EnerSys PowerSafe RL Series, PowerSafe RM Series, PowerSafe RN Series, PowerSafe RH-420, PowerSafe RH Series Installation, Operating And Maintenance Instruction

1 Publication No: EN-GAZ-Standard-IOM 001 Dec 2012

INSTALLATION, OPERATING
MAINTENANCE INSTRUCTIONS

type RL …, RM …, RN …, RH …

Battery voltage: Capacity (5 h):

T

y

pe of cell: Number of cells:

Assembled and commissioned by: Date:

Warning!

The gases emitted during charging are explosive. The electrolyte (potassium hydroxide, KOH) is highly
co

rrosive. Exposed metal parts of the battery always conduct a voltage and are electrically active parts.

Precautions in accordance with DIN EN 50272, Part 2 have to be observed.

Observe the instructions for use and
place them visibly close to the
battery! Work only on batteries after
receiving instruction from qualified
personnel!

Warning: Risk of fire, explosion, or
burns! Avoid any short circuit!
Metallic parts under voltage on the
battery, do not place tools or items
on top of the battery!

Electrolyte is highly corrosive!

When working on batteries wear
safety glasses and protective
clothing. All metallic personal
objects, such as rings, watches,
bracelets etc. shall be removed
before starting work on the battery!
Only use insulated tools! Comply
strictly with the accident prevention
regulations and your national Health
and Safety standards as well as DIN
EN 50272, Part 1.

Cells are heavy!
Make sure they are safely
installed!
Only use suitable transport
equipment!

Electrolyte is harmful to skin and
eyes. Therefore, after an accidental
contact with the electrolyte flood the
eyes immediately with large
quantities of clean water for an
extended period of time of at least
15 minutes. In all cases, consult a
doctor immediately!
Clothing contaminated with
electrolyte should be washed in
water immediately!

No smoking! Do not allow naked
flames, embers or sparks near the
battery due to the risk of explosion
or fire!

The Installation, Operation and Handling Instructions must be strictly observed. Non-compliance
with the Maintenance and Handling Instructions, replacing with unoriginal spares, usage other
than specified, use of additives to the electrolyte and unauthorized tampering will invalidate any
entitlement to warranty.

Used batteries with this symbol are reusable products and have to be

put into a recycling system. Used batteries must be disposed of as
special waste in accordance with all standards.

WARNING!

Never use sulphuric acid or acidic

water.

Acid will damage the battery!

2 Publication No: EN-GAZ-Standard-IOM 001 Dec 2012

1. Receiving the battery

The cells are not to be stored in
packaging, therefore, unpack the battery
immediately after arrival. Do not overturn
the package. The battery cells are
equipped with a blue plastic transport plug.
The battery can be delivered:

- Filled and charged/ the battery
is ready for installation. Replace
the transport plug with the vent
cap included in our accessories
just before use;

- Filled and discharged/ Replace
the transport plug with the vent
cap included in our accessories
just before use; or

- Unfilled and discharged/ do not
remove the transport plug until
ready to fill the battery.

The battery must not be charged with
the transport plug in the cells as this
can damage the battery.

2. Storage

The rooms provided for storing the
batteries must be clean, dry, cool (+10 °C
to 30 °C - in compliance with IEC 60623)
and well ventilated. The cells are not to be
stored in closed packaging and must not
be exposed to direct sunlight or UV­radiation.

If the cells are delivered in plywood
boxes, open the boxes before storage
and remove the packing material on the
top of the cells. If the cells are delivered
on pallets remove the packing material
on the top of the cells.

2.

1 Uncharged and unfilled cells

Provided the correct storage conditions
are met then the cells and batteries can be
stored for long periods without damage if
they are deeply discharged, drained and
well sealed. It is very important that the
cells are sealed with the plastic transport
plug tightly in place. It is necessary to
check after receipt and at least every year.
Leaky plugs allow the carbon dioxide from
the atmosphere to infiltrate the cell, which
will result in carbonation of the plates. This
may influence the capacity of the battery.

2.2 Charged and filled cells/
discharged and filled cells

Filled cells can be stored for up to 12
months from the time of delivery. Storage
of filled cells at a temperature above
+30 °C results in loss of capacity of
approximately 5% per 10% year. It is very
important that the cells are sealed with the
plastic transport plugs tightly in place. In
case of loss of electrolyte during
transportation, refill the cell with distilled
water to the “MAX” mark before storage.

