Exide Technologies 93.10 User Manual
®
INSTALLATION
&
OPERATING
INSTRUCTIONS
SECTION 93.10 2013-05
YOUR GNB REPRESENTATIVE
SALESPERSON
TELEPHONE
LOCATION
GNB SERVICE ASSISTANCE
1-800-241-4895
INDEX
SECTION 1
1.0 General Information . . . . . . . . . . . . . . . . . . . .1
SECTION 2
2.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . .1
SECTION 3
3.0 Receipt of Shipment . . . . . . . . . . . . . . . . . . .1
3.1 Concealed Damage . . . . . . . . . . . . . . . . . . . .2
3.2 Electrolyte Levels . . . . . . . . . . . . . . . . . . . . . .2
SECTION 4
4.0 Storage Prior to Installation . . . . . . . . . . . . . .2
4.1 Storage Location . . . . . . . . . . . . . . . . . . . . . .2
4.2 Parts and Accessories . . . . . . . . . . . . . . . . . .2
4.3 Storage Interval . . . . . . . . . . . . . . . . . . . . . . .2
4.4 Dry Charged Batteries . . . . . . . . . . . . . . . . . .2
SECTION 5
5.0 Rack Assembly . . . . . . . . . . . . . . . . . . . . . . .2
SECTION 6
6.0 Unpacking and Handling . . . . . . . . . . . . . . . .2
SECTION 7
7.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .3
7.1 Battery Location . . . . . . . . . . . . . . . . . . . . . . .3
7.2 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . .3
7.3 Temperature Variation . . . . . . . . . . . . . . . . . .3
7.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . .3
7.5 Placement of Cells . . . . . . . . . . . . . . . . . . . . .3
7.6 Connecting Cells . . . . . . . . . . . . . . . . . . . . . .4
7.7 Completing Installation . . . . . . . . . . . . . . . . .6
Page
ECTION 12
S
12.0 Cell Voltage Variation . . . . . . . . . . . . . . . . . .10
12.2 Cell Voltage Variation–Damp Covers . . . . . .11
12.2 Cell Voltage–Temperature Correction . . . . .11
12.3 Correction Factor . . . . . . . . . . . . . . . . . . . . .11
SECTION 13
13.0 Pilot Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SECTION 14
14.0 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SECTION 15
15.0 Water Additions . . . . . . . . . . . . . . . . . . . . . .12
15.1 Water Purity . . . . . . . . . . . . . . . . . . . . . . . . .12
SECTION 16
16.0 Tap Connections . . . . . . . . . . . . . . . . . . . . .12
SECTION 17
17.0 Temporary Nonuse . . . . . . . . . . . . . . . . . . .12
SECTION 18
18.0 Battery Cleaning . . . . . . . . . . . . . . . . . . . . .12
18.1 Styrene Acrylonitrile Containers with
Butadiene Styrene Covers . . . . . . . . . . . . . .12
18.2 Polycarbonate Containers and Covers . . . .12
SECTION 19
19.0 Connections . . . . . . . . . . . . . . . . . . . . . . . . .13
19.1 Connection Resistance . . . . . . . . . . . . . . . .13
19.2 Retorquing Connections . . . . . . . . . . . . . . .13
19.3 Connection Resistance Measurement . . . . .14
Page
SECTION 8
8.0 Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . .7
8.1 Constant Voltage Method . . . . . . . . . . . . . . .7
8.2 Initial Charge-Electrolyte Levels . . . . . . . . . .7
SECTION 9
9.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
9.1 Floating Charge Method . . . . . . . . . . . . . . . .7
9.2 Float Charge-Float Voltages . . . . . . . . . . . . .7
9.3 Voltmeter Calibration . . . . . . . . . . . . . . . . . . .8
9.4 Cycle Method of Operation . . . . . . . . . . . . . .8
9.5 Recharge . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SECTION 10
10.0 Equalizing Charge . . . . . . . . . . . . . . . . . . . . .8
10.1 Equalizing Frequency . . . . . . . . . . . . . . . . . .8
10.2 Equalizing Charge Method . . . . . . . . . . . . . .9
10.3 Equalizing Individual Cells . . . . . . . . . . . . . . .9
10.4 Equalizing Charge—Electrolyte Levels . . . . .9
SECTION 11
11.0 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . .9
11.1 Hydrometer Readings . . . . . . . . . . . . . . . . .10
11.2 Correction for Temperature . . . . . . . . . . . . .10
11.3 Correction for Electrolyte Level . . . . . . . . . .10
11.4 Specific Gravity Range . . . . . . . . . . . . . . . .10
TABLES
TABLE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TABLE B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TABLE C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TABLE D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
TABLE E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
STATIONARY BATTERY MAINTENANCE
REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
FIGURES
FIGURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
FIGURE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FIGURE 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
FIGURE 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
FIGURE 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
FIGURE 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
FIGURE 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
FIGURE 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
FIGURE 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
FIGURE 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
FIGURE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SECTION 1
1.0 General Information
D. When preparing electrolyte, always pour acid into water,
NEVER
will result in excess heat and violent chemical reaction
which may cause serious injury to personnel.
