Exide Technologies 93.10T User Manual

®

INSTALLATION

&

OPERATING

INSTRUCTIONS

FOR TCX TUBULAR

LEAD-CALCIUM BATTERIES

SECTION 93.10T 2012-07

YOUR GNB INDUSTRIAL POWER REPRESENTATIVE

SALESPERSON ________________________________

TELEPHONE____________________________________

LOCATION______________________________________

GNB

SERVICE ASSISTANCE

1-800-241-4895

INDEX

SECTION 1

1.0 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SECTION 2

2.0 Receiving Batteries . . . . . . . . . . . . . . . . . . . .2

SECTION 3

3.0 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

SECTION 4

4.0 Battery Assembly and Installation . . . . . . . . .2

4.1 Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

4.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . .2

4.3 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . .3

4.4 Electrolyte Level . . . . . . . . . . . . . . . . . . . . . .3

4.5 Cell Positioning . . . . . . . . . . . . . . . . . . . . . . .3

4.6 Flash Arrestors . . . . . . . . . . . . . . . . . . . . . . .3

4.7 Contact Sufaces . . . . . . . . . . . . . . . . . . . . . .3

4.8 Electrical Connections . . . . . . . . . . . . . . . . . .3

4.9 Connection Resistance . . . . . . . . . . . . . . . . .3

4.10 Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . .3

SECTION 5

5.0 Equalizing Charge . . . . . . . . . . . . . . . . . . . . .3

Page

ABLES

T

TABLE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TABLE B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TABLE C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

STATIONARY BATTERY

MAINTENANCE REPORT . . . . . . . . . . . . . . . . . . .7

FIGURES

FIGURE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Page

SECTION 6

6.0 Specific Gravity . . . . . . . . . . . . . . . . . . . . . . .4

SECTION 7

7.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

SECTION 8

8.0 Cell Voltage Variation . . . . . . . . . . . . . . . . . . .4

SECTION 9

9.0 Water Addition . . . . . . . . . . . . . . . . . . . . . . . .5

SECTION 10

10.0 Tap Connections . . . . . . . . . . . . . . . . . . . . . .5

SECTION 11

11.0 Pilot Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

SECTION 12

12.0 Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

CAUTION! Before proceeding with the unpacking,

handling, installation and operation of a lead-acid storage
battery, the following general information should be reviewed
together with the recommended safety precautions.

A lead-acid battery is an electrochemical device that
contains electrolyte. The electrolyte is corrosive and can
cause injury.

Lead-acid batteries, when installed, are capable of high
voltage that can cause electrical shocks to personnel.

All lead-acid batteries in the course of normal operation
g

enerate gases that could be explosive.

material or staining from leaking electrolyte would indicate
rough handling. If such conditions are found, make notation
on delivery receipt before signing. If battery damage is
found, request an inspection by the carrier and file a damage
claim. Also notify your GNB

2.2 Shortly after receipt (within 15 days), examine all
b

atteries for concealed damage. Pay particular attention to

p

acking materials exhibiting damage or electrolyte staining.
Perform examination prior to installation and disposal of
packing materials. Examine cells for container damage,
misaligned elements, broken plates, or any other visible
damage.

®

Industrial Power representative.

SECTION 1

1.0 SAFETY

1.1 Follow your company’s safety instructions when working
with or near industrial lead-acid batteries. Thoroughly
familiarize yourself with industry and government guidelines
for charging, handling, and maintaining industrial batteries.

1.2 Assign battery and charger care to properly trained
personnel. The battery contains sulfuric acid. Avoid sulfuric
acid contact with skin, eyes, or clothing. Wear a rubber
apron, gloves, boots, and goggles or face shield when
handling, checking, filling, or charging batteries.

1.3 Keep water readily available for flushing spilled
electrolyte from eyes or skin. Obtain medical attention
immediately.

1.4 Batteries produce hydrogen. Keep open flames away.
Do not check electrolyte level with a cigarette lighter or
match. Use a flashlight or permanent lights only. Do not
smoke or create sparks when working on batteries.

1.5 Lift batteries by the provided handles. If necessary,
utilize a hoist, crane, or lift-truck. Move batteries via truck,
conveyors, or rollers. Make sure equipment is of ample
strength and properly installed. Be sure to place a rubber
mat or similar insulating material across tops of batteries
when handling.

