Exide Technologies 92.61 User Manual
SECTION 92.61 2013-09
Installation and Operating
Instructions
For
ABSOLYTE
UL Recognized Component
®
GP Batteries
INDEX
Page
SECTION 1
1.0 General Information ............................................................................................................. 1
SECTION 2
2.0 Safety Precautions ............................................................................................................... 1
2.1 Sulfuric Acid Electrolyte Burns ............................................................................................. 1
2.2 Explosive Gases .................................................................................................................. 1
2.3 Electrical Shock and Burns .................................................................................................. 1
2.3.1 Static Discharge Precautions for Batteries .......................................................................... 1
2.4 Safety Alert .......................................................................................................................... 2
2.5 Important Message .............................................................................................................. 2
SECTION 3
3.0 Receipt of Shipment ............................................................................................................. 2
3.1 Concealed Damage ............................................................................................................. 2
SECTION 4
4.0 Storage Prior to Installation .................................................................................................. 2
4.1 Storage Location .................................................................................................................. 2
4.2 Storage Interval .................................................................................................................... 2
SECTION 5
5.0 Installation Considerations ................................................................................................... 2
5.1 Space Considerations .......................................................................................................... 2
5.2 Battery Location and Ambient Temperature Requirements ................................................. 2
5.3 Temperature Variations ....................................................................................................... 4
5.4 Ventilation ............................................................................................................................ 4
5.5 Floor Loading ....................................................................................................................... 4
5.6 Floor Anchoring .................................................................................................................... 4
5.7 Connecting Cables: Battery System to Operating Equipment ............................................. 4
5.7.1 Paralleling ............................................................................................................................ 4
5.8 Stacking Limitations ............................................................................................................. 4
5.9 Terminal Plates .................................................................................................................... 4
5.10 Grounding ............................................................................................................................ 4
SECTION 6
6.0 Unpacking and Handling ...................................................................................................... 5
6.1 General ................................................................................................................................ 5
6.2 Accessories .......................................................................................................................... 5
6.3 Recommended Installation Equipment and Supplies .......................................................... 5
6.4 Unpacking ............................................................................................................................ 5
6.5 Handling ............................................................................................................................... 5
SECTION 7
7.0 System Arrangements ......................................................................................................... 6
7.1 Module Arrangements .......................................................................................................... 6
7.2 Dummy Cells within a Module .............................................................................................. 7
SECTION 8
8.0 System Assembly ................................................................................................................ 7
8.1 Horizontal - Single Stack ...................................................................................................... 7
8.1.1 Bottom I-Beam Supports ...................................................................................................... 7
8.1.2 Handling ............................................................................................................................... 8
8.1.3 Horizontal Stacking .............................................................................................................. 8
8.2 Horizontal-Multiple Stacking ................................................................................................ 10
8.2.1 Stack Tie Plates ................................................................................................................... 11
SECTION 9
9.0 Connections ......................................................................................................................... 12
9.1 Post Preparation .................................................................................................................. 12
9.2 Connections - System Terminals ......................................................................................... 12
9.3 Connections - INTER-Module .............................................................................................. 12
9.4 Connections - INTER-Stack ................................................................................................. 12
9.5 Connections - Torquing ........................................................................................................ 12
9.6 Connections - Check ............................................................................................................ 12
