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RS-2109
User Manual
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C&D Technologies RS-2109 User Manual

MSE
®
DCS
®
RS02109/0814/CD 1 ww w.cdtechno.com
SAFETY PRECAUTIONS
Only authorized and trained personnel familiar with battery installation, preparation, charging, and maintenance should be permitted access to the battery.
WARNING
SHOCK HAZARD – Do not touch un-insulated batter y, connectors or term inals. Be sur e to discharge static electricity from tools and technician by touching a grounded surface near the batteries, but away from the cells and flame arresters.
All tools should be adequately insulate d to avoid the possibility of shorting conn ec tions. Do not lay tools on the top of the battery.
Although VRLA batteries are sealed and emit no gas during normal operation, they contain potentially explosive gases, which may be released under abnormal operating conditions, such as a charger malfunction. It is the responsibility of the customer to provide adequate ventilation so hydrogen gas accumulation in the battery area does not exceed two percent by volume. However, normal air circulation in a ventilated facility will preclude any hydrogen build-up even during equalize charging. Never install batteries in a sealed cabinet or enclosure. If you have any questions, contact your local C&D representative.
This battery contains sulfuric acid, which can cause severe burns. In case of skin contact with electrolyt e, r emove contaminated clothing and flush affected areas thoroughly with water. If eye cont act has occurred, f lush for a minimum of 15 minutes with large amo unt s of running water and seek immediate medical attention.
Warning
Risk of fire, explosion or burns. Do not disassemble, heat above 80ºC (175ºF) or incinerate
MPORTANT
NOTE
FOR ADDITIONAL INFORMATION CONTACT:
C&D Technologies, Inc. Technical Service Department 1400 Union Meeting Road
P.O. Box 3053 Blue Bell, PA 19422-0858 Telephone 1-800-543-8630 +1 (215)619-2700 FAX 215-619-7899
customersvc@cdtechno.com
Check C&D’s web site for further details www.cdtechno.com
This manual is to be used for the ins tallation and operating of C&D’s Liberty MSE or Liberty DCS series of batteries.
Liberty 2V (Liberty MSE & Liberty DCS) VALVE REGULATED LEA D-A CID BATTERIES TECHNI CAL MANUAL
Table of Contents
Part 1 - Introduction .............................................................................................................................. 5
1.1 Cell Characteristics...................................................................................................................... 5
Part 2 - Recommended Technical References ................................................................................. 6
Part 3 - Safety Precautions ................................................................................................................. 7
3.1 Recommended Tool s .................................................................................................................. 7
3.2 Personal Protection Equipment (Safety) ...................................................................................... 7
3.3 Installation Equi pm ent, T ools and Sup pl i e s ................................................................................. 8
Part 4 - Receiving ................................................................................................................................ 8
4.1 Inspection at Time of Delivery ..................................................................................................... 8
4.2 Damage and Shortage Situations ................................................................................................ 8
Part 5 Storage ...................................................................................................................................... 9
5.1 Storage Conditions ...................................................................................................................... 9
5.2 Storage Temperature and Duration ............................................................................................. 9
Part 6 - Installation .............................................................................................................................. 9
6.1 Locating Battery System .............................................................................................................. 9
6.2 Ventilation .................................................................................................................................. 11
6.3 Floor Loading and Anchor i ng .................................................................................................... 11
6.4 Spill Containment ...................................................................................................................... 11
6.5 Electrical Connections ............................................................................................................... 11
6.6 Terminal Plates ......................................................................................................................... 12
6.7 Numbering Cells ........................................................................................................................ 12
6.8 Interconnection .......................................................................................................................... 12
6.9 Tap Connections ....................................................................................................................... 13
Part 7 - Initial Charging ..................................................................................................................... 14
7.1 Initial Charge ............................................................................................................................. 15
Table 1 – Charging Requirements ............................................................................................... 15
7.2 Initial Charge Records ............................................................................................................... 15
Liberty 2V (Liberty MSE & Liberty DCS) VALVE REGULATED LEA D-A CID BATTERIES TECHNI CAL MANUAL
Table of Contents
Part 8 - Battery Operation................................................................................................................. 17
8.1 Float Charging ........................................................................................................................... 17
8.2 Cycle Charging .......................................................................................................................... 17
8.3 Equalize or Freshening Charging .............................................................................................. 18
8.3.1 Equalize or Freshening Charge Float Charge Applications ................................................ 18
8.3.2 Equalize or Freshening Charge Cyclic Applications ............................................................ 18
8.4 Temperature Effects on Batteries .............................................................................................. 19
Part 9 – Maintenance ........................................................................................................................ 20
9.1 Monthly Inspection .................................................................................................................... 20
9.2 Quarterly .................................................................................................................................... 20
9.3 Semi-Annually ........................................................................................................................... 20
9.5 Performance Tests .................................................................................................................... 21
Part 10 - Battery Degradation ........................................................................................................... 21
10.1 General Information and Precautions ...................................................................................... 21
10.2 Float versus Cycle Life ............................................................................................................ 21
10.3 Low Float Voltage and Sulfation .............................................................................................. 22
10.4 Hydration ................................................................................................................................. 22
10.6 Parallel Battery Strings ............................................................................................................ 23
10.7 High Temperature Operation ................................................................................................... 23
Appendix............................................................................................................................................ 24
Appendix A – Installation of Modules .............................................................................................. 24
Appendix B - Termin al Connections ................................................................................................ 30
Appendix C – MSDS 14-355 Liberty MSE & Liberty DCS ............................................................... 31
Appendix D – Handling and Replacement of Individual Cells .......................................................... 31
Appendix E – Battery Inspection Report .......................................................................................... 33
Appendix F – Recycling ................................................................................................................... 35