1.6 Never lay metal tools, such as wrenches or other material
on top of batteries.

1.7 Insulate tool handles to protect against shorting.

1.8 Make sure that all battery connections are properly
prepared and tightened to prevent possible injury to
personnel or failure of system.

1.9 If acid is spilled on the floor, apply a strong neutralizer,
like baking soda. Check local regulations regarding disposal
of neutralized waste.

SECTION 2

2.0 RECEIVING BATTERIES

2.1 Immediately upon receipt of shipment, examine for
possible damage caused in transit. Damaged packing

SECTION 3

3.0. STORAGE

3.1. If the battery is not to be installed at the time of receipt,
it is recommended that it be stored indoors in a cool [16°C
(60°F) to 32°C (90°F)], clean, and dry location. Do not top
load pallets as possible battery damage may occur.

3.2. Prior to planned installation of the battery, the accessory
parts should be opened and checked against shipping
invoice (or battery system drawings) for completeness.
Checking parts before storage will eliminate potential delays
during installation.

3.3. The storage interval from date of shipment to the date of
installation/initial charge should not exceed six (6) months.
(Assumes 77°F/25°C average storage temperature. Assume
three months maximum storage time for 90°F/32°C average
temperatures.) Storage beyond the stated period can result
in sulfated plates, which can be detrimental to battery life and
performance. Failure to store the battery in accordance with
the above recommendations may void the warranty.

SECTION 4

4.0 BATTERY ASSEMBLY

AND INSTALLATION

4.1 SITE

It is recommended that the battery be installed indoors in a
clean and dry location. The battery should be shielded from
direct sunlight, heating units or steam pipes as they can
cause temperature gradients in the electrolyte and negatively
impact battery performance. The floor should be level and
capable of supporting the weight of the batteries (and rack).

4.2 VENTILATION

All lead-acid batteries in the course of normal operation
generate gases that could be explosive.Ventilation should be
provided in the battery room to prevent hydrogen gas from
exceeding a concentration of 1%. Concentrations above this
value can result in an explosive mixture that can be ignited
by sparks from adjacent electrical equipment. All air moved
by ventilation should be exhausted to the outside and not be
allowed to re-circulate into other confined areas.

2

4.3 TEMPERATURE

A battery location having an ambient temperature of 25°C
(

77°F) will result in optimum battery life. Batteries operated
above this temperature will suffer reduced life, while batteries
operated below this temperature may exhibit suppressed
c

apacity. Though brief temperature excursions between 0°C
(32°F) and 40°C (104°F) can be tolerated, the normal
o

perating temperature is between 16°C (60°F) and 32°C
(

90°F).

4.4 ELECTROLYTE LEVEL

During normal operation, the electrolyte level should be
between the high and low marks on the battery container.
Upon receipt of the battery, the electrolyte level may be a bit
lower than this mark; after charging, it may be higher. The
reason is that gas bubbles formed during charge will adhere
to the battery plates, displacing and raising the electrolyte
level. Do not attempt to adjust the electrolyte either
immediately upon receipt or immediately after the initial
charge.

4.5 CELL POSITIONING

By now, it is assumed that the rack has been assembled.
Determine the desired position of the positive and negative
terminals. Measure and mark the center of the rack.
Determine the number of battery blocks that will fit on a
step/tier of the rack. If that number is odd, position the
centerline of the first battery block on the centerline of the
rack step/tier. If the number is even, position the end of
battery block on the centerline of the rack step/tier. Work
from the center out, positioning the positive terminal next to
the negative terminal of the adjacent cell.

4.6 FLASH ARRESTORS

After the batteries have been positioned on the rack (but
before the inter-unit and inter-tier connections have been
made), replace the shipping caps with the provided
flame/flash arrestors.

4.7 CONTACT SURFACES

Gently clean the contact surfaces of the battery terminal
posts using a 3M Scotch Brite or similar scouring pad. Coat
the electrical contact surfaces lightly with provided No-Ox
grease.

connecting the battery string to the charger/load, measure
the total voltage at the battery terminals. The voltage should
be equal to the number of cells times the voltage of one cell.
For example, 60 cells times 2.09 volts per cell = 125.40 volts
(1.250 SG) or 60 cells times 2.05 volts per cell = 123.0 volts
(1.215 SG).