9.7 Connection Resistance ........................................................................................................ 12
9.8 Cell Numerals ...................................................................................................................... 12
9.9 Warning Label ...................................................................................................................... 12
9.10 Battery Nameplate ............................................................................................................... 12
SECTION 10
10.0 Protective Module Covers .................................................................................................... 17
10.1 Module Cover Installation .................................................................................................... 17
SECTION 11
11.0 Initial Charge ........................................................................................................................ 17
11.1 Constant Voltage Method .................................................................................................... 17
SECTION 12
12.0 Operation ............................................................................................................................. 18
12.0.1 Cycle Method of Operation .................................................................................................. 18
12.1 Floating Charge Method ...................................................................................................... 18
12.2 Float Charge - Float Voltages .............................................................................................. 18
12.3 Voltmeter Calibration ........................................................................................................... 18
12.4 Recharge ............................................................................................................................. 18
12.5 Determining State-of-Charge ............................................................................................... 18
12.6 Effects of Float Voltage ........................................................................................................ 19
12.7 Float Current and Thermal Management ............................................................................. 19
12.8 AC Ripple ............................................................................................................................. 19
12.9 Ohmic Measurements .......................................................................................................... 19
SECTION 13
13.0 Equalizing Charge ................................................................................................................ 19
13.1 Equalizing Frequency .......................................................................................................... 19
13.2 Equalizing Charge Method ................................................................................................... 20
SECTION 14
14.0 Pilot Cell ............................................................................................................................... 20
SECTION 15
15.0 Records ................................................................................................................................ 20
SECTION 16
16.0 Tap Connections .................................................................................................................. 21
SECTION 17
17.0 Temporary Non-Use ............................................................................................................ 21
SECTION 18
18.0 Unit Cleaning ....................................................................................................................... 21
SECTION 19
19.0 Connections ......................................................................................................................... 21
SECTION 20
20.0 Capacity Testing .................................................................................................................. 21
LIST OF ILLUSTRATIONS
Page
3 Fig. 1A-B Typical Systems - Top View
5 Fig. 2 Packed Modules
5 Fig. 3 Unpacking Modules
6 Fig. 4 Handling - Lifting Strap Placement
6 Fig. 6A-B-C Typical Horizontal Stack Arrangements - Front Views
7 Fig. 7 Typical Horizontal Stack Arrangements - Back to Back and End to End
7 Fig. 8 Hardware Installation for 2.67” Wide I-Beam Support
7 Fig. 9 Hardware Installation for 4.5” Wide I-Beam Support
7 Fig. 10 Completed I-Beam Support to Module Installation
8 Fig. 11 Handling Module - Base Support Assembly
8 Fig. 12A Tip-Over Procedure - Shackle-Strap Usage
9 Fig. 12B Tip-Over Procedure
9 Fig. 13 Module with Base Assembly After Tip-Over
9 Fig. 14 Horizontal Stacking - Shackle-Strap Usage
10 Fig. 15 Handling and Stacking Horizontal Modules
10 Fig. 16 Hardware Installation Sequence
10 Fig. 17A Installing Hardware
10 Fig. 17B Completed Horizontal Stack
10 Fig. 18 Positioning Horizontal Base Modlule
11 Fig. 19A Horizontal Stacks - Back to Back Positioning
11 Fig. 19B Completed Horizontal Stacks - Side by Side
11 Fig. 20A-B Tie Plate Assemblies - Horizontal Stacks
13 Fig. 21 Various Inter Stack and Intra Stack Connections - Horizontal Arrangements
14 Fig. 22 Terminal Plate Kit - 6 Cell Modules
15 Fig. 23 Terminal Plate Kit - 3 Cell Modules
16 Fig. 24 Installation Guide for Absolyte GP Transparent Cover
22 Fig. 25 Absolyte Battery Maintenance Report
APPENDICES
24 A Temperature Corrected Float Voltages
25 B Maximum Storage Interval Between Freshening Charges Versus
Average Storage Temperature
26 C Bonding and Grounding of Battery Rack
27 D Absolyte GP Maximum Module Stack Heights
SECTION 1
1.0 General Information
The Absolyte GP battery is of the valve-regulated lead-acid
(VRLA) design and so can operate with lower maintenance (e.g.
no maintenance water additions) in comparison to conventional
flooded lead-acid batteries. The Absolyte GP VRLA design
is also inherently safer than conventional flooded lead-acid
batteries. Under normal operating conditions and use, the
Absolyte GP battery minimizes hydrogen gas release, and
virtually eliminates acid misting and acid leakage. However, there
is the possibility that under abnormal operating conditions (e.g.
over-charge), or as a result of damage, misuse and/or abuse,
potentially hazardous conditions (hydrogen gassing, acid misting
and leakage) may occur. Thus, GNB recommends that Section
2.0 of these instructions entitled “SAFETY PRECAUTIONS” be
reviewed thoroughly prior to commissioning, and strictly followed
when working with Absolyte GP batteries.