Part 1 - Introduction

The Libert y 2V batt eri es (Li bert y MSE or L ibert y DCS) r efer ence d in th is docum ent ar e stat io nary, lead-acid batteries. They are constructed with an absorbent glass mat (AGM) and are charact er ized as Valve Regulated Lead-Ac id (VR LA). As VRL A, t here is no free flowing electrolyte. They are constructed with lead-calcium alloy grids, dilute sulfuric acid (electrolyte) enclosed in a flame retardant thermoplastic container (non-flame retardant container also available) with a safety vent and a flame arresting disk to prohibit a spark from entering the head space of the cell. This type of battery is nearly 100% recyclable. At the end of life, please dispose of properly or consult C&D for recycling information.
The Liberty 2V batteries are designed to provide reliable service life with minimal maintenance when used in accor danc e wit h this manual. They are a single cell unit producing a nominal two volts per cell, which are connected in series for the desired system voltage. The cells are housed in steel modules, coated with acid resistant paint. These modules come in varying heights, depending on the cell size and two widths (3 cells wide and 4 cells wide), and can be stacked up to 84” high while maintaining their seismic ratin gs.
The Liberty 2V series are to be inst alled in a horizontal position with al l connections accessible from the front of the system assembly. These cells are not designed for operation in any other orientation.
The Liberty MSE series is designed for float operation with minimal cycling. Typical applications include Telecom, Switchgear/Control and other non-UPS applications which are subjected to 20 or fewer cycles per year.
The Liberty DCS series is designed for cycling applications. Typical applications include Off­Grid/Unreliable grid Telecom, Renewable energy or other stationary applications requiring a high number of cycles throughout the life of the cell.

