SLS
RAILWAY DIESEL STARTING
BATTERIES
INSTALLATION AND OPERATING INSTRUCTIONS
CAUTION – READ THE ENTIRE INSTALLATION AND OPERATING INSTRUCTION BEFORE PLACING BATTERIES IN SERVICE.
1.0 SAFETY
• Assign battery and charger care to properly
trained personnel. Follow your company’s Safety
Instructions when working with or near diesel
starting batteries. Thoroughly familiarize yourself
with industry and government guidelines (OSHA,
ANSI, etc.) for charging, handling and maintaining
diesel batteries.
• In normal use, the Element battery will not
generate or release hydrogen gas, will not release
acid mist, and will not leak acid. This is because
Element batteries are designed differently than
conventional lead acid batteries, in order to
operate with low maintenance. However, there
is the possibility that under abnormal operating
conditions, or as a result of damage, misuse and/
or abuse, these potentially hazardous conditions
(hydrogen gassing, acid mist, and leaking
electrolyte) could occur.
• 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.
• 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,
flames, and smoking materials away from the
battery area.
• Lift batteries with a hoist, crane, lift truck, or
similar equipment. Move batteries on trucks,
conveyors or rollers. Make sure equipment is of
ample strength and properly installed.
• Never lay metal tools, such as wrenches or other
material on top of a battery.
• Disconnect the battery from the locomotive when
performing main- tenance and repair on the motor
or the electrical system.
• Open or “break” the battery circuit before
attempting repairs to terminal connections.
2.0 RECEIVING BATTERIES
Immediately upon delivery, examine the battery for
possible damage caused in transit. Damaged packing
material or staining from leaking electrolyte could indicate
rough handling.
If there is evident damage, the receipt should be signed
and both copies (carrier’s and receiving copies) marked
“Shipment Received Damaged”. The carrier should
be called immediately and asked to make a “Carrier’s
Inspection for Damage Report”.
If “concealed” damage is later detected, the carrier should
be called immediately and requested to make a “Carrier’s
Inspection for Concealed Damage Report”. After
inspection by the carrier, arrangements should be made
with the local GNB® Industrial Power representative to
have the battery repaired before placing it in service.
CAUTION
Before placing the battery in service, review
and adhere to the Safety Guidelines listed in
Section 1.0.
3.0 INITIAL CHARGE
Batteries lose some charge during shipment as well as
during the period prior to installation. A battery should
be installed and given its initial charge as soon after
receipt as possible. Battery positive (+) terminal should
be connected to the charger positive (+) terminal and the
battery negative (-) terminal should be connected to the
charger negative terminal.
3.1 Constant Voltage Method
CAUTION
Do not use chain or wire rope slings.
POST THESE INSTRUCTIONS IN THE
BATTERY MAINTENANCE AREA.
Constant voltage is the only recommended charging
method.
Determine the maximum voltage that may be applied
to the system equipment. This voltage, divided by the
number of cells connected in series (16 cells per battery
tray) will establish the maximum volts per cell (VPC) that
is available.
Input from the generating system to the battery is
controlled by the voltage regulator. It is important to make
sure that the regulator is known to be in a satisfactory
operating condition and adjusted to the correct operating
voltage.
Table A lists the recommended voltages and charge
times for the initial charge. Select the highest voltage the
system allows to perform the initial charge in the shortest
time period.
TABLE A
Initial Charge (77°F)
Volts per Volts per Time-Hrs
Cell Battery (Minimum)
2.30 36.80 24
2.35 37.60 12
NOTE: Time periods listed in Table A are for77°F (25°C).
For other temperatures, a compensation factor of 0.003
V/°F (0.0055V/°C) per cell is recommended. The minimum
voltage is 2.20 VPC, temperature correction does not
apply below this voltage. The maximum voltage is 2.35
VPC, temperature correction does not apply above this
voltage.
V
corrected
= V
25°C
- ((T
- 25°C) x (.0055V/°C))
actual
or
= V
V
corrected
77°F
- ((T
- 77°F) x (.003V/°F))
actual
If the voltage regulator is not in good operating condition
or is adjusted to an incorrect operating voltage, the
battery will not function satisfactorily because the charge
it receives will be insufficient (undercharge) or excessive
(overcharged). In severe cases of bad regulation and
overcharging, failure can take place within a year.
A bad regulator or one set too low can cause undercharge
– a condition that will literally starve the battery to death.