Individual cell voltage readings are possible with the removal
o

f the small black plastic caps on top of the battery cover.
These cell voltage caps can be removed gently with the use
of a pair of pliers. Initially, the cell voltage measurement
points maybe covered with epoxy. FIRMLY insert voltage
meter probes to establish a good connection/reading. When
individual cell voltage readings are completed, lightly coat
the measurement points with NO-OX grease and replace the
small black plastic caps.

4.9 CONNECTION RESISTANCE

Connection resistance or micro-ohm (µΩ) measurements
should be taken at the time of installation and annually
thereafter. Initial measurements at installation become
benchmark values. Future values are compared to this
benchmark as an indication of connection integrity.
Re-torque of connections should be performed annually or
when connection resistance increases to more than 20%
over the benchmark value.

4.10 INITIAL CHARGE

The first charge that the battery receives after shipping,
storage and installation is very important as it may affect the
life of the battery. Determine the maximum charge voltage
output that the charge system can provide and charge the
battery in the least amount of time possible according to
Table A. This maximum voltage divided by the number of
cells connected in series is the maximum charge voltage per
cell (VPC). If long periods of continuous charging are not
possible at the installation, (e.g. photovoltaic applications)
the battery should be charged where such capability exists.

The recommended times given in TABLE A are considered
minimum. Charge the cells until the charge current tapers
and stabilizes for 3 hours. Then, charge the battery for the
times and voltages given in TABLE A.

SECTION 5

4.8 ELECTRICAL CONNECTIONS

Install the provided stainless steel hardware and torque the
cell connector (or terminal plate) to the post. Target
connection torque is 100 - 110 inch-lbs. (11.3-12.0 N-m). Re­torque the stainless steel hardware 24 hours after the initial
tightening to allow for relaxation of the lead-hardware
connection.

Electrical connections must be clean to minimize voltage
drop and prevent connector heating. If corrosion is
observed, DO NOT RE-TORQUE! The connection must be
disassembled, cleaned, neutralized, and then re-torqued.

Install the inter-tier cables as necessary. Do not connect
cables directly to the battery post. Utilize the terminal plates
provided for main terminal and inter-tier connections. Re­check to be certain that the batteries are connected positive
terminal to negative terminal throughout the string. Before

5.0 EQUALIZING CHARGE

An equalizing charge is a special charge given to the battery
in operation when one of the following conditions exist:

• The specific gravity of cells is more than 10 points lower

than its full charge value.

• The on-charge voltage of any cell is more than 0.05 VPC

below the average.

• It is desired to recharge the battery in the least amount of

time possible.

• It has been a year since the last equalizing charge.

5.1. Equalize the cells until the charge current tapers and
stabilizes for 3 hours, then charge according to the values
given in TABLE B.

3

TABLE A – Initial Charge Voltage per Cell

(VPC) and Time after Current

Stabilization for 1.215 and 1.250 SG TCX

Time (hours)

VPC 1.215 SG 1.250 SG

2.32 222 412

2.35 166 304

2.38 126 222

2.41 96 164

2.42 88 148

2.50 42 78

TABLE B – Equalizing Voltage per Cell

(VPC) and Time after Current

Stabilization for 1.215 and 1.250 SG TCX

Time (hours)

VPC 1.215 SG 1.250 SG

2.32 111 206

2.35 83 152

2.38 63 111

2.41 48 82

2.42 44 74

2.50 21 39

decreases as the battery is discharged and increases as the
battery is recharged.

6

.2 Specific gravity is expressed to the third decimal place,
e.g.1.250, and is measured by a hydrometer float enclosed
in a glass barrel/rubber bulb syringe. Holding the hydrometer
vertically, draw sufficient electrolyte into the barrel. The
reading should be taken when a) no hand pressure is being
e

xerted on the bulb and b) the float is not touching the side
of the hydrometer glass. The gravity is then read on the
hydrometer scale at the flat surface of the electrolyte. (See
Figure 1).

6.3 When making specific gravity readings, corrections must
be made for variations in the temperature of the electrolyte.
For each 1.67°C (3°F) difference in temperature of the
electrolyte above 25°C (77°F), add one point (0.001) to the
hydrometer reading. Conversely, for each 1.67°C (3°F)
difference below 25°C (77°F), subtract one point (0.001) from
the observed hydrometer reading.