1.1 Cell Characteristics

Under normal float operation, Liberty 2V batteries can be installed in proximity to electronic equipment and in computer rooms with occupied space. However, if subjected to excessive overcharge voltage, hydrogen and oxygen can be vented into the atmos phere. Therefor e, lea d ac id batt eri es sho uld never be installed in an airtight enclosure. Sufficient precautions must be take n to pre vent excessive overcharge and containment of potential explosive off gases. All Lead-Acid batteries, including Liberty 2V, are capable of generating excessive potentially explosive gases when charged for prolonged periods at voltages higher than initial or equalizing charge. The Liberty 2V cells are equipped with a “flash arrestor and pres sure r elief valv e” assem bly th at se als the c el ls dur ing norm al charge and operation but allows it to safely vent in case of overcharge. Removing the valve assembly can cause th e r ele as e of po te nt i al ly explosive gases and such action will void the warranty.

Part 2 - Recommended Technical References

These instructions assume a certain level of competence by the installer/user. Installers must have the appropriate knowledge and experie nce to safely install the batteries. The design of the battery room, system wiring, protect ion, e n vir onm ent al , f ir e, a nd s af et y r eq uir em ent s m ust c om pl y with applicable codes required by the governing enforcement agency.
The following is a partial list of the codes that may have direct impact on your installation. This list is not meant to be comprehensive. Consult with your local building, electrical and fire protection agencies to get proper direction to the local codes that will affect your installation.
• NEC National Electric Safety Code, ANSI C2-1993 (or latest revision)
• UBC Uniform Building Code or locally applied Building Code
• IBC International Building Code
Federal Codes that may directly affect your battery room design and battery installation.
• 29CFR1926.441 Safety Requirements for Special Equipment
• 29CFR1910.151(c) Medical Services and First Aid
• 29CFR1 910.268(g) Telecommunications
• 29CFR1910.305(j) Wiring Methods, Components and Equipment
• STD 1-8.2(e) OSHA Standing Directive
The following references to IEEE documents contain relevant information. They should be consulted for safe handling, installation, testing, and maintaining standby batteries. You may also refer to the battery brochure for additional information, specific to the battery.
• IEEE 1187 “Recommended Practice for Design and Installation of Valve-Reg ulat ed Lea d-Acid Storage Bat ter ies for Stationary Applications”
• IEEE 1188 “Recommended Practice for Maintenance, Testing, and Replacement of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Application”
• IEEE 1189 “Guide for Selection of Valve-Regulated Lead-Acid (VRLA) Batteries for Stationary Application”
• IEEE 1375 “Guide for Protection of Stationary Battery Systems”
• IEEE 1491 “Guide for Selection and Use of Battery Monitoring Equipment in Stationary
Applications”
• IEEE P1578 “Guide for Battery Spill Containment”
Copies may be obtained by contacting: The Institute of Elec t rical and Electronic Engineer s (IEEE), Inc. IEEE Customer Service 445 Hoes Lane PO Box 1331 Piscataway, NJ 08855-1331
customer.service@ieee.org
or visit the IEEE web site: www.standards.ieee.org

Part 3 - Safety Precautions

This batter y is de sign ed for in dust ri al, stat io nar y use only and is not intended for application in vehicular, starting, lighting and ignition (SLI), and the operation of portable tools and appliances. Use in accord ance with this manual or al l I EEE battery procedures. Use of this product other than in accordance with these instructions may produce hazardous and unsafe operating conditions, leading to damage of equipment and/or personal injury.
Do not expose the batteries to open flame or electrical arc. Do not tamper with the vent, as this will void the warranty.
Do not use any petroleum based cleaning or lubrication solution on the battery jar or cover. Failure to follow this warning may result in damage to the container and will void the warranty.
As a notice to all technicians and personnel in the near proximity of the batteries, a BCI warning label is in plain view to indicate the potential hazards of battery systems.
Figure 1 - BCI warn in g label

3.1 Recommended Tools

The below lists are general recommendation and is not intended as a complete and specific list. Each installation may require specia l tools that cannot be identified without knowing the specific applications. Review the appropriate industry recommendations, state and local codes for the specific information.

