C&D Technologies 41-7525 User Manual
TECHNICAL MANUAL
VRLA Batteries
26-206 Ampere-Hour Capacity
Battery Installation
41-7525
And
Start up Guide
(For Rack Mounted Systems)
41-7525/0514/CD www.cdtechno.com
Table of Contents
Page
12V VRLA Battery System Description
Series Connected Batteries
...........................................................................................
.................................................. ..................................
Two strings of Batteries Connected in Parallel
VRLA Battery Safety Hazards
Electrical
Disposal
..............................................................................................................................
..............................................................................................................................
Fire, explosion and Heat
Installation Tools and Equipment
Preparation for System Installation
Receiving Instructions
....................................................................................................................
........................................................................................................
...............................................................................................................
...................................................................................................
................................................................................................
Storage Instructions and Task Flow Chart
Cabling - (1 each) Two-tier Rack - (10 each) 12 VDC batteries for 120 VDC
Cabling - (2 each) Four-tier Racks - (40 each 12 VDC batteries for 480 VDC
Locating the Batteries on the Rack
Battery Terminal Preparation
..........................................................................................................
...............................................................................................
Fig. 1
....................... ..................................
..................................... .......................
Fig. 2
Fig. 3
Fig. 4
Fig. 5
........................
........................
3
3
3
4
4
4
4
5
5
5
6
7
7
8
Numbering the Batteries
Inter-unit Connections
Inter-tier, Inter-row and Inter-rack Connections
Inter-Unit Cable Configurations
Inter-Tier Cable Configurations
Inter-Row Cable Configurations
Inter-Rack Configurations
Battery Connection to the Load/Charger
.................................................................................................................
............................................................................................. .............
..............................................................................
................................................................... ..............
................................................................... ...............
.................................................................. ..............
...........................................................................
.......................................................................................
Parallel Connection of individual Battery Strings
Battery System Pre-Operational Checks
Initial Freshening Charge
Initial Float Charging
..............................................................................................................
..................................................................................................................
Optional Battery Tests and Checks
.......................................................................................
...............................................................................................
Fig. 6
Fig. 6
Fig. 7
Fig. 8
Fig. 9
..............
...........................................................................
8
8
9
10
12
13
14
15
15
15
15
15
16
41-7525/0514/CD 2 www.cdtechno.com
12V VRLA BATTERY SYSTEM
JUNCTION
BOX
+
_
L1
L3
L2
L4
STRING B
STRING A
CIRCUIT
BREAKER B
CIRCUIT
BREAKER A
NOTE: L1 + L2 = L3 + L4
OPEN RACK INSTALLATION AND
SYSTEM CHECKOUT GUIDE
General Information
This document provides a guide for use during
receiving, installation and checkout of the 12V
VRLA batteries of 25 through 200 ampere-hours
capacity on open rack systems.
This guide may not be complete within itself
and should be used in conjunction with the
following:
1. Rack Installation Drawing (M16285)
2. Specification Sheet for individual battery
3. Self Discharge and Inventory Control
technical bulletin #41-7272
4. Integrity Testing technical bulletin #41-7264
5. Operational Qualification and Warranty
Registration Checklist technical bulletin
#41-7471
The typical 12V battery system is a group of the 6
or 12 VDC individual batteries connected in series
to provide a higher voltage and power to a critical
load during commercial power outages. Typical
system voltages are in the range of 12 through
480 VDC depending on the application. For
example 12, 24 and 48 VDC might be used for
communications equipment standby power while
from 72 to 480 VDC might be used for data center
UPS systems.
The lead acid battery has a nominal voltage of 2
VDC per cell. A 6 volt battery has 3 cells. Just as
the voltage of a battery system is increased by
connecting the individual multicell blocks in series,
the ampere-hours and kilowatt capacity of the
systems can be increased by connecting strings of
series connected batteries, in parallel. Refer to
Figures 1 and 2 for examples of series and parallel
connected batteries.
Other related C&D Technologies pamphlets
which may be of interest include:
1. Impedance and Conductance Testing
technical bulletin #41-7271
2. Acceptance and Capacity Testing
technical bulletin #41-7135
3. UPS Applications and VRLA Battery Sizing
technical bulletin #41-7334
Figure 1-Series Connected Batteries
4. Communications Applications and VRLA
Battery Sizing technical bulletin #41-7361
C&D Technologies 12V VRLA Battery
System General Description
The 12V valve regulated lead acid (VRLA)
battery is a lead acid battery which facilitates
the recombination of internally generated
gasses. As a result the battery vents minimal
gas during normal conditions and does not
require the addition of water to the electrolyte.
The electrolyte is either in a gelled form or is
absorbed in the blotter type of separator thus
eliminating any free liquid electrolyte. Each cell
within the battery contains a self resealing
pressure relief vent to relieve any excess
pressure generated during overcharge and the
battery is otherwise essentially sealed.