!
Before proceeding with the unpacking, handling, installation and operation of this VRLA storage battery,
the following general information
should be reviewed together with the
recommended safety precautions.
CAUTION!
signicantly reduce hydrogen formation. Tests have shown
that 99% or more of generated gases are recombined within
the cell under normal operating conditions. Under abnormal
operating conditions (e.g. charger malfunction), the safety
valve may open and release these gases through the vent.
The gases can explode and cause blindness and other
serious injury.
Keep sparks, ames, and smoking materials away from the
battery area and the explosive gases.
All installation tools should be adequately insulated to
minimize the possibility of shorting across connections.
DANGER
ELECTRICAL SHOCK
AND BURNS
Never lay tools or other metallic objects on modules as
shorting, explosions and personal injury may result.
2.3 Electrical Shock and Burns
Multi-cell systems attain high voltages, therefore, extreme
caution must be exercised during installation of a battery system to prevent serious electrical burns or shock.
Interrupt the AC and DC circuits before working on batteries
or charging equipment.
SECTION 2
2.0 Safety Precautions
2.1 Sulfuric Acid Electrolyte Burns
DANGER SULFURIC
ACID ELECTROLYTE
BURNS
“Warning: Risk of re, explosion or burns. Do not disassemble, heat above 50°C or incinerate.” Batteries contain
dilute (1.310 nominal specic gravity) sulfuric acid electrolyte
which can cause burns and other serious injury. In the event
of contact with electrolyte, ush immediately and thoroughly
with water. Secure medical attention immediately.
When working with batteries, wear rubber apron and rubber
gloves. Wear safety goggles or other eye protection. These
will help prevent injury if contact is made with the acid.
DANGER
EXPLOSIVE GASES
2.2 Explosive Gases
Assure that personnel understand the risk of working with
batteries, and are prepared and equipped to take the necessary safety precautions. These installation and operating
instructions should be understood and followed. Assure that
you have the necessary equipment for the work, including
insulated tools, rubber gloves, rubber aprons, safety goggles
and face protection.
!
If the foregoing precautions are not fully
understood, clarication should be obtained
from your nearest GNB representative.
Local conditions may introduce situations
not covered by GNB Safety Precautions. If
so, contact the nearest GNB representative
for guidance with your particular safety problem; also refer to applicable federal, state
and local regulations as well as industry
standards.
CAUTION!
2.3.1 Static Discharge Precautions for Batteries
When maintaining the batteries, care must be taken to prevent
build-up of static charge. This danger is particularly signicant
when the worker is electrically isolated, i.e. working on a rub-
ber mat or an epoxy painted oor or wearing rubber shoes.
Hydrogen gas formation is an inherent feature of all lead
acid batteries. Absolyte GP VRLA batteries, however,
Prior to making contact with the cell, discharge static electricity by touching a grounded surface.
- 1 -
Wearing a ground strap while working on a connected battery
string is not recommended.
2.4 Safety Alert
The safety alert symbol on the left appears
throughout this manual. Where the symbol
appears, obey the safety message to avoid
!
personal injury.
2.5 Important Message
The symbol on the left indicates an impor-
tant message. If not followed, damage to
and/or impaired performance of the battery
may result.
SECTION 3
Charge) at 6 month intervals thereafter. Storage at elevated
temperatures will result in accelerated rates of self discharge.
For every 18°F (10°C) temperature increase above 77°F
(25°C), the time interval for
the initial freshening charge and subsequent freshening
charges should be halved. Thus, if a battery is stored at
95°F (35°C), the maximum storage interval between charges
would be 3 months (reference Appendix B). Storage beyond
these periods without proper charge can result in excessive
sulphation of plates and positive grid corrosion which is
detrimental to battery performance and life. Failure to charge
accordingly may void the battery’s warranty. Initial and
freshening charge data should be saved and included with the
battery historical records; (see Section 15 - Records).