3.2 Personal Protecti on E quipment (Safety)

• Use standard battery safety practices
• Rubber or Neoprene – Acid Resistant Gloves
• Protective apron
• Face shield/safety glasses or ANSI approved goggles
• Rubber soled safety shoes/boots
• Portable or permanent eye wash station

3.3 Installation Equipm e nt , Tools and Supplies

• Lifting sling or appropriately sized platform – for lifting cells into modules or modules into position.
• Fork lift or portable crane.
• Insulated steel toed safety shoes & remove all metals, i.e. rings, etc – to ensure no short circuits.
• Bicarbonate of soda, 1 lb per gallon of water – to neutralize and clean up any electrolyte.
• Metric insulated tools – to ensure no short circuits between connections.
• Insulated torque wrench – to ensure no short circuits between connections.
• Digital voltmeter with three – digits and 0.25% accuracy minimum – to record initial cell open circuit
voltages & ensure correct assembly.
• Digital Micro-Ohm meter (DLRO) – to measure connection resistances.
• Optional, one of the following; res ist ance, conductanc e or impedance meter – to r ecord initial
ohmic measurement s .
• Non-metallic brush or pad for cleaning connections – to ensure clean connections for good integrity.
• NO-OX-ID grease and applicator brush – to ensure good connection integrity throughout service life.
• Minimum of (2) lifting straps (lifting capacity 500 lbs + each).

Part 4 - Receiving

4.1 Inspection at Time of Delivery

Great care has been taken to pack the battery for shipment to ensure its safe arrival. As soon as you receive the battery, check the packing m ate r ia l f or evi d en ce of dam ag e in t r ans it. I f the packing mater ia l is physically damaged or wet acid stains are present, make a notation on the delivery receipt before you accept
the shipment/delivery.
NOTE:
Freight Carriers generally require that the carriers’
representative inspect concealed damage within 10 days
from date of delivery to determine responsibility.
The resolution of such claims may extend up to nine months.
Verify the number of cartons and skids against the bill of lading and verify their contents against the packing l ists. K eep a cop y of the ver if ied l ists for your i nsta llat io n recor ds. It is impor ta nt to co nfirm that the accessory package is pr ese n t a nd th e qua nt i t ie s ar e cor r ec t. If he lp is req u ir ed, c al l C &D c ust om er service dep art m en t t o re p ort any discrepancies.

4.2 Damage and Shortage Situat ions

C&D ships FOB Pharr, TX (zip code 78577) (title/ownership passes to the ship-to/end user at t h e Pha rr , T X warehouse ) . If s h ipm ent s ar e d amaged or if cartons or skids are damaged or missing, a claim must be filed with the carrier. Plac e an immediate order f or replacement with C&D. P ay both the original invoice and the replacement invoice using th e replacement cost as t he amount of freight dam ages or shortages involved as part of your claim. If individual component items are missing, a shortage report should be filed within 30-days fr om the dat e of rec ei ving a sh ipment with C&D customer service department. Mail (express mail recommended), e-mail customersvc@cdtechno.com component-packing list. This verified list should show both the name of the packer, as well as the quantities of items checked off by the receiver.
, call 1-800-543-8630 or fax a copy of the VERIFIED

Part 5 Storage

5.1 Storage Conditions

Store batteries indoors in a cool, well ventilated, clean, dry location and place in service as soon as possible after receiving.