41-7525/0514/CD 3 www.cdtechno.com
Figure 2-Two Strings of Batteries
Connected in Parallel
VRLA Battery Safety Concerns
Installation and servicing of the 12V VRLA
battery should only be performed and
supervised by personnel knowledgeable of lead
acid batteries and required personal and equipment
safety precautions. Keep unauthorized
personnel away from the batteries and
installation activity.
Electrical Hazards
Battery systems present a risk of electrical
shock and high short circuit currents. The
following precautions should be observed when
installing and maintaining VRLA batteries:
1. Remove all personal metal objects
(watches and rings).
2. Use insulated tools.
3. Wear full eye protection and rubber gloves.
4. Observe circuit polarities.
5. Do not make or break live circuits.
6. Prior to handling batteries on a metal rack,
assure the battery is not inadvertently
grounded by measuring the voltage between
the battery and the rack. It should be zero.
If not, determine the cause and correct prior
to proceeding.
Disposal
Lead acid batteries must be recycled. Batteries
contain lead and dilute sulfuric acid. Dispose of
in accordance with Federal, State and local
regulations. Do not dispose of in a landfill, lake
or other unauthorized location.
Chemical Hazards
Any gelled or liquid emissions from a VRLA
battery is electrolyte which contains dilute
sulfuric acid, which is harmful to the skin and
eyes; is electrically conductive; and is
corrosive.
Neutralize any spilled electrolyte with the special
solutions contained in a spill kit or with a solution
of 1 lb. bicarbonate of soda to 1 gallon of water.
Fire, Explosion and Heat Hazards
Lead acid batteries can contain an explosive
mixture of hydrogen gas which can vent under
overcharging conditions.
Do not short circuit terminals.
Do not smoke or introduce sparks in the vicinity of
the battery.
Do not install and charge batteries in a sealed
container.
Mount the individual batteries with 0.5 inches of
space between the batteries to allow for
convection cooling. If contained, assure the
container or cabinet and room have adequate
ventilation to prevent an accumulation of potentially
vented gas.
Refer to the current issue of the National Electric
Code.
Caution
Do not attempt to remove the vents (valves) from
the 12V VRLA battery or add water. This presents
a safety hazard and voids the warranty.
Caution
The individual batteries may weigh from 25 to 180
pounds depending on part number. Exercise care
when handling and moving batteries. Assure the
use electrolyte which contains dilute sulfuric acid
which is of appropriate handling equipment.
If electrolyte contacts the skin, wash immediately
and thoroughly. If electrolyte enters the eyes,
wash thoroughly for 10 minutes with clean
water or a special neutralizing eye wash solution
and seek immediate medical attention.
41-7525/0514/CD 4 www.cdtechno.com
Required Installation Tools
& Equipment
At a minimum, the following tools and
equipment are required to install the 12V
VRLA battery.
1. Digital voltmeter.
2. Socket wrench, insulated.
3. Torque wrench calibrated in inch-pounds,
insulated.
4. Box end wrench, insulated.
5. Battery lifting equipment (handles) and fork
lift to lift pallets of batteries.
6. Rubber gloves.
7. Full face shield.
8. Plastic apron.
9. Portable eyewash.
10. Spill kit.
11. Fire extinguisher (class C).
The following equipment is optional depending
on the type of checkout to be performed.
1. Micro-ohm meter.
2. Battery resistance, impedance or
conductance test set.
3. 100 amp momentary load test set.
4. System load bank (DC if to be performed at
the battery and AC if to be performed by
loading a UPS output).
Preparation for System Installation
The installation of the battery system involves a
series of activities from planning and initial
receipt through final checkout and warranty
registration. The sequence of these tasks are
presented in Figure 3 and should be thoroughly
studied and understood before proceeding.
As part of this preparation activity the installer
should develop a system schematic diagram
which identifies how the individual batteries are
to be placed on the rack, interconnected and
numbered. Figure 4 is a schematic for a typical
system of 30 each 12 volt batteries on a single
3 tier rack while Figure 5 is a schematic for a
typical string of 40 each 12 volt batteries on two
each 3 tier racks. The cabling received with
the system presumes a specific rack and
installation configuration.
d
n
a
d
le
mb
e
s
s
a
e
b
t
s
mu
s
k
c
a
r
e
h
t
ly
s
u
io
v
Ob
.
ies
r
e
t
t
ba
he
t
of
ion
t
a
ll
a
t
s
in
o
t
r
io
pr
lled
a
t
s
in
ed
in
a
nt
o
c
e
r
a
mbly
e
s
as
k
c
a
r
e
h
t
or
f
ns
io
t
c
u
r
t
s
n
I
.
s
k
c
a
r
e
h
t
h
it
w
d
e
iv
e
c
e
r
t
n
me
u
c
o
d
e
at
r
a
p
e
s
a
in
n
o
i
t
a
r
Ope
.