SECTION 5
5.0 Installation Considerations
3.0 Receipt of Shipment
Immediately upon delivery, examine for possible damage
caused in transit. Damaged packing material or staining from
leaking electrolyte could indicate rough handling. Make a
descriptive notation on the delivery receipt before signing.
Look for evidence of top loading or dents in the steel modules. If cell or unit damage is found, request an inspection by
the carrier and le a damage claim.
3.1 Concealed Damage
Within 10 days of receipt, examine all cells for concealed
damage. If damage is noted, immediately request an inspec-
tion by the carrier and le a concealed damage claim. Pay
particular attention to packing material exhibiting damage or
electrolyte staining. Delay in notifying carrier may result in
loss of right to reimbursement for damages.
SECTION 4
4.0 Storage Prior to Installation
4.1 Storage Location
If the battery is not to be installed at the time of receipt, it is
recommended that it be stored indoors in a cool [77°F (25°C)
or less], clean, dry location. Do not stack pallets or cell terminal damage may occur.
4.2 Storage Interval
The storage interval from the date of battery shipment to the
date of installation and initial charge should not exceed six
(6) months. If extended storage is necessary, the battery
should be charged at regular intervals until installation can
be completed and oat charging can be initiated. When in
extended storage, it is advised to mark the battery pallets
with the date of shipment and the date of every charge. If
the battery is stored at 77°F (25°C) or below, the battery
should be given a freshening charge (perform per Section 11
Initial Charge) within 6 months of the date of shipment and
receive a freshening charge (perform per Section 11 Initial
!
Prior to starting installation of the Absolyte Battery System, a
review of this section is strongly recommended.
Any modications, alterations or additions to
an Absolyte system, without the expressed
written consent of GNB Engineering, may void
any warranties and/or seismic qualications.
Contact your GNB representative for additional
information.
5.1 Space Considerations
It is important to know certain restrictions for the area where
the battery is to be located. First, a designated aisle space
should be provided to permit initial installation as well as for
service or surveillance. After installation, any additional equipment installed after the battery should not compromise access
to the battery system.
A minimum aisle space of 36 inches from modules / 33 inches
from covers should be available adjacent to the battery system. See Figure 1 for typical space allocations required.
Following the spacing requirements will aid in maintenance
of the battery and help maintain air ow to battery surfaces to
enhance heat dissipation.
NOTE: When planning system space requirements, allow at
least 6 inches past system total length wherever a terminal
plate assembly is to be located. (See Figure 1A)
Figure 1 A-B are typical. For total length, width and height
dimensions of connected systems, consult layout/wiring diagram for the particular system.
5.2 Battery Location & Ambient
Temperature Requirements
It is recommended that the battery unit be installed in a clean,
cool, dry location. Floors should be level. Absolyte batteries
can be installed in proximity to electronic equipment.
A location having an ambient temperature of 75°F (24°C)
to 77°F (25°C) will result in optimum battery life and performance. Temperatures below 77°F (25°C) reduce battery
charge efciency and discharge performance. Temperatures
above 77°F (25°C) will result in a reduction in battery life (see
table below.)
- 2 -
FIGURE 1A - HORIZONTAL END TO END
FIGURE 1B - HORIZONTAL BACK TO BACK
FIGURE 1 - TYPICAL SYSTEMS (TOP VIEW)
- 3 -
Annual Average Maximum Percent
Battery Battery Reduction
Temperature Temperature In Battery Life
77°F (25°C) 122°F (50°C) 0%
86°F (30°C) 122°F (50°C) 30%
95°F (35°C) 122°F (50°C) 50%
104°F (40°C) 122°F (50°C) 66%
113°F (45°C) 122°F (50°C) 75%
122°F (50°C) 122°F (50°C) 83%
For example: If a battery has a design life of 20 years at 77°F
(25°C), but the actual annual average battery temperature is
95°F (35°C), the projected service life of the battery is calculated to be only 10 years.