Example:

Hydrometer Cell Corrected to

Reading Temperature Correction 25°C (77°F)

1.253 20°C (68°F) -.003 1.250

1.257 30°C (86°F) +.003 1.260

1.254 35°C (95°F) +.006 1.260

Reading

SECTION 6

6.0 SPECIFIC GRAVITY

6.1 The Specific Gravity (SG) of a fully charged battery is

1.215 ± 0.010 or 1.250 ± 0.010. Specific gravity is used to
determine the cell’s state of charge (SOC). The value

SECTION 7

7.0 OPERATION

7.1 Operating the battery outside the specified float
voltage range can be detrimental to battery life and
performance. Failure to operate the battery within the
specified float range may void the warranty.

TABLE C – Recommended Float
Voltages @ 25°C (77°F)

SG Float VPC

1.215 2.17-2.25

1.250 2.25-2.35

7.2 Ideally, 108% to 115% of the ampere-hours removed
during discharge from a battery should be restored upon
recharge to insure 100% state of charge.

7.3 The battery should not be over-discharged. Do not
discharge the battery lower than 1.65 VPC for high rates (e.g.
15 minutes) or lower than 1.85 VPC for very low rates (e.g.
24 hours).

SECTION 8

Figure 1

8.0 CELL VOLTAGE VARIATION

8.1 Temperature. Cell voltage variation can occur due to
temperature. To properly analyze battery voltage uniformity
within the string, voltage readings should be corrected for
(battery electrolyte) temperature. The battery temperature
correction factor for voltage equals 0.003 volts for each
degree Fahrenheit (0.0055 V/°C) using a base 77°F (25°C).

4

The correction factor is added to the measured battery
voltage above 77°F(25°C). The correction factor is
subtracted from the measured battery voltage below
77°F(25°C).

Example:

Cell Voltage Corrected

Voltage Cell Correction Cell Voltage

Readings Temperature Factor @ 25°C (77°F)

2.300 20°C (68°F) -0.027 2.273

2.300 30°C (86°F) 0.027 2.327

2.300 35°C (95°F) 0.054 2.354

8.2 Damp Covers. Cell Voltage variation can occur when the
battery covers become wet or damp. Electrolyte spilled from
specific gravity measurements can cause parasitic current
paths across the tops of cell covers. These paths reduce the
quantity of current going through the battery and result in
undercharging and voltage variation. Eliminate the paths by
cleaning the battery cover with a solution of baking soda and
water (1 pound soda per gallon of water). Apply a cloth
dampened with the solution and neutralize acid until fizzing
stops, then wipe area with a clean cloth dampened only with
water to remove the soda. Do not get any of the baking soda
solution inside the battery.

SECTION 9

9.0 WATER ADDITIONS

indicator of the battery condition between scheduled overall
individual cell readings.

1

1.2 It is recommended that a different pilot cell be selected
each year to provide a representative specific gravity for the
battery.

SECTION 12

12.0 Records

1

2.1 A complete recorded history of the battery operation is
required. These records will show when corrective action
may be required to eliminate charging, maintenance or
environmental problems. These records will also be required
for consideration of warranty.

12.2 Data should be recorded on the Stationary Battery
Maintenance Report shown at the end of this manual.
Report headings should be filled in completely during the
actual dates(s) of installation.

12.3 Upon completion of the initial charge and with the
battery floating at the recommended float voltage for one
week, read and record individual cell voltages, connection
resistances, specific gravities (corrected to 25°C / 77°F),
ambient temperature plus cell temperatures and electrolyte
levels for 10% or more of the cells. The cell temperature
readings should be taken at each step/tier of the rack to
reflect the actual conditions.

9.1 The water in the electrolyte of a battery is lost by
evaporation and through hydrolysis into its component
hydrogen and oxygen gases. Both the water vapor and
electrolytic gases are liberated to the environment through
the cell vent. Periodically it will be necessary to add water to
the battery. When necessary to add water to the battery, do
so before the battery is equalized. This will allow added
water and electrolyte to properly mix.

9.2 The use of distilled or de-ionized water is recommended
to minimize the chance of adding harmful impurities into the
battery.

SECTION 10

10.0 TAP CONNECTIONS

GNB advises against tapping portions of the battery as this
condition may cause unbalanced charging. The untapped
portion may get overcharged while the tapped portion may
become undercharged resulting in poor performance and
reduced life.

12.4 The first set of readings will be the basis for comparison
with subsequent readings to reflect possible operating
problems and the need for corrective action.