water into acid. Failure to follow this precaution
Caution! Before proceeding with the unpacking, handling,
installation and operation of this lead-acid storage battery,
the following general information should be reviewed together with the recommended safety precautions.
A lead-acid battery is an electro-chemical device containing
e
lectrolyte which is a dilute solution of sulfuric acid and
water. This electrolyte is corrosive and can cause injury.
L
ead-acid batteries, when installed, are capable of high volt-
age which can cause electrical shocks to personnel.
All lead-acid batteries, in the course of normal operation,
generate gases which could be explosive.
Stationary batteries (when installed) are usually on float
charge continually, unless on discharge in the event of AC
failure, or on recharge following a discharge.
SECTION 2
BATTERY WARNING STATEMENT
DANGER
HIGH VOLTAGE
High voltages are present on most battery systems.
Exercise caution and REMOVE ALL METAL
OBJECTS FROM PERSON when working on or
around battery.
EXPLOSIVE GASES
Gases produced by battery can be explosive. DO NOT
SMOKE, USE AN OPEN FLAME, CREATE AN ARC
or SPARKS IN VICINITY OF BATTERY. WEAR EYE
PROTECTION.Personnel should discharge static
charges from their person to ground before working on
battery. Ventilate well in an enclosed space and when
charging.
ACID BURNS
Battery contains SULFURIC ACID WHICH CAN
CAUSE SEVERE BURNS. Avoid getting in eyes, on
skin,or on clothing.In case of contact, flushimmediately and thoroughly with clean water. OBTAIN MEDICAL
ATTENTION.
2.0 Safety Precautions
A. Wear rubber apron, gloves and safety goggles (or face
shield) when handling, installing, or working with batteries. This will help prevent injury due to splashing or
spillage of sulfuric acid.
E. If electrolyte comes into contact with skin or clothing,
immediately wash with water and neutralize with a solution of baking soda and water. Secure medical treatment. If electrolyte comes into contact with the eyes,
wash or flush with plenty of clean water. Secure medical
treatment immediately.
F. Exercise care when handling cells. When lifting straps
and strap spreaders are provided, use them with appropriate mechanical equipment to safely handle cells and
avoid injury to personnel.
G. Promptly neutralize and remove any electrolyte spilled
when handling or installing cells. Use a baking soda/water
solution (1 lb. per gallon of water) to prevent possible
injury to personnel.
H. Make sure that all battery connections are properly pre-
pared and tightened to prevent possible injury to personnel or failure of system.
I. Familiarize personnel with battery installation, charging
and maintenance procedures. Restrict access to battery
area, permitting trained personnel only, to reduce the
possibility of injury.
J. Whenever possible, when making repairs to charging
equipment and/or batteries, interrupt AC and DC circuits
to reduce the possibility of injury to personnel and damage to system equipment. This is particularly important
with high voltage systems (110 volts and above).
K. When maintaining a connected battery string, care
must be taken to prevent a build-up of static charge.
This danger is particularly significant when the worker is
electrically isolated, ie. 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. Wearing a
ground strap while working on a connected battery string
recommended.
is not
NOTE: 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. Here again, 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.
