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92.80
User Manual
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Exide Technologies 92.80 User Manual

Installation and Operating
Instructions
For
®
ABSOLYTE
GX Batteries
SECTION 92.80 2012-04
TABLE OF CONTENTS
2.0 Sulfuric Acid Electrolyte Burns ....................................................................................................6
2.1 Explosive Gases..........................................................................................................................6
2.2 Electrical Shock and Burns .........................................................................................................6
2.2.1 Static Discharge Precautions for Batteries..................................................................................6
2.3 Safety Alert ..................................................................................................................................6
2.4 Important Message......................................................................................................................6
3.0 Receipt of Shipment ....................................................................................................................6
3.1 Concealed Damage.....................................................................................................................7
4.0 Storage Prior to Installation .........................................................................................................7
4.1 Storage Location .........................................................................................................................7
4.2 Storage Interval ...........................................................................................................................7
SECTION 5: INSTALLATION CONSIDERATIONS...........................................................................................7
5.0 General........................................................................................................................................7
5.1 Space Considerations .................................................................................................................7
5.2 Battery Location & Ambient Temperature Requirements ............................................................7
5.3 Temperature Variations................................................................................................................9
5.4 Ventilation ....................................................................................................................................9
5.5 Floor Loading...............................................................................................................................9
5.6 Floor Anchoring ...........................................................................................................................9
5.7 Connecting Cables: Battery System to Operating Equipment ....................................................9
5.7.1 Paralleling....................................................................................................................................9
5.8 Stacking Limitations.....................................................................................................................9
5.9 Terminal Plates............................................................................................................................9
5.10 Grounding....................................................................................................................................9
SECTION 6: UNPACKING..............................................................................................................................10
6.0 General......................................................................................................................................10
6.1 Accessories ...............................................................................................................................10
6.2 Recommended Installation Equipment and Supplies................................................................10
6.3 Unpacking..................................................................................................................................10
6.4 Handling of Modules..................................................................................................................10
SECTION 7: SYSTEM ARRANGEMENTS ....................................................................................................11
7.0 Module Arrangements ...............................................................................................................11
SECTION 8: SYSTEM ASSEMBLY ................................................................................................................11
8.0 Module Assembly Identification .................................................................................................11
8.1 Bottom Supports (I-beams) .......................................................................................................11
8.2 Handling of Modules..................................................................................................................12
8.3 Tip Over Procedure ...................................................................................................................12
8.4 Horizontal-Multiple Stacks .........................................................................................................13
8.4.1 Stacking Base Modules .............................................................................................................13
8.4.2 Stack Tie Plates.........................................................................................................................13
8.4.3 Horizontal Stacking....................................................................................................................14
SECTION 9: ELECTRICAL CONNECTIONS.................................................................................................14
9.0 Post Preparation ........................................................................................................................14
9.1 Connections - System Terminals...............................................................................................14
9.2 Connections - InterMODULE.....................................................................................................14
9.3 Connections - InterSTACK.........................................................................................................14
9.4 Torquing .....................................................................................................................................14
9.5 Connections - Check .................................................................................................................14
9.6 Connection Resistance..............................................................................................................15
SECTION 10: IDENTIFICATION LABELS........................................................................................................15
10.0 Surfaces.....................................................................................................................................15
10.1 Cell Numerals ............................................................................................................................15
10.2 System Polarity Labels ..............................................................................................................15
10.3 Warning Label ...........................................................................................................................15
10.4 Battery Nameplate.....................................................................................................................15
SECTION 11: PROTECTIVE MODULE COVERS ...........................................................................................15
