Exide Technologies 95.10 User Manual
INSTALLATION
&
OPERATING
INSTRUCTIONS
INDEX
Section 1 - GENERAL INFORMATION
1.0 Relay Gel Batteries 1
Section 2 - SAFETY PRECAUTIONS
2.0 Safety Alert 1
2.1 Sulfuric Acid Burns 1
2.2 Explosive Gases 1
2.3 Electrical Shock and Burns 1
2.4 Important Message 2
Section 3 - RECEIPT OF SHIPMENT
3.0 Delivery Inspection 2
3.1 Concealed Damage 3
Page
Section 4 - STORAGE PRIOR TO INSTALLATION
4.0 Storage Location 3
4.1 Storage Interval 3
Section 5 - GENERAL INSTALLATION CONSIDERATIONS
5.0 Battery Location 3
5.1 Battery Orientation 4
5.2 Ventilation 4
5.3 Temperature Variations 4
5.4 Floor Loading 4
5.5 Floor Anchoring 4
5.6 Open Circuit Voltage Check 5
Section 6 - RACK SYSTEM - INSTALLATION
6.0 Placement of Units 5
(continued on next page)
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INDEX (continued)
Section 7 - ELECTRICAL INSTALLATION CONSIDERATIONS
7.0 Connecting Cables 5
7.1 Paralleling 5
7.2 Connection Preparation 5
7.3 Torqueing 6
7.4 Connections 6
7.5 Connection Check 6
7.6 Battery To Charger Connection 6
7.7 Connection Resistance 7
Section 8 - INITIAL CHARGE
8.0 Constant Voltage Initial Charge 7
Section 9 - OPERATION
Page
9.0 Float Charge 8
9.1 Float Voltages 8
9.2 Voltmeter Calibration 9
9.3 Recharge 9
9.4 Determining State of Charge 10
9.5 Effects of Temperature 10
9.6 Effects of Float Voltage 11
Section 10 - EQUALIZATION
10.0 Equalizing Charge 11
10.1 Equalizing Frequency 11
Section 11 - MAINTENANCE SCHEDULE 12
Section 12 - TAP CONNECTIONS 13
Section 13 - TEMPORARY NON-USE 13
Section 14 - UNIT CLEANING 13
Battery Maintenance Report Template 14
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SECTION 1 - GENERAL INFORMATION
1.0 RELAY GEL VRLA BATTERIES
In normal use, the battery will not release hydrogen gas or acid mist, and will not leak
acid. However, there is the possibility that under abnormal operating
conditions hydrogen gassing, acid mist, and leaking electrolyte could occur. Thus
®
GNB
Industrial Power recommends that Section 2 of these instructions entitled
“SAFETY PRECAUTIONS” be reviewed thoroughly and strictly followed when working
with batteries.
SECTION 2 - SAFETY PRECAUTIONS
2.0 SAFETY ALERT
The safety alert symbol at left appears
throughout this manual. Where the symbol
appears, obey the safety message to avoid
personal injury.
CAUTION
Before proceeding with the unpacking, handling, installation and
operation of this sealed lead-acid storage battery, the following
general information should be reviewed together with the
recommended safety precautions.
DANGER
2.1 SULFURIC ACID BURNS
SULFURIC ACID BURNS
Batteries contain sulfuric acid which can cause burns and other serious injury. In the
event of contact with sulfuric acid, 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 to prevent injury if contact is made with
the acid.
DANGER
2.2 EXPLOSIVE GASES
EXPLOSIVE GASES
Batteries could generate explosive gases, which when released, can explode and
cause blindness and other serious injury. If the safety vent opens while the explosive
gases are being generated (e.g., in the event of a charger malfunction), these explosive
gases will be released.
Keep sparks, flame and smoking materials away from the battery area and
explosive gases.
DANGER
ELECTRICAL SHOCK
2.3 ELECTRICAL SHOCK AND BURNS
AND BURNS
All installation tools should be adequately insulated to minimize the possibility of shorting across connections.
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Never lay tools or other metallic objects on the batteries as shorting, explosions and
personal injury may result.
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.
Loose or dirty connectors/connections can cause battery fires. Keep all connectors/
connections clean and torques at proper values. Keep outside of batteries clean and
dry. Neutralize any acid corrosion with a cloth moistened with a solution of baking soda
and water, then wipe off all traces of soda.
Do not move or shift racks/cabinets once installed without first disconnecting load to
rack/cabinet and all inter-rack/cabinet connections. Consult wiring diagrams for location
of these connections.
Do not lift cells by terminal posts. Do not tamper with post seals, protective covers,
pressure relief vents or other battery components.
Disconnect the AC and DC circuits before working on batteries or charging equipment.
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.
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 before proceeding to install or service these batteries. Refer to
applicable federal, state and local regulations as well as industry
standards.
2.4 IMPORTANT MESSAGE
The symbol at left indicates an important
message. If not followed, damage to and/or
impaired performance of the battery may
result.
SECTION 3 - RECEIPT OF SHIPMENT
3.0 DELIVERY INSPECTION
Immediately upon delivery, examine for possible damage caused in transit. Damaged
packing material 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 immediately. Any battery with post or seal damage
should be replaced.
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3.1 CONCEALED DAMAGE
Within 15 days of receipt, examine all batteries for concealed damage. If damage is noted,
immediately request an inspection by the carrier and file a concealed damage claim. Any
delay in notifying carrier may result in loss of right to reimbursement for damages.
SECTION 4 - STORAGE PRIOR TO INSTALLATION
4.0 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. Do not stack pallets or
possible battery damage may occur.
4.1 STORAGE INTERVAL
The storage intervals between the date of shipment and the date of initial charge
should not exceed six (6) months. The battery should be given its initial charge (refer to
Section 8) before the end of the above stated storage interval. Storage at elevated
temperatures will result in accelerated rates of self discharge. A general rule of thumb
is that for every 10°C (18°F) increase above 25°C (77°F) the time interval for initial
charge should be halved. For example, if a battery was stored at 35°C (95°F) the initial
charge time interval would be 3 months. If the battery was stored at 30°C (86°F) the
initial charge time interval would be 4.5 months. Storage beyond these periods without
proper charge can result in excessive sulfation of the plates which is detrimental to
battery performance and life.
SECTION 5 - GENERAL INSTALLATION CONSIDERATIONS
Prior to starting the installation of the RELAY GEL battery system, a review of this section is strongly recommended.
5.0 BATTERY LOCATION
It is recommended that the battery be installed in a clean, cool, dry location. Floors
should be reasonably level and able to support the battery weight. A location having an
ambient temperature of 25°C (77°F) will result in optimum battery life and performance.
Temperatures below 18°C (65°F) reduce battery efficiency. Temperatures above 27°C
(80°F) will result in a reduction of battery life. Continuous operation above 50°C (122°F)
is not recommended.
A designated aisle space should be provided to permit initial installation and future
service or surveillance of the batteries.
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