)
C
5°
2
(
F
°
7
7
at
ed
t
a
r
e
r
a
s
ie
er
t
t
a
b
e
Th
g
n
i
g
r
a
sch
i
d
e
th
se
a
cre
e
d
l
l
s wi
re
tu
a
r
e
p
m
r te
e
l
o
t co
a
e
s
a
e
cr
e
d
l
l
i
s w
e
r
tu
a
r
e
p
m
te
d
te
va
e
l
t e
a
n
o
ti
a
r
e
p
. O
e
m
ti
e
lif
%
0
5
a
is
e
r
e
Th
y.
r
e
t
t
a
b
e
h
t
f
o
e
lif
ll
a
r
e
v
o
e
h
t
.
F
°
7
7
e
v
o
b
a
F
°
5
1
h
c
a
e
r
o
f
n
io
t
c
du
e
r
ons
i
ruct
t
ns
I
ng
vi
i
ce
e
R
ly
h
g
u
o
r
o
h
t
e
b
ld
ou
h
s
t
n
e
m
p
i
h
s
e
h
t
t
ip
e
c
e
r
n
o
p
U
g
n
i
g
cka
a
p
e
th
to
e
g
a
m
a
d
l
ca
ysi
h
y p
n
a
r
fo
d
cte
e
sp
n
i
e
r
a
ems
it
of
ies
it
t
n
a
qu
r
e
p
o
r
p
e
h
t
e
r
u
s
s
a
o
t
nd
a
d
e
n
e
p
o
be
n
he
t
d
l
u
o
h
s
s
e
g
a
k
c
a
p
e
Th
.
d
e
iv
e
c
e
r
o
n
s
i
e
r
e
h
t
e
r
u
s
as
o
t
d
e
t
c
e
p
s
in
s
ie
r
e
t
at
b
e
h
t
d
n
a
n
e
iv
g
e
b
uld
o
h
s
n
io
t
n
e
t
t
a
l
ia
c
e
p
S
.
ge
ma
a
d
n
e
d
id
h
d
ive
rece
e
f th
ls o
a
n
rmi
e
t
d
n
rs a
e
n
i
ta
n
co
e
th
to
s.
ie
r
tte
a
b
e
th
t
a
h
t
e
n
rmi
te
e
d
d
n
l a
ria
te
a
m
f
ill o
b
e
th
r to
fe
Re
n
o
d
e
b
scri
e
s d
a
d
n
a
te
le
mp
co
re
a
d
ive
e
i
b
re
uld
he
t
co
e
d co
in
w
les a
ial a
r
he
ba
ll o
n
g
compo
c
l.
a
ri
te
f ma
or the
ed,
co
e
rri
ca
t o
n
te
ted
n
accesso
nd
r
e
r
o
is not
e
h
cte
a
t
n
w
r
e
f th
assu
to
u
n
d
ceived.
e
n
e
n
ie
g
lo
sh
d
ith
e sh
mb
ts b
s Cu
ip
a
in 1
ip
e
r
r o
e
e
ri
Sho
e
p
n
th
s a
o
sto
g
n
i
d
0 d
me
e
ba
f
uld th
f th
p
cla
a
a
n
p
s
e wron
e
m
amage
t from t
b
n
un
s a
chn
.
tteries are
shipped
fully cha
lf-discharge will occur d
n of the transit time and
harged open circuit voltage is
er cell (6.36 to
er of p
b
m
nu
e
rs, th
e
p
a
u
o
m sh
i
ys.
uld b
sho
t
str
r in
e
p
ro
ha
ries,
te
t
on
tified
n
e
d
i
unt
e co
typ
g
vice
r
r Se
rge
uring transit and
6.48 and
ackag
r
ie
rr
ca
file
e
b
ld
ted
c
spe
n
i
e
s,
ction
u
kits,
e
r
a
w
rd
ill o
b
e
th
corr
n
i
be
act
t
con
e,
a
n
o
s so
a
d, however
12.72
es is
d
f
ct
e
s
ms re
ite
e
th
any d
If
fe
if
d
o
sh
with
Th
n
a
ra
d
b
ca
mate
r t
o
C&D Te
possible
The
some se
the degree is a functio
temperature. The fully c
2.12 to 2.16 volts p
to 12.96 VDC for 6 and 12 volt batteries respectively).
on rece
Up
2.07 volts p
ipt the batte
er cell o
rie
r 6.2 a
nd 12.4
volts fo
r 6 and
uld be a minimum of
s sho
12 volt batteries respectively. If at these minimum
voltages the batteries should be recharged as
soon as possible. If at or below 2 volts per cell
(6 and 12 volts) the batteries should not be used
and the vendor should be contacted immediately.
41-7525/0514/CD 5 www.cdtechno.com
Loading...