11.0 General......................................................................................................................................15
11.1 Module Clear Cover Installation ................................................................................................15
SECTION 12: BATTERY CHARGING ..............................................................................................................15
12.0 Initial Charge .............................................................................................................................15
12.1 Constant Voltage Method ..........................................................................................................15
SECTION 13: BATTERY OPERATION.............................................................................................................17
13.0 Cycle Method of Operation........................................................................................................17
13.1 Floating Charge Method............................................................................................................17
13.2 Float Charge - Float Voltages....................................................................................................17
13.3 Recharge ...................................................................................................................................19
13.4 Determining State-of-Charge ....................................................................................................19
13.5 Effects of Float Voltage..............................................................................................................19
13.6 Float Current and Thermal Management ..................................................................................19
13.7 AC Ripple ..................................................................................................................................19
13.8 Ohmic Measurements ...............................................................................................................19
SECTION 14: EQUALIZING CHARGE.............................................................................................................20
14.0 General......................................................................................................................................20
14.1 Equalizing Frequency ................................................................................................................20
14.2 Equalizing Charge Method ........................................................................................................20
SECTION 15: RECORDKEEPING ...................................................................................................................21
15.0 Pilot Cell ....................................................................................................................................21
15.1 Voltmeter Calibration .................................................................................................................21
15.2 Records .....................................................................................................................................21
SECTION 16: TAP CONNECTIONS ................................................................................................................21
16.0 Tap Connections........................................................................................................................21
SECTION 17: TEMPORARY NON-USE ..........................................................................................................21
17.0 Temporary Non-Use ..................................................................................................................21
SECTION 18: UNIT CLEANING.......................................................................................................................21
18.0 Unit Cleaning .............................................................................................................................21
SECTION 19 CONNECTIONS MAINTENANCE.............................................................................................21
19.0 Connections...............................................................................................................................21
SECTION 20 CAPACITY TESTING.................................................................................................................22
20.0 Capacity Testing ........................................................................................................................22
LIST OF ILLUSTRATIONS
AGE FIGURE DESCRIPTION
P
8 Fig. 1 Typical System Spacing
0 Fig. 2 Packaged Modules
1
10 Fig. 3 Unpacking Modules
10 Fig. 4 Handling - Lifting Strap Placement
11 Fig. 5 Handling - Module
11 Fig. 6 Typical System Arrangements
11 Fig. 7 I-Beam Hardware Installation
11 Fig. 8 I-Beam Support Installed
12 Fig. 9 Tip-Over Procedure - Shackle-Strap Usage
12 Fig. 10 Tip-Over Procedure - Photo
12 Fig. 11 Module After Tip-Over
12 Fig. 12 Horizontal Stacking - Shackle-Strap Usage
13 Fig. 13 Handling and Stacking Horizontal Modules
13 Fig. 14 Hardware Installation Sequence
13 Fig. 15 Installing Hardware
13 Fig. 16 Completed Horizontal Stack
13 Fig. 17 Positioning Horizontal Base Modules
13 Fig. 18 Tie Plate Assemblies
14 Fig. 19 Stack Connections
16 Fig. 20 Terminal Plate Kit Materials & Assembly
18 Fig. 21 Module Clear Cover Materials & Assembly
24 Fig. 22 Sample Record Form
LIST OF TABLES
PAGE TABLE DESCRIPTION
7A Temperature Effects on Life
9B Absolyte GX Stacking Limitations
17 C Equalize Charge Voltages
19 D Float Voltage Effects on Life
20 E Equalize Charge Voltages
APPENDICES
PAGE APPENDIX DESCRIPTION
25 A Temperature Corrected Float Voltages
26 B Maximum Storage Interval Between Freshening Charges
Versus Average Storage Temperature
27 C Bonding and Grounding of Battery Rack
SECTION 1: GENERAL
.0 General Information
1
AUTION!
C
Before proceeding with the unpacking, handling, instal­lation and operation of this sealed lead-acid storage battery, the following information should be reviewed thoroughly. The safety procedures should be strictly adhered to when working with Absolyte GX batteries.
SECTION 2: SAFETY MESSAGES
2.0 Sulfuric Acid Electrolyte Burns
DANGER!
SULFURIC ACID ELECTROLYTE
BURNS
"Warning: Risk of fire, explosion or burns. Do not disassemble, heat above 50°C or incinerate." Batteries contain dilute (1.295 nominal specific gravity) sulfuric acid electrolyte which can cause burns and other serious injury. In the event of contact
with electrolyte, flush 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 electrolyte.
Ensure 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, rub-
ber gloves, rubber aprons, safety goggles and face protection
2.2.1 Static Discharge Precautions for Batteries
DANGER!
ELECTRICAL SHOCK AND BURNS
HIGH VOLTAGE…
RISK OF SHOCK.
O NOT TOUCH
D UNINSULATED
ERMINALS OR
T
ONNECTORS.
C
CAUTION!
If the foregoing precautions are not fully understood, clarifica­tion 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.
When maintaining a connected battery string, care must be taken to prevent build-up of static charge. This danger is particularly significant when the worker is electrically isolated, i.e. working on a rubber mat or an epoxy painted floor or wearing rubber shoes.
Prior to making contact with the cell, discharge static electricity by touching a grounded surface.
2.1 Explosive Gases
DANGER!
EXPLOSIVE GASES
Hydrogen gas formation is an inherent feature of all lead acid batteries. Absolyte GX VRLA batteries, however, significantly 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, flames, 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.
Never lay tools or other metallic objects on modules as shorting, explosions and personal injury may result.
2.2 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.
Wearing a ground strap while working on a connected battery string is not recommended.
2.3 Safety Alert
The safety alert symbol on the left appears througout this manual. Where the symbol appears, obey the safety message to avoid personal injury.