B. Prohibit smoking. Keep flames and sparks of all kinds away
from vicinity of storage batteries as liberated or entrapped
hydrogen gas in the cells may be exploded,causing injury to
personnel and damage to cells.
C. Never place metal tools on top of cells, since sparks due to
shorting across cell terminals may result in an explosion of
hydrogen gas in or near the cells. Insulate
protect against shorting.
tool handles to
SECTION 3
3.0 Receipt of Shipment
Immediately upon delivery by the carrier, examine for possible damage caused in transit. Damaged packing material or
staining from leaking electrolyte would indicate rough handling.
1
If such conditions are found, make description notation on
delivery receipt before signing. If cell damage is found, request
an inspection by the carrier and file a damage claim. Also notify local
GNB representative of action taken.
3.1 Concealed Damage
Storage beyond the above stated periods can result in sulphated plates which can be detrimental to battery life and
performance.
he battery should be given its initial charge (see Section
T
8.0) before the end of the above stated storage intervals and
repeated for each additional storage interval.
Shortly after receipt (within 15 days), examine all cells for concealed damage. Pay particular attention to packing material
exhibiting damage or electrolyte staining. Perform examination
prior to installation and disposal of packing materials. Cells with
electrolyte levels more that 1/2" below top of plates have suffered probable permanent damage due to plate exposure to air.
If this condition or other cell damage is found, request an inspection by the carrier immediately and file a concealed damage
claim. Examine cells for container damage, misaligned elements, broken plates, or any other visible damage.
3.2 Electrolyte Levels
Cells are shipped with electrolyte levels about 1/8" below the
high level line. During shipment, the levels drop due to the loss
of gases from internal cell components. The amount of drop in
level will vary with each type of cell. Electrolyte levels, when
received, may range from the high level line to slightly below the
low level line. If this condition exists, make no addition of electrolyte or water at this time (see Section 8.2). If certain cells
have low electrolyte levels, with less than 1/2" of plates exposed
to air, add battery grade sulphuric acid of the same specific gravity as the remaining cells; thus bringing low level cells up to the
average level of other cells.
SECTION 4
4.0 Storage Prior to Installation
If permanent installation is deferred for an extended time
eriod, the battery may be temporarily connected and main-
p
tained on a floating charge (see Section 9).
Failure to charge in accordance with the above can void the
battery's warranty.
4.4 Dry-Charged Batteries
For batteries shipped dry-charged, follow special handling
and preparation instructions supplied as well as appropriate
sections of this Manual.
SECTION 5
5.0 Rack Assembly
Assembly of the battery rack should be completed in accordance with the GNB drawing and/or instructions included
with the rack.
SECTION 6
6.0 Unpacking and Handling
Most cells are packed in individual corrugated cartons.
Some smaller size cells are packed in a master carton containing 2 (two) or 3 (three) cells. Cartons are shipped on
wood pallets.
4.1 Storage Location
If the battery is not to be installed at the time of the receipt, it is
recommended that it be stored indoors in a cool, 60°F (15.6° C)
to 90° F (32° C), clean, dry location. Do not top load pallets or
possible cell damage may occur. Storage or transport of flooded
lead-acid batteries at temperatures exceeding 120°F (49°C) can
cause detimental effects on plastic components and battery
state of health which may void warranty.
4.2 Parts and Accessories
Prior to planned installation of battery, the separately packaged
parts and accessories should be opened and checked against
shipping invoice for completeness. Discovery of missing or
incorrect parts during installation may cause delays resulting
from reordering and shipment of replacements. Store parts in
safe location to prevent loss.
4.3 Storage Interval
For batteries shipped wet, fully-charged, the following storage
intervals from date of shipment to date of installation and initial
charge should not be exceeded:
Lead-Antimony Types:
Three (3) Months
Lead Calcium Types:
Six (6) Months
Figure 1
2
Remove material holding cartons to pallets, exercising care
when cutting banding material to prevent injury. If individual
cells are to be moved to another location, do not remove carton at this time. Exercise caution if using a two-wheeled
hand truck and, to prevent spillage of electrolyte, do not tilt
cell more than 25 degrees from vertical. When cells have
been brought to the installation sight, remove carton sleeve
and top corrugated spacers.
