Exide Technologies GB4007 User Manual

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.

corrected

= V

25°C

- ((T

- 25°C) x (.0055V/°C))

actual

= 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.

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