2.4 Important Message
The symbol on the left indicates an impor­tant message. If not followed, damage to and/or impaired performance of the battery may result.
SECTION 3: DELIVERY INFORMATION
3.0 Receipt of Shipment
Immediately upon delivery, examine packaging 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. If cell or unit damage is found, request an inspection by the carrier and file a damage claim.
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3.1 Concealed Damage
Within 10 days of receipt, examine all cells for concealed damage. If damage is noted, immediately request an inspection by the car-
ier and file a concealed damage claim. Pay particular attention to
r packing material exhibiting damage or electrolyte staining. Delay in notifying carrier may result in loss of right to reimbursement for damages.
SECTION 4: STORAGE INFORMATION
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 clear 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 flow to battery surfaces to enhance heat dissipation.
4.0 Storage Prior to Installation
o not remove shipping materials if a storage period is planned,
D unless charging is required per Section 4.2.
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 (25°C, 77°F), clean, dry location.
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 float 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 its initial charge (refer to Section 10) within 6 months of the date of shipment and receive a freshening charge (perform per Section 10 Initial 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 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 batteryʼs warranty.
NOTE: When planning system space requirements, allow at
least 6 inches past system total length wherever a terminal plate assembly is to be located (Figure 1A). Allow 4.5” minimum between back to back stacks (Figure 1B).
See Figure 1 for typical space allocations required. For total length, width and height dimensions of connected systems, con­sult layout/wiring diagram for the particular system.
Any modifications, alterations or additions to an Absolyte GX system, without the expressed written consent of GNB’s Engineering, may void any warranties and/or seismic qualifications. Contact your GNB repre­sentative for additional information.
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.
A location having an ambient temperature of 24°C (75°F) to 25°C (77°F) will result in optimum battery life and performance. Temperatures below 25°C (77°F) reduce battery charge efficiency and discharge performance. Temperatures above 25°C (77°F) will result in a reduction in battery life (see Table A on Page 9).
TABLE A
TEMPERATURE EFFECTS ON LIFE
Maximum Annual Maximum Percent Average Battery Battery Reduction Temperature Temperature In Battery Life
NOTE: Storage in temperatures above 25°C (77°F)
will result in loss of operating life.
Initial and freshening charge data should be saved and included with the battery historical records (see Section 15).
SECTION 5: INSTALLATION CONSIDERATIONS
5.0 General
Prior to starting installation of the Absolyte GX Battery System, a review of this section is strongly recommended.
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
25°C (77°F) 50°C (122°F) 0% 30°C (86°F) 50°C (122°F) 30% 35°C (95°F) 50°C (122°F) 50% 40°C (104°F) 50°C (122°F) 66% 45°C (113°F) 50°C (122°F) 75% 50°C (122°F) 50°C (122°F) 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 life of the battery is calculated to be only 10 years.
The battery temperature shall not be allowed to exceed 50°C (122°F). Minimum battery temperature is -40°C (-40°F). Temperature records shall be maintained by the user in accordance with the maintenance schedule published in this manual.
7
TYPICAL SYSTEM SPACING (TOP VIEW)
8
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 3°C (5°F).
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 required. Consult your local building and fire codes for require­ments that may apply to your specific location.
ventilation and or battery room is
DO NOT SELECT CABLE SIZE BASED ON CURRENT CAR­RYING CAPACITY ONLY. Cable size selection should provide
o greater voltage drop between the battery system and operat-
n ing 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 sufficient load backup time, it is important to min­imize the differences 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).
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. Sufficient 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 con­figuration involved. Consult layout/wiring diagram for the battery system weight Prior to installation, a determination should be made that the floor integrity is adequate to accommodate the battery system.
5.6 Floor Anchoring
Where seismic conditions are anticipated, floor anchoring should be provided. Such anchoring is the responsibility of the user.
Where non-seismic conditions are anticipated, anchoring is rec­ommended for maximum stability.
Four 9/16” (14.3 mm) holes are provided in the I-Beam for anchoring. To maintain seismic certification, 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.
• 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.
5.8 Stacking Limitations
There are recommended limits on stacked (horizontal only) bat­tery configurations, see Table B and consult your layout/wiring diagram.
TABLE B
Absolyte GX Stacking Limitations for the 2-Cell Tray
GX System Non-Seismic Seismic
GX2000 6 High 6 High GX3000 6 High 6 High GX4000 6 High 6 High GX5000 6 High 6 High GX6000 6 High 6 High
3-Cell GX2000 trays provide UBC Zone 4 compliance when stacked 4 modules high and UBC Zone 1 compliance at 8 mod­ules high.
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.
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