Deka Unigy II Installation And Operation Manual
NB Module
®
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
Receiving & Storage
Receiving Inspection ..........................................3
Unpacking ..........................................................3
System Shipment................................................3
Storage ..............................................................4
Installation
General ..............................................................5
Grounding ..........................................................5
Electric Code for Maintenance Access ..............5
Floor Anchoring & Module Arrangement ............5
Hardware Torque Values ....................................5
System Installation
Module Installation..............................................5
Cell Installation ..................................................8
Electrical Connection
Top Termination ................................................10
Side Termination ..............................................11
Connector Assembly ........................................13
Final Assembly..................................................13
Safety Shield Assembly ....................................14
System Operations
Charge Voltage ................................................15
Temperature Compensation ............................15
Cell Voltage ......................................................15
Rectifier Ripple Voltage ....................................15
Record Keeping ................................................15
Maintenance
Annual Inspection ............................................16
Battery Cleaning ..............................................16
Capacity Testing ..............................................16
Cell Removal Procedure ..................................16
Cell Weight & Volume ......................................17
Battery Maintenance Report ............................18
Appendix A ....................................................19
Appendix B ....................................................20
2
SAFETY PRECAUTIONS
lthough all valve-regulated batteries have the electrolyte
A
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
upervised by personnel familiar with batteries and battery
s
safety precautions.
WARNING: Risk of fire, explosion or burns. Do not
disassemble, heat above 40°C, or incinerate.
Protective Equipment
Although VRLA batteries can vent or leak small amounts of
electrolyte, electrical safety is the principle but not the only
concern for safe handling. Per IEEE 1188 recommendations,
the following minimum set of equipment for safe handling of
the battery and protection of personnel shall be available:
1. Safety glasses with side shields, or goggles, or face
shields as appropriate. (Consult application specific
requirements)
2. Electrically insulated gloves, appropriate for the installation.
3. Protective aprons and safety shoes.
4. Portable or stationary water facilities in the battery
vicinity for rinsing eyes and skin in case of contact
with acid electrolyte.
5. Class C fire extinguisher.
6. Acid neutralizing agent.
7. Adequately insulated tools.
8. Lifting devices of adequate capacity, when required.
Procedures
The following safety procedures should be followed during
installation: (Always wear safety glasses or face shield
when working on or near batteries.)
1. These batteries are sealed and contain no free electrolyte.
Under normal operating conditions, they do not present
any acid danger. However, if the battery jar or cover is
damaged, acid could be present. Sulfuric acid is harmful
to the skin and eyes. Flush affected area with water
immediately and consult a physician if splashed in the
eyes. Consult MSDS for additional precautions and first
aid measures.
2. Prohibit smoking and open flames, and avoid arcing in
the immediate vicinity of the battery.
3. Do not wear metallic objects, such as jewelry, while work-
ing on batteries. Do not store un-insulated tools in pockets
or tool belt while working in vicinity of battery.
4. Keep the top of the battery dry and clear of tools and other
foreign objects.
5. Provide adequate ventilation (per IEEE standard 1187 and/or
local codes) and follow recommended charging voltages.
6. Extinguishing media: Class ABC extinguisher.
Note: CO2may be used but not directly on the cells due
to thermal shock and potential cracking of cases.
7. Never remove or tamper with the pressure relief valves
unless for cell replacement. Warranty void if vent valve is
removed.
8. Inspect all flooring and lifting equipment
for functional adequacy.
9. Adequately secure battery modules, racks, or cabinets to
he floor.
t
10. Connect support structures to ground system
in accordance with applicable codes.
1. The below IEEE Standards contain additional information.
1
Other standards may be relevant to your specific application.
IEEE 1187 – Recommended Practice for Installation
Design of VRLA Batteries
IEEE 1188 – Recommended Practice for Maintenance,
Testing, of VRLA Batteries
IEEE 1189 – Selection of VRLA Batteries for
Stationary Applications
RECEIVING & STORAGE
Receiving Inspection
Upon receipt, and at the time of actual unloading, each
package should be visually inspected for any possible damage
or electrolyte leakage. If either is evident, a more detailed
inspection of the entire shipment should be conducted and
noted on the bill of lading. Record receipt date, inspection date
and notify carrier of any damage.
Unpacking
1. Always wear eye protection.
2. Check all batteries for visible defects such as cracked
containers, loose terminal posts, or other unrepairable
problems. Batteries with these defects must be replaced.
3. Check the contents of the packages against the packaging
list. Report any missing parts or shipping damage to your
East Penn agent or East Penn Mfg. Co. immediately.
4. Never lift batteries by the terminal posts.
5. When lifting batteries, the proper equipment is needed
such as a forklift or a portable crane. Always check the
lifting capacities of the equipment being used and never
lift more than one module and/or cell at a time.
System Shipment
Battery System will be received with cells and modules on
separate pallets. Amount of pallets dependent on number of
cells and module type.
