5.
IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for PowerSafe™ mSeries Lead-Acid Battery Systems that should be followed during the installation and maintenance of the battery system. Only a qualified EnerSys® service representative who is knowledgeable in batteries and the required precautions should perform servicing of the batteries. Keep unauthorized personnel away from batteries.
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 in the rack shipment. iv www.enersys.com Publication No.
TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i 1.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.0 BATTERY TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 10.0 PILOT CELL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 11.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 11.1 Battery Cleaning . . . . . . . . . . . . . . . . . . . . . . .
1.0 GENERAL INFORMATION 1.1 Introduction EnerSys® modular valve-regulated lead acid (VRLA) batteries have unique features that make them easy to install and maintain. These batteries are composed of absorbed glass mat (AGM) separators with flat plates and/or gelled electrolyte with tubular positive plates. The AGM retains the acid between the plates to ensure long float service.
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. 2 www.enersys.com Publication No.
2.0 SAFETY 2.1 General PowerSafe™ valve-regulated lead acid batteries are reduced-maintenance batteries that operate on recombinant principles and are safer than conventional "wet cell" lead-acid batteries.
2.3 Safety Precautions 2.3.1 Sulfuric Acid Burns Because VRLA cells are sealed, they normally do not present an acid danger. However, they do contain sulfuric acid, which can cause burns and other serious injuries. Always wear protective clothing AND use the correct safety tools. In case of SKIN CONTACT with sulfuric acid, IMMEDIATELY 1. REMOVE contaminated CLOTHING 2. FLUSH the area THOROUGHLY with WATER 3. Get MEDICAL ATTENTION, if required.
2.3.2 Explosive Gases Batteries can generate gases, which when released can explode, causing blindness and other serious personal injury. Always wear protective clothing and use the correct safety tools. Eliminate any potential of sparks, flames or arcing. IN CASE OF FIRE: To extinguish a fire in a battery room containing lead-acid batteries, use a CO2, foam or dry-chemical extinguishing medium. Do NOT discharge the extinguisher directly onto the battery.
IF BATTERY SYSTEM IS GROUNDED: (system is intentionally grounded by connecting a battery terminal to ground) 1. An increased shock hazard exists between the terminal of opposite polarity and ground, (i.e., dirt and acid on top of battery cell touching rack). 2. If an unintentional ground develops within the already grounded system, a short circuit may occur and cause explosion or fire. IF BATTERY SYSTEM IS GROUNDED: 1.
3.0 INSPECTING THE BATTERY SHIPMENT 3.1 General Precautions have been taken to pack the battery units, individual cells or cabinets containing batteries for shipment to ensure their safe arrival. However, upon receipt, you should inspect for evidence of damage that may have occurred during transit. WARNING During inspections, take precautions against electrical shock. You are handling LIVE batteries. 3.
3.3 Concealed Damage Within 15 days of receipt, unpack the cells/batteries and check for concealed damage. Remember, you are handling a LIVE battery. Take precaution against a shock hazard. Follow all safety precautions as noted in Section 2.0. Note any: • damage to packing material. • wetness or stains, indicating electrolyte leakage. If damage is noted: 1. Request an inspection by the carrier. 2. File a concealed-damage claim.
4.0 BATTERY STORAGE BEFORE INSTALLATION 4.1 General Batteries should be unpacked, installed and charged as soon as possible after receipt. However, if this is impractical, follow the instructions below for storing the battery before installation. 4.2 Storage Location 1. Store batteries indoors in a clean, dry and cool location. Storage at higher temperatures will result in accelerated rates of self-discharge and possible deterioration of battery performance and life. 2. Do NOT stack pallets.
4.3 Advanced Preparation If storage time is likely to be exceeded, make advance preparation to have an adequate charger available and adjacent to an appropriate AC supply voltage. Positioning 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).
BEFORE INSTALLATION READ THIS SECTION THOROUGHLY. 5.0 INSTALLATION CONSIDERATIONS 5.1 General If you have any questions concerning the installation considerations, contact your 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.
TABLE 5.1 (continued) CONSIDERATION RECOMMENDATION Ventilation No special battery room or ventilation is required. However, do NOT install in an airtight enclosure. Grounding It is recommended that the modules or racks be grounded in accordance with NEC and/or local codes. Floor Reasonably level. Shimming up to 1/4” (6mm) maximum to level battery front to rear and side to side. Capable of supporting the weight of the battery as well as any auxiliary equipment.
To select the proper cable 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 provide no greater voltage drop than required between the battery system and the operating equipment as determined by the equipment/system supplier.
6.0 UNPACKING AND HANDLING FOR INSTALLATION 6.1 General Battery modules are shipped upright on pallets. All accessories for installation and use are supplied as optional prepackaged kits and are shipped on separate pallet(s) and/or in box(es). Cells may be packed in wooden boxes, which must be opened completely and carefully. The cells must then be handled as described in the appropriate Installation Manual. DO NOT lift any cell by the terminal posts as this will void the warranty.