Temperature records shall be maintained by the user in accordance with the maintanence schedule published in this manual.
The battery temperature shall not be allowed to exceed the
maximum temperature shown above. It is important to maintain
the battery temperature as close to 77°F (25°C) as possible to
achieve the optimum service life from your battery.
5.3 Temperature Variations
Sources of heat or cooling directed on portions of the battery
can cause temperature variations within the strings, resulting
in cell voltage differences and eventual compromise of battery
performance.
Heat sources such as heaters, sunlight or associated equipment
can cause such temperature variations. Similarly, air conditioning or outside air vents may cause cell string temperature variations. Every effort should be made to keep temperature variations within 5°F (3°C).
5.4 Ventilation
The Absolyte battery is a Valve Regulated Lead Acid (VRLA)
low maintenance design. Tests have confirmed that under
recommended operating conditions in stationary applications,
99% or more of gases generated are recombined within the
cell. In most cases, no special ventilation and or battery room
is required. Consult your local building and fire codes for
requirements that may apply to your specic location.
!
Four 9/16” (14.3 mm) holes are provided in each I-Beam
support for anchoring. To maintain seismic certication, use
four anchor bolts per horizontal support. Anchor design is the
responsibility of the purchaser/installer.
5.7 Connecting Cables: Battery
System to Operating Equipment
The Absolyte cell is a UL recognized component. Battery
performance is based on the output at the battery terminals.
Therefore, the shortest electrical connections between the
battery system and the operating equipment results in maximum total system performance.
DO NOT SELECT CABLE SIZE BASED ON CURRENT
CARRYING CAPACITY ONLY. Cable size selection should
provide no greater voltage drop between the battery system
and operating equipment than necessary. Excess voltage drop
will reduce the desired support time of the battery system.
5.7.1 Paralleling
Where it is necessary to connect battery strings in parallel in
order to obtain sufcient load backup time, it is important to
minimize the difference in voltage drop between the battery
strings in parallel in order to promote equal load sharing upon
discharge. Therefore, equal resistance of cable connections
for each parallel string is important. When paralleling multiple
strings to a load or common bus, please follow these guidelines:
• Each parallel string must have the same number of cells
(same string voltage).
• The cables connecting the positive and negative terminals of
each string to the load (or bus) should be of the SAME SIZE
(i.e. same capacity/cross-sectional area).
• The cables connecting the positive and negative terminals
of each string to the load (or bus) should be of the SAME
LENGTH. Choose the shortest cable length that will connect
the battery string that is furthest from the load, and cut all
cables used to connect each string to the load to this same
length.
Hydrogen and oxygen gases can be vented to the atmosphere
under certain conditions. Therefore, the battery should never be
installed in an air-tight enclosure. Sufcient precautions must be
taken to prevent excessive overcharge.
5.5 Floor Loading
The floor of the area where the battery system is to be
installed should have the capability of supporting the weight
of the battery as well as any auxiliary equipment. The total
battery weight will depend on the cell size, number of cells,
as well as module conguration involved. Prior to installation, a determination should be made that the oor integrity is
adequate to accommodate the battery system.
!
5.6 Floor Anchoring
Where seismic conditions are anticipated, floor anchoring
must be implemented.
Where non-seismic conditions are anticipated, anchoring of horizontally stacked systems is recommended for maximum stability.
5.8 Stacking Limitations
There are recommended limits on stacked battery congurations. Please refer to Appendix D for additional information.
NOTE: Horizontal module arrangement only.
5.9 Terminal Plates
Each system is supplied with a terminal plate assembly for
the positive and negative terminations. These should always
be used to provide proper connection to the operating equipment and cell terminals. Any attempt to connect load cables
directly to cell terminal may compromise battery system performance as well as the integrity of cell post seals.