5.2 Storage Temperat ure and Duration

The recommended temperat ure for stor age is 50°F (10°C) to 77°F (25°C). Liberty 2V cells may be stored at these temperatures f or approxim atel y si x months; longer storage is detrimental to t he cell and can void the warranty if they are not given a freshening charge within that time period. A convenient measurement to check the condition of the cell d uri ng st or ag e i s t o me as ure t he O p en C ir cu it Vol tag e (OCV). A fully charged Liberty 2V c el l has an appr oxi mate O CV of 2.1 6 volt s. If th e Li bert y 2V series cell OCV dr ops m or e t han 0. 0 4 v olts f r om its rec ei ve d v olt ag e or measures less than 2. 12 vo lts , a freshening charge is required. Be sure to record dates and conditions (voltage, current and recharge
times) for all charges during storage.
Avoid exposure of a partially discharged cell to temperatures less than 0.0°F (-18°C), as this may cause the battery electrolyte to freeze. This can permanently damage the battery and can cause potentially hazardous leakage.
Higher than normal storage temperature (77°F [25°C] nominal) will accelerate internal self-discharg e of a cell by a factor of two for each 15°F (10°C) over nominal 77°F (25°C) storage temper ature. This, in turn, will reduce th e al lowable tim e befor e init ia l and/ or boost charging.
If a freshening char ge is required, it is very important that boost or freshening c harges (2.35 v/c for 12 to 16 hours) be gi ven at the appropriate t im e t o avoid major remedial action or loss of product as noted in Part 7.

Part 6 - Installation

6.1 Locating Battery System

Install the batteries in a clean, cool, and dry location. Avoid areas with direct sunlight and heat sourc es, including electrical equi pment vents or exhausts. The recommend ed batt er y room tem perat ur e of 77°F (25°C) provides the best combination of performance and life. Lower temperatures will reduce battery performance, while higher temperatures will improve battery performance but reduce battery service life.
Avoid sources of hot or cold air that could cause temperature variations of ±5°F (3°C) within th e battery assembly. Such variations will compr om ise o pt imum bat t er y p erfo r m ance s uc h as t h e f l oat voltages of individual cells.
For additional information on installing batteries in modular systems, refer to the Appendix for installation details.
When considering room layouts and determining the necessary floor space required for mounting a given system the below diagram is a guide to C&D’s recommended system clearances. Should a question or concern arise please contact your C&D sales representative for further details. Each system is shipped with an Applications Engineering System layout which goes into further detail on system layouts and floor anchoring.
Notes:
1. Allow a minimum of 2.00” from the back of any system to a wall or any other obstruction/equipment.
2. Allow a minimum of 4.00” between systems (side to side) where no side termination is being used. Reference supplied C&D connection diagram for additional details.
3. Allow a minimum of 6.00” between systems (side to side) where side termination is being used.
4. Allow a minimum of 4.00” spacing from any wall/equipment to the side of any system.
5. When installing systems back to back allow a minimum of 2.00” spacing from module to module as shown in the diagram below.
6. Always allow for a minimum of 36.00” aisle space in front of the system for suitable handling equipment.
7. There may be a de-rating of anchor bolt load ratings due to the proximity of anchor holes. Reference anchor bolt manufacturer’s data for additional information.
•
•
•
•
•

6.2 Ventilation

Although the Liberty 2V bat teries ar e valve r egul ated, t hey can produce minimal gas emis s ion s d ur ing normal operation. If exposed to abnormal high voltage charging, the cells may vent potentially explosive hydrogen gas. Hy drogen gas when accumu lat ed in a c onfined area t hat exce e ds f our (4% ) p er cen t b y volume in air is explosive. C&D recommends not allowing hydrogen gasses of greater than one (1%) percent b y vo lume to a cc um ul ate. C ontact the loc al c o de enforcement off icer t o determine what codes and levels are applicable to your battery room installatio n. Lead acid batteries should never be installed in a
sealed, non-ventilated cabinet or enclosure.
VRLA batteries subjected to extreme overcharge voltages have the potential to relea se h ydr oge n g as at a rat e of 0.0 002 6 9 cu b ic f eet pe r m i nut e per ampere of charging current at 77°F (25°C). The Liberty 2V series testing shows that they re c omb in e at near ly 99% effi cienc y und er nor mal conditions. However, compliance with appropriate safety measures regarding hydrogen evolution is essential for the safety of the equipment and personnel.