In this case, more power is drawn out of the battery than
is replaced. As a result, the battery gradually runs down
until it is so low that it fails completely. Undercharge is
indicated by decreasing open circuit voltage readings.
The correct operating or battery float voltage to be set
on the regulator is that which will maintain the battery in
a fully charged condition. This correct setting depends
on two factors – operating temperature and locomotive
work schedule. It is recommended that voltage regulator
adjustments be made while the engine is at operating
speeds.
See Section 7 for temperature compensated operating/
float voltages.
7.0 OPERATING VOLTAGES
See Section 6.0 Voltage Regulator for recommended float
voltage ranges at various ambient temperature ranges.
4.0 INSTALLING THE BATTERY (BLOCKING)
Negligence in properly blocking the battery in the
compartment could permit battery shifting and may cause
damage. All trays should be securely blocked, but care
should be taken to avoid over tight wedging. Clearance
of about 1/8” should be left between the blocking and the
battery trays.
5.0 TERMINAL CONNECTIONS
Make original connections clean and tight. Inspect
terminal connections regularly and keep them clean and
tight. Corrosion can be reduced by greasing connections
with “NO-OX” grease after cleaning with household
ammonia or baking soda in water (1 lb/gal water).
6.0 VOLTAGE REGULATOR
The battery is only one part of a total system, all of the
parts of which are interrelated and interdependent. The
battery simply stores energy in a chemical form for use
when the generating system is not running. It is not a
source of power, but merely a reservoir. The battery
supplies power for starting, but as soon as the engine is
running, the generating system must replace the power
withdrawn from the battery.
7.1 Single Step Charging
Correct battery float voltage at different environmental
temperatures are as follows:
Temperature Float Voltage
(Volts per Cell)
Greater than 90°F 2.20 – 2.23
65°F to 90°F 2.23 – 2.27
50°F to 65°F 2.27 – 2.31
Less than 50°F 2.31 – 2.35
The effect of the locomotive work schedule on the correct
float voltage is determined with experience. If the battery
is used for starting very frequently, float voltages should
be set at the higher end of the range indicated at the
appropriate temperature; similarly, for infrequent battery
usage, float voltages should be set at the lower end of the
range.
7.2 Two Step Charging
For two step charging the following strategy should
be followed:
Bulk Charge: Charge at temperature compensated
constant voltage between 2.33 and 2.38 vpc. Charge
for 6 hours or until current decreases to Current
stated in Table B or until temperature reaches 104°F
(40°C). Switch to float charge.
TABLE B
Page 3 Chart
Chart 1: Two Step Charging
Battery Current (amps)
SLS-710 21.3
SLS-550 16.5
SLS-520 15.6
SLS-500 15.0
SLS-500E 15.0
Float Charge: Charge at temperature compensated
constant voltage between 2.20 and 2.35 vpc. If
temperature exceeds 131 deg F (55 deg C), decrease
voltage to 2.20 vpc.
The maximum charge rate for each battery type is:
SLS-710….180 amps
SLS-550….138 amps
SLS-520….132 amps
SLS-500…..125 amps
SLS-500E…125 amps
Voltage tolerances +/- 1% and current tolerances +/- 0.5
amp.
Chart 1 Two Step Charging
2.4
2.38
2.36
2.34
2.32
2.3
2.28
2.26
Voltage (volts per cell)
2.24
2.22
2.2
2.18
0 10 20 30 40 50 60
32
50
68
25
86
77
Temperature
2
FLOAT
CHARGE
104 122 140
(deg C)
(deg F)
9.1 Each Shop Visit – Tray Covers Remain in Place
• Check the battery State of Charge (SOC) by
measuring the Open Circuit Voltage (OCV)
with “No Load” attached to the battery. A fully
charged battery will show an OCV of 68.8 volts
per set or 34.4 volts per tray. If the battery is
more then 15% discharged, with OCV less than
67.8 volts per set or 33.9 volts per tray, apply a
“Boost Charge” of 2.35 volts per cell or 75.2 volts
per set until the charge current is reduced to a
value that is equal to 3 amps per 100 Amp-hour
of the C/8 capacity rating.
• Monitor the battery temperature to make sure it
does not exceed 104° F (40° C).
9.2 Annual Health Check – Tray Covers Removed
• Check the SOC by measuring the OCV with “No
Load” attached to the battery per the Shop Visit
instructions (Section 9.1).