5.10 Grounding
It is recommended that the modules or racks be grounded in
accordance with NEC and/or local codes. See Appendix C for
recommended procedure.
- 4 -
SECTION 6
6.3 Recommended Installation
Equipment and Supplies
6.0 Unpacking and Handling
PACKED MODULES
Figure 2
6.1 General
Do not remove shipping materials if a storage period is
planned, unless charging is required per Section 4.2.
• Fork lift or portable boom crane
• Chalk line
• Line Cord
• Torpedo level (Plastic)
• Plywood straight edge 1/2” x 4” x 48”
• Torque wrenches
• Ratchet wrench with 10, 13, 17, 19 mm sockets and 2
and 15 mm deep sockets
• Box wrenches of 10, 13, 15, 17 and 19 mm sizes
• Vinyl electrical tape
• Paper wipers
• 3M Scotch Brite® scour-pads™†
• Hammer drill (oor anchoring)
† Trademark of 3M
6.4 Unpacking
Carefully remove bolts and protective shipping hood. See
Figure 3. Remove the bolts holding modules to shipping pallet. Also remove hardware bolting upper channels of modules
together. Do not remove modules at this time. Base supports
for horizontally stacked modules are more easily attached
before removing modules from pallet (see Section 8.0 System
Assembly and Section 9.0 Connections).
The battery modules are generally packed in groups. Lag
bolts retain the modules to the shipping pallet together with
a protective hood bolted in place. Modules are also bolted
together at the top adjacent channels. See Figure 2.
6.2 Accessories
Accessories are packed separately and will include the
following: (Note: Some items may not be provided depending
on battery conguration).
• Layout/wiring diagram
• Installation and operating instructions
• Lifting straps and lifting shackles
• Protective covers and hardware
• Terminal plate assembly kits and covers
• Module tie plates (where required) (i.e. side-by-side
stacks)
• Vertical or horizontal supports (i.e. I-beams)
• Lead-Tin Plated copper intercell connectors
• Assembly hardware
• NO-OX-ID® “A”* grease
• Battery warning label
• Battery nameplate
• Cell numerals with polarity indicators
• Shims (leveling)
• Drift pins
• Seismic Shims (where required). Included with systems
containing stacks of 7 or more modules in height.
Note: Placement of modules on shipping pallet has no rela-
tionship to nal installation.
UNPACKING MODULES
Figure 3
6.5 Handling
The design of the modular tray permits handling by a fork lift,
portable crane or by a hoist sling (see Figure 4). Whichever
method is used, make sure equipment can safely handle the
module weight.
!
*Registered Trademark of Sanchem Inc.
NOTE: Check battery components against supplied drawings
to assure completeness. Do not proceed with installation until
all accessory parts are available.
Always use the two lifting straps and four lifting shackles for
lifting and placement of modules.
- 5 -
CAUTION!
If a fork lift or portable crane is used
to handle modules in a horizontal
position, a piece of insulating material such as heavy cardboard, rubber
insulating mats or plywood should be
used between handling equipment and
module tops to prevent shorting of
module top connections with metal
parts of lift equipment.
Figure 6A
NOTE:
1) Straps must be criss-crossed.
2) Lifting shackle orientation and proper channel hole use
must be observed.
3) See Figure 14 for handling modules in horizontal orientation.
4) Never lift more than two joined modules with straps and hooks.
HANDLING - LIFTING STRAP PLACEMENT
Figure 4
SECTION 7
7.0 System Arrangements
7.1 Module Arrangements
Absolyte batteries are recommended for installation in a
horizontal orientation only. However, vertical installation is
approved for 50G systems consisting of single cell modules.
Figures 6 and 7 are typical arrangements and are not intend-
ed to represent all conguration possibilities.
Module stack height limitation depends on cell size and
the seismic requirements of the application. Please refer to
Appendix D for additional information.
Figure 6B
HORIZONTAL SINGLE STACK BACK TO BACK
- 6 -
Figure 6C
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