3
RECEIVING & STORAGE CONT.
Module Shipment
All battery accessories (connectors, terminal plates, hardware)
ill be included with a module pallet. The pallet will be indicat-
w
ed with an “Accessory” sticker. The “Accessory” module pallet
will include a base and a top plate. 3 x 2 modules will be
shipped two high with base plate and top plate on top of the
module assembly. 2 x 2 modules will be shipped 3 high with
ase plate & top plate on either side of the module assembly.
b
3 x 2 Module Assembly
Cell Shipment
Each cell will be in an individual sleeve. There will be a
aximum of 6 cells per pallet.
m
Storage
1. Cells should be stored indoors in a clean, level, dry, cool
location. Recommended storage temperature is 0°F to 90°F
(–18°C to 32°C).
2. Stored lead-acid cells self discharge and must be
given a boost charge to prevent permanent performance
degradation.
0°F to 77°F (-18°C to 25°C) storage:
Batteries should be recharged six months from date
of manufacture.
>77°F (25°C) storage:
Use the chart below for recharge intervals. Voltage read-
ings should be taken on a monthly basis. Cells that reach
2.10V per cell or less should be recharged regardless of
scheduled interval. Record dates and conditions for all
charges during storage.
3. If a boost charge is required; the recommended charge is
24 hours at a constant voltage equal to 2.40V per cell.
4. Do not store beyond 12 months.
5. Store in horizontal position only.
2 x 2 Module Assembly
4
INSTALLATION
General
Caution should be taken when installing batteries to insure no
amage occurs. The battery cabinet, tray, rack, etc. shall be
d
inspected for sharp edges that could cause damage to the
battery casing. Batteries shall not be dropped, slid, or placed on
rough or uneven surfaces such as tray lips or grated flooring.
Mishandling of batteries could result in equipment damage or
uman injury. East Penn will not be liable for damage or injury
h
as a result of mishandling or misuse of the product.
Grounding
When grounding the battery system, proper techniques should
be applied per electrical standards, such as NEC and/or local
codes. All module structural bolting connections are provided
with grounding washers. Two sets of 0.201 diameter x .750"
center holes are provided on the back side of the top plate to
accept a # 6 x .750 center compression grounding lug. The
holes must be tapped for a 1/4-20UNC thread and paint must
be removed for a proper grounding pad location. *
*Note: Battery system and/or individual module grounding, if
required, is the installer’s responsibility.
SYSTEM INSTALLATIONS
ll parts should be verified against packaging list.
A
Report any missing parts.
Module Installation
Assemble system per the following details.
1. Remove floor-mounting base support from module pallet.
2. Position base(s), consult included system layout diagram
for required configuration. Bases are required to be
level prior to installing modules.
3. Multiple stack systems should have a minimum of 4.00"
between bases. The additional spacing is for proper
installation of modules.
Electric Code for Maintenance Access Refer to ANSI/NFPA70 National Electric Code for access and working space
requirements around the battery. A minimum of 36" aisle
space is recommended in front of the battery for service and
inspection. Additional spacing may be required to meet
earthquake seismic requirements.
Module Arrangement See East Penn Mfg. Co.’s system layout
diagram. One is supplied with each shipment. If it cannot be
located, contact East Penn Mfg. Co. for a copy. Refer to your
delivery number, located on the packing slip. This will aid in
obtaining the proper diagram.
Hardware Torque Requirements
Bolt Size Torque/Retorque
1/2-13 100ft-lb 135.5 Nm
3/8-16 45ft-lb 61.0 Nm
1/4-20 125 in-lb 14.1 Nm
4. Anchor holes can be marked and drilled with bases in
place. All anchor holes in base (16 per base) are required
to be used to meet NEBS Zone 4 seismic requirements.
Anchors required to be installed prior to modules being
installed onto base. Reference Appendix A for base plate
anchor hole layout.
Consult local building codes for anchor bolt
requirements. Anchor bolts not included.
5
SYSTEM INSTALLATIONS CONT.
. Remove hardware holding modules together (4 bolt
5
assemblies) and holding modules to pallet (4 bolt
assemblies). Hardware removed from module to
module will be reused to attach modules to modules.
Hardware holding modules to pallet can be discarded.
Module to Pallet Disassemble
7. Base and module layout should be compared to system
layout diagram. All ½-13 x 1.75" hardware (2 per corner)
are to be installed on the inside of the module for module
o base connection. All hardware should be checked for
t
proper torque before proceeding. Star washers are to be
installed with teeth towards module to ensure proper
grounding. Consult “Hardware Torque Requirements”
(pg 5) for proper torque values.
Module to Module Separation
6. Install modules onto bases using supplied lifting straps.
Consult below diagram for proper sling attachment and
lifting. Consult included system layout diagram for module
position.
CAUTION: Never lift more than one module at a time
with the supplied lifting slings.
6
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