6.3 Recommended Installation Equipment and Supplies Before working with the battery system, be sure that you have the proper protective clothing, safety equipment and insulated tools as specified in Section 2.0. The following is a list of equipment typically recommended for installation of a PowerSafe™ VRLA Battery System. TABLE 6.
7.0 INITIAL and/or FRESHENING CHARGE Batteries lose some initial charge during shipment and storage. Depending on storage time, a battery may require a freshening charge. See Section 4.0 for battery storage times. Constant voltage is the ONLY charging method allowed. Confirm that your charger bus is a constant voltage type. (Most modern chargers are the constant voltage type.) 1.
8.0 OPERATION 8.1 General The sealed design of the VRLA batteries makes it impossible to measure specific gravity as a state-of-charge indicator. The state-of-charge can be identified to some degree by the amount of charging current going to the battery exceeding 2.35 volts per cell. 8.1.1 Determining the State-of-Charge The following method can be used to determine the state-of-charge of the battery. 1. Place the battery on charge/recharge following a discharge. Read the ammeter.
8.2 Float Operation In this type of operation, the battery and the critical load circuits are continuously connected in parallel with a constant voltage charger.
8.2.1 Float Charge Method A float charge is given after the battery has been given its initial charge. To perform a float charge, follow the procedure below after the battery has been given its initial charge: 1. Determine that the VOLTS PER CELL nominal value is within the 2.23 to 2.27 range. This can be done by measuring the total battery string voltage and dividing by the number of cells in the string. Make sure the voltage does NOT exceed the maximum voltage for the connected load. 2.
8.3 Equalizing Charge Under NORMAL conditions an equalizing charge is NOT required. An equalizing charge is a special charge given to a battery when nonuniformity in voltage has developed between cells. It is given to restore all cells to a fully charged condition. Nonuniformity of cells may result from: • low float voltage due to improper adjustment of the charger. • a panel voltmeter that reads high, resulting in a low charger output voltage. • selection of too low a float voltage.
8.3.1 Equalizing Charge Method Constant voltage charging is the method for giving an equalizing charge. To perform an equalizing charge, follow the procedure below: 1. Determine the maximum voltage that may be applied to the system equipment. 2. Divide this voltage by the number of cells connected in a series. This is the MAXIMUM VOLTS PER CELL to be used for the equalizing charge. This number should NOT exceed 2.35 VOLTS PER CELL average. 3. Use Table 8.2 to determine the equalize charge time.
9.0 BATTERY TAPS Connections made to a battery for tapping a certain group of cells to provide a voltage other than the total battery voltage is NOT recommended and can void the warranty. Tapping results in an imbalance of the system during charging and discharging, causing unsatisfactory operation. 10.0 PILOT CELL One cell in a battery is usually selected as a pilot cell. It becomes an indicator of the general condition of the entire battery with regard to voltage, gravity, and temperature.
11.1.2 Battery Taps To clean mild corrosion from the battery: 1. Disconnect the battery. 2. Remove corrosion by wiping with a cloth dampened with bicarbonate of soda solution [mix 1 gallon (4l) of water with 1 lb. (500g) of bicarbonate of soda]. Follow with a cloth dampened with clear water. 3. Dry with a clean cloth. 4. With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the entire bolted connection.
11.2 TEST PROCEDURES 11.2.1 Procedure for Battery Capacity Tests Use the following test procedure or use the test procedure described in IEEE std. 1188. An equalizing charge, as described in Section 8.3, must have been given within the last 7 days. (Battery should be returned to float for 7 days before the test.) 1. Make sure all battery connections are clean, tight and free of corrosion. 2.
K TABLE TABLE 11.1 Initial Temperature Factor K Publication No. US-VR-OM-002 March 2008 (˚C) (˚F) 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 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.
11.3 Maintenance Records A complete recorded history of the battery operation is essential for obtaining satisfactory performance. Good records will show when corrective action may be required to eliminate possible charging, maintenance or environmental problems.
BATTERY MAINTENANCE REPORT - DDm, DDS, DDV, DGX, mSeries, and SC
BATTERY MAINTENANCE REPORT - DDm, DDS, DDV, DGX, mSeries, and SC
12.0 TEMPORARY NON-USE (EXTENDED OUTAGE) 12.1 Installed/Out-of-Service System If an INSTALLED battery is expected to STAND IDLE longer than the storage period recommended for the storage temperature (see Table 4.1 on page 9), treat as follows: 1. Before taking the battery out of service, give it an equalizing charge according to Section 8.3.1. 2. After the charge, open the connections at the battery terminals to remove load from the battery. 3.
NOTES 30 www.enersys.com Publication No.
PRECAUTIONS* 1. Do not bring any heat or flame source near battery. 2. Do not remove pressure relief valves. 4. Do not tamper with seal nuts on the cell post. 5. Do not remove lead coating from post or connectors and expose any bare copper. 6. Do not allow cell temperature to exceed 105˚F during charging. 7. Do not clean cell with anything other than water/bicarbonate of soda. 8. Do not over torque connections. 9. Do not store VRLA type batteries for over six months without charge, at normal temperatures.