• Check all inter-cell connections and terminal
connections to assure a torque reading of 100 inlbs. Confirm this torque reading by turning the
torque wrench clockwise only. Do not re-torque
by first loosing and re-tightening.
• Check the OCV of all cells. It should be 2.15 volts
per cell with “No Load” attached to the battery.
No cell should read lower than 30 millivolts from
the average OCV of all the cells in the battery
system.
• Re-torque the tray bolts to 160 in-lbs.
• Clean all of the terminal connections with
Scotch-Brite® Green and apply Sanchem Inc.
NO-OX-ID® “A” grease to them.
10.0 STORAGE OF SPARE BATTERIES
8.0 VENTILATION
Clean all ventilating openings to remove any collection
for dirt or dust that might prevent the free circulation of
air. As explained in Section 1.0, explosive gases can be
produced if abnormal operating conditions exist (e.g.
charger malfunction).
9.0 MAINTENANCE
Because this is an Element battery, there is little to do
regarding maintenance operations. The top of the
battery should be kept clean and dry and may be
washed to remove any accumulated foreign matter. In
the unlikely event of an accidental contamination with
electrolyte or lead, contain the spill and notify your local
GNB representative who is equipped to handle any
environmental concerns. Spill kits can be ordered through
your local sales representative by calling 1-888-563-6300.
Never attempt to add water to the battery – it has been
designed to function without any such additions over its
entire life. Any attempt to remove the vent caps shall void
the warranty.
Spare charged batteries should be given regular good
housekeeping care. A clean, cool, dry place, free from
dust and debris, should be selected for storage space.
If stored at temperatures of 77°F (25°C) or below, the
battery should receive an initial charge (see Section 3.0)
within 3 months and recharged at 3-month intervals
thereafter. Storage at elevated temperatures will result in
accelerated rates of self-discharge. For every 18°F (10°C)
increase above 77°F (25°C), the time interval for initial/
maintenance charging should be halved. Thus, if a battery
were stored at 95°F (35°C), the initial charge should be
performed within 1.5 months and recharged at 1.5-month
intervals thereafter.
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.
11.0 REMEMBER THESE IMPORTANT FACTS
A Division of Exide Technologies
For maximum battery life and performance, always be
aware of these potential problem areas and take the
appropriate action to correct them should they occur.
SHORT CIRCUITS: Cause electrical leaks that run
batteries down.
CARELESSNESS: Running battery down with lights or
accessories left on when engine is not running.
POOR, DIRTY CONNECTIONS: Corrosion builds up
resistance that impedes (often stops) the flow of power to
and from the battery.
LOW REGULATOR SETTINGS: Limit the flow of
recharging current to the battery thereby starving it.
HIGH OR UNCONTROLLED REGULATOR: Permits
excessive flow of current to the battery causing excessive
loss of water and premature failure.
12.0 WARRANTY AND RECORDS
Diesel starting batteries are warranted against
manufacturing defects or factors under GNB control.
There are many factors under the control of the battery
user that can damage the battery.
records of voltage regulator output or battery float
voltages, together with the temperature range for which
adjustment is made, must be kept.
Such records can alert the user to the existence of
abnormal conditions in his application that can adversely
affect the battery. Preventive actions can then be taken
promptly to ensure the battery is not damaged.
13.0 RECYCLING
U.S. Federal and State Regulations require that lead acid
batteries be handled and disposed of in compliance with
strict guidelines. GNB offers disposal service for lead acid
batteries. In the USA, call 1-888-438-5865 to arrange
pick-up or to get additional information. In Canada, call
1-800-231-9081. In Mexico, call 1-630-862-2225.
The most important user-controlled factor is the battery
float voltage set on the voltage regulator of the locomotive
generating or charging system. Many battery users
rou- tinely keep records of monthly readings of voltage
regulator output with the engine at idle and at operating
speed. As explained in Section 7.0, correct adjustment
of the bat- tery float voltage is critical in ensuring battery
performance. To keep the warranty valid, quarterly
For additional information:
In the USA, call 1-800-GNB-RAIL
In Canada, call 1-800-268-2698
In Mexico, call 1-771-791-4972
GNB Industrial Power
USA – Tel: 800.872.0471
Canada – Tel: 800.268.2698
www.exide.com
www.tpscrail.com
GB4007 2013-01
Z99SLS710
Loading...