3. Installation

EN 50272-2:2001 “Accumulators and
battery installations, stationary battery
installations” is binding for the setting up
and operation of battery installations. For
non stationary installations specific
standards are valid.

3.1 Location

Install the battery in a dry and clean room.
Avoid direct sunlight and heat in all cases.
The battery will give the optimal
performance and maximum service life if
the ambient temperature lies between
+ 10 °C and + 30 °C.

3.2 Ventilation

During the last part of charging the battery,
gases (oxygen and hydrogen mixture) are
emitted. At normal float charge the gas
evolution is very small but some ventilation
is necessary. Special regulations for

ventilation might be required in your
area for certain applications. If no
regulations are fixed DIN EN 50272,

Part 2:2001 should be met.

3.3 Setting up

Always follow the assembly drawings,
circuit diagrams and other separate
instructions. The transport plugs have to
be replaced by the vent caps included in
the accessories. If batteries are supplied
“filled and charged” , all the electrolyte
levels should be checked and, if
necessary, topped up as described in
point 3.4.

Cell connectors and/or flexible cables
should be checked to ensure they are
tightly seated. Terminal nuts, screws and
connectors must be tightly seated. If
necessary, tighten with a torque wrench.

Torque loading for:
M10: 8 Nm
M16: 20 Nm
M20: 25 Nm
Female thread:
M 8: 20 – 25 Nm
M10: 25 – 30 Nm

The connectors and terminals should be
corrosion-protected by coating with a thin
layer of anti-corrosion grease.

3.4 Electrolyte

The electrolyte for NiCd batteries consists
of diluted caustic potash solution (specific
gravity 1.20 kg/litre ± 0.01 kg/litre) with
a lithium hydroxide component, in
accordance with IEC 60993. The caustic
potash solution is prepared in accordance
with factory regulations. The specific
gravity of the electrolyte does not allow
any conclusion to be drawn on the
charging state of the battery. It changes
only slightly during charging and
discharging and is only minimally related
to the temperature.

-

Battery delivered unfilled and

discharged/ if the electrolyte is

supplied dry, it is to be mixed to
the enclosed mixing instruction.
Remove the transport plugs from
the cell just before filling. Fill the
cells up to 20 mm above the
lower level mark “MIN”. Steel
cased cells have to be filled up to
the top edge of the plates. When
using battery racks fill cells before
installing. Only use genuine
electrolyte.

- Battery delivered filled and
charged or discharged/ check
electrolyte level. It should not be
less than 20 mm below the upper
level mark “MAX” (see 5.2).

3.5 Commissioning

A good commissioning is very important.
The following instructions are valid for
commissioning while 20 °C to 30 °C. For
different conditions please contact the
manufacturer. Charging at constant
current is preferable. If a site test is
requested it has to be carried out in
accordance with IEC 60623.

According to IEC 60623, 0.2 C5 A is also
expressed as 0.2 It A. The reference test
current It is expressed as:
It A = Cn Ah
1 h

Example:

0.2 ItA means:
20 A for a 100 Ah battery or
100 A for a 500 Ah battery

3.5.1 Commissioning with constant
current

Battery delivered unfilled and
discharged /after a period of 5 hours from

filling the electrolyte, the battery should be
charged for 15 hours at the rated charging
current 0.2 It A. Approximately 4 hour after
the end of charging, the electrolyte level
should be adjusted to the upper electrolyte
level mark “MAX” by using only genuine
electrolyte. For cells with steel cases, the
electrolyte level should be adjusted to the
maximum level according to the
“Instruction for the control of electrolyte
level”. During the charge the electrolyte

level and temperature should be
observed (see point 5.4). The
electrolyte level should never fall below
the “MIN” mark.

Battery delivered filled and discharged

/the battery should be charged for 15
hours at the rated charging current 0.2 It A.
Approximately 4 hours after the end of
charging, the electrolyte level should be
adjusted to the upper electrolyte level
mark “MAX” by using distilled or deionized
water in accordance with IEC 60993. For
cells with steel cases, the electrolyte level
should be adjusted to the maximum level
according to the “Instruction for the control
of electrolyte level”.