12.5 Monthly - Observe the general appearance and
cleanliness of the battery. Record battery terminal voltage.
Check electrolyte levels and adjust if necessary. Check for
cracks in the battery and any signs of leakage. Note any
evidence of corrosion at terminals and/or connectors.
Record pilot cell voltage, specific gravity and temperature.

12.6 Quarterly - Supplement the monthly inspection and
record keeping with all battery voltages and specific
gravities. Check and record the electrolyte temperature of
one cell on each level of the rack(s).

12.7 Annual - Supplement Quarterly reports by tightening all
bolted connections to the specified torque values. Record
connection resistances of each battery post to battery post,
battery post to terminal. Remake any connections that are
more than 20% above installation base value. Check
integrity of the rack.

12.8 Record dates of any equalizing charges as well as total
quantity of water when added. Always record any
maintenance and/or testing conducted.

SECTION 11

11.0 Pilot Cell

11.1 A pilot cell is selected in the series string to reflect the
general condition of all cells in the battery regarding specific
gravities, float voltage and temperature. It serves as an

5

GB-1000F

®

A

Division of Exide Technologies

WHEN ADVICE IS DESIRED PLEASE FORWARD A DUPLICATE OF THIS REPORT TO YOUR GNB REPRESENTATIVE

6

STATIONARY BATTERY PLASTIC CELL NUMERAL APPLICATION

®

To insure proper adhesion of the pressure sensitive plastic
cell numerals, and polarity markings supplied with your
GNB®Flooded Classic Battery, the following procedure
should be followed:

4. Numerals are shipped mounted on a plastic backing

strip. They are easily removed by peeling back the plas­tic strip. Keep finger contact with adhesive backing on
numeral to a minimum.

1. Numerals and polarity markings should not be applied
until after the cells have been installed on the rack. It is

ecommended that they be applied to jar surfaces only,

r
and not to cell covers or rack rails.

2. Clean the plastic jar surface, in the area where the
numeral is to be located, by using a cloth dampened
with a washing soda solution. Immediately dry the area
using a soft dry cloth to remove residual washing soda.

CAUTION!!

they may cause damage to the plastic jar material.

3. It is a general practice to designate the positive terminal
cell as #1 with succeeding cells in series in ascending
order.

Do not use any solvent type materials as

TYPICAL BATTERY NAMEPLATE

5. Locate and place numeral on side of jar, being careful
that there is no conflict with electrolyte level lines or side

ails of SEISMIC TYPE RACKS. For clean appearance,

r
exercise care in numeral placement so that all the
numerals are in the same relative position on each cell.

Install polarity markings on the appropriate cells in the
same manner.

6. Following application of cell numerals and polarity mark­ings, use a dry cloth to rub entire surface of each label
to insure proper surface contact.

Note: Design and/or specifications subject to change
without notice. If questions arise, contact your local
sales representative for clarification.

NO. OF CELLS TYPE SERIAL NO.

CAPACITY AMPERE HRS. AT HR. RATE

SPECIFIC GRAVITY

GNB Industrial Power, Aurora, IL 60504

7

NOTES

8

A Division of Exide Technologies

®

GNB Industrial Power –
The Industry Leader.

GNB Industrial Power, a division of Exide Technologies, is a
global leader in network power applications including

communication/data networks, UPS systems for computers
and control systems, electrical power generation and
distribution systems, as well as a wide range of other
industrial standby power applications. With a strong
manufacturing base in both North America and Europe and a
truly global reach (operations in more than 80 countries) in
sales and service, GNB Industrial Power is best positioned to
satisfy your back up power needs locally as well as all over
the world.

GNB Industrial Power

USA – Tel: [phone]
Canada – Tel: [phone]

www.gnb.com

Based on over 100 years of technological innovation the
Network Power group leads the industry with the most
recognized global brands such as ABSOLYTE
FLOODED CLASSIC®, MARATHON®, ONYX®, RELAY GEL®,
SONNENSCHEIN
symbolize quality, reliability, performance and excellence in
all the markets served.

GNB Industrial Power takes pride in its commitment to a
better environment. Its Total Battery Management program,
an integrated approach to manufacturing, distributing and
recycling of lead acid batteries, has been developed to
ensure a safe and responsible life cycle for all of its products.

®

, and SPRINTER®. They have come to

®

, GNB

®

SECTION 93.10T 2012-07