6.3 Floor Loading and Anchori ng

Floor loading and anchoring requirements are the responsibility of the user/installer and all applicable building codes and regu lations must be follo wed. C&D provides connection drawings, weights, dimensions, and floor loading information on our system drawings for reference which is supplied with every shipment.
The Liberty 2V floor-mounting base has provisions f or floor anchoring. Consult the applicable building codes and regulations for specific requirements. In all cases, floor anchoring is considered mandatory with floor anchors to be installed in all l ocations provide d unless otherwise specified. Floor anchor sizing and hardware are the responsibil ity of the user/installer.

6.4 Spill Containment

Although t he Lib erty 2V batteries contain no free flowing electrolyte, it is the sole responsibility of the user/installer to follow all local building and fire codes applicable to the battery installation. It is recommended consulting the local fire marshal or building inspector to determine if spill containment is required.

6.5 Electrical Connections

WARNING:
Always use protective ins ulating equipment, such as gloves, shoes, eye and
face protection. Wrenches and other tools must be properly insulated.
Observe local, state, and national electric codes at all times. Always work with the battery
ungrounded. Battery ground connections, if required, should be made last.
To avoid working with high voltages, brea k the battery down into convenient
lower-voltage modules, equal to or less than 48-volts.
Always maintain a firm grasp on tools and hardware when working on the battery.
Dropped hardware can cause a short cir cuit, possibl y resulting i n serious pers onal injury and/or damage to the equipment.
Before working on the battery, be sure to discharge static electricity that can build
up on tools or the technician by touching a grounded surface in the vicinity of the battery.
6.6 Terminal Plates (If part of the battery system)
For reasons of safety, it is r ecom m ende d t h at t er m in a l plates be insta l led bef ore connector install at ion as des cr i be d i n se ct io n 6.8. Interco nn ect c el ls an d m odu l es wit h t in-plated (standard) copper connectors and 6mm stainless steel hex head bolts and washers in accordance with the connection diagram supplied with each battery shipment.
Prior to installation, lightly brush (with a plastic brush or burlap) the battery terminals and terminal plate contact surfaces. Then apply a thin coating of NO-OX-ID type grease. The Liberty 2V battery terminals are made of a brass alloy with a tin coating cast inside a lead terminal. Terminal plates are made of copper with a thin tin coating. Once coated with protective NO-OX-ID type grease, any “exposed”, “un­tinned” areas, no matter if from the factory or due to over brushing, will be protected from oxidation by the grease thus not require reworking. Optional: preheat the NO-OX-ID type grease and apply warm. After working with any lead component, wash your hands.

6.7 Numbering Cells

For ease of identification and for record keeping, all cells of a battery should be numbered. Plastic peel-and-stick numbers are furnished in the ac cess ory k it. Comm on pr acti ce is to sta rt wit h “1” on t he cover of the incoming (+) positive ter minal of t he batter y and follow the e lectr ical c ircuit with succeeding numbers on the cell covers.

6.8 Interconnection

Cell series connection is made from the (+) of one cell to the (-) of the next sequential cell. I t is essent ial that the cell locat ion and orient ation match the included drawing. All connections must be made as indicated on the drawing with no deviations. If no drawing is provided or it is lost, contact C&D before making any connections.
The cells ship with NO-OX-ID grease applied by the factory to the terminals, however it may be necessary to rework prior to connecting the cells with the supplied inter-cell connectors. Refer to t he Appendix for additional instructions for reapplying NO-OX-ID grease.
Prior to installation, lightly brush (with a plastic brush or burlap) the battery terminals and any contact surfaces of the inter-unit connections. Then apply a thin coating of NO-OX-ID type grease to both the battery terminals and contact surfaces of the inter-unit connectors prior to installation. The Liberty 2V battery terminals are made of a brass alloy with a thin tin coating cast inside a lead terminal. The inter­unit connectors (cables and bus bars) are made of copper and have a thin lead or tin coating. Once coated with protective NO-OX-ID type grease, any “exposed”, “un-tinned” coated areas, no matter if from the factory or due to over brushing, will be protected from oxidation by the grease thus not require reworking. Optional: preheat the NO-OX-ID type grease and apply warm. After working with any lead component, wash your hands.
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