7.3 Temperature Variation
The location of rack arrangement should result in no greater
than 5°F (2.78°C) variation in cell temperatures in a series
string at any given time. If a greater variation is found, steps
should be taken to correct the condition. When uniform cell
temperature is maintained, the need for equalizing charges
may be eliminated or reduced in frequency.
DO NOT LIFT CELLS BY THEIR TERMINAL POSTS.
Support the cells from the bottom when handling and
unpacking. In general, units weighing less than 75 pounds
are handled manually, being supported from the bottom.
After removal of outer carton and top spacers, the cell should still
be resting in the bottom corrugated tray. This tray is designed to
be easily broken away to permit positioning of a lifting strap
under the cell with a minimal amount of cell tilting.
A lifting strap and a strap spreader are furnished for use with
mechanical lifting devices, when cells weigh 75 pounds or
more. See Figure 1 which shows typical positioning of strap
and spreader. Large cells are provided with 2 lifting straps
and a special spreader for stability in handling during installation.
Always use lifting straps and spreaders, when provided,
together with suitable mechanical lifting devices to prevent
injury to personnel or damage to cells.
Platform lifts of adequate capacity to handle cell weights and
dimensions may be used provided they are stable and capable of reaching needed heights and used on smooth and
level floor conditions.
Never slide cells across rough surfaces as severe scratching
of plastic container bottom may result in stressing and rupturing of the jar with subsequent loss of electrolyte. At all
times, exercise care when handling cells to prevent scratching of plastic jars and covers.
SECTION 7
7.0 Installation
7.1 Battery Location
It is recommended that the battery be installed in a clean,
cool, dry location. Cells should not be exposed to heating
units, strip heaters, radiators, steam pipes or sunshine
through a window. Any of these conditions can cause a serious electrolyte temperature variation among cells within a
battery (see Section 7.3).
7.2 Temperature
A battery location having an ambient temperature of 75°F
(24°C) to 77°F (25°C) will result in optimum battery life.
Batteries operated in high ambient temperatures will result
in reduced life. Therefore, for longer life and ease of maintenance, locations having cooler ambient temperatures are
recommended. The normal battery operating temperatures
are between 60°F (16°C) and 90°F (32°C).
7.4 Ventilation
In the operation of lead-acid battery whether it be on initial
charge, float charge, equalizing charge or recharge following
a discharge, hydrogen and oxygen gases are produced.
This results from electrolysis of the water portion of the electrolyte by the charging current.
Ventilation should be provided in the battery room or area to
prevent hydrogen, liberated from the cells in service, from
exceeding a 1% concentration. Concentrations above this
percentage can result in an explosive mixture, which could
be ignited by sparks from adjacent electrical equipment as
well as accidental sparks or open flames introduced by personnel. All air moved by ventilation in the battery room or
area should be exhausted into the outside atmosphere and
should not be allowed to recirculate into other confined
areas.
7.5 Placement of Cells
It is assumed at this point that the battery rack has been
assembled. Study the rack layout and wiring drawings to
determine proper location of the positive and negative terminals of the battery; this will establish correct positioning of
the initial cell on each rack row. Cells are normally installed
with plate edges perpendicular to rack length.
Measure and mark the center of the rack stringer length.
Determine the number of cells to be placed in each row.
When an odd number of cells are in the row, place the center of the initial cell at the center point of the rack stringer
length.
When an even number of cells are in the row, locate the initial cells so that the center of the space between the cells
coincides with the center mark of the stringer length.
To minimize friction of cells when transferring from platform
lift to the rack rails or for positioning of cells, talcum powder
may be used on the platform surface or plastic rack strips to
ease movement.
CAUTION!
DO NOT USE ANY OTHER TYPE OF
LUBRICANT SUCH AS GREASE OR OIL AS
THEY MAY CONTAIN MINERAL SPIRITS
WHICH CAUSE CRAZING AND CRACKING
OF THE PLASTIC JAR MATERIAL.
DO NOT USE METAL RODS, SCREWDRIVERS, ETC. THROUGH POST HOLES
TO LATERALLY MOVE CELLS AS CELL
SHORTING AS WELL AS DAMAGE TO THE
POST SEALS COULD OCCUR.
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