8A & 8G BATTERY INSTALLATION
AND OPERATING INSTRUCTIONS
!
SAFETY PRECAUTIONS
Although all valve-regulated batteries have the electrolyte immobilized within the cell, the electrical hazard
associated with batteries still exists. Work performed on
these batteries should be done with the tools and the
protective equipment listed below. Valve-regulated
battery installations should be supervised by personnel
familiar with batteries and battery safety precautions.
WARNING: Risk of fire, explosion, or burns. Do not
disassemble, heat above 40°C, or incinerate.
Protective Equipment
Although VRLA batteries can vent or leak small amounts
of electrolyte, electrical safety is the principle but not the
only concern for safe handling. Per IEEE 1188 recommendations, the following minimum set of equipment for
safe handling of the battery and protection of personnel
shall be available:
• Safety glasses with side shields, or goggles, or face
shields as appropriate. (Consult application specific
requirements)
• Electrically insulated gloves, appropriate for the installation.
• Protective aprons and safety shoes
• Portable or stationary water facilities in the battery
vicinity for rinsing eyes and skin in case of contact with
acid electrolyte.
• Class C fire extinguisher
• Acid neutralizing agent.
• Adequately insulated tools.
• Lifting devices of adequate capacity, when required.
SAFETY PRECAUTIONS
(con’t)
Procedures
Consult User Manual of specific application for
additional Safety & Operating requirements.
The following safety procedures should be followed
during installation: (Always wear safety glasses or
face shield.)
1. These batteries are sealed and contain no free electrolyte. Under normal operating conditions, they do not
present any acid danger. However, if the battery jar or
cover is damaged, acid could be present. Sulfuric acid
is harmful to the skin and eyes. Flush affected area
with water immediately and consult a physician if
splashed in the eyes. Consult MSDS for additional
precautions and first aid measures.
2. Prohibit smoking and open flames, and avoid arcing in
the immediate vicinity of the battery.
3. Do not wear metallic objects, such as jewelry, while
working on batteries. Do not store un-insulated tools in
pockets or tool belt while working in vicinity of battery.
4. Keep the top of the battery dry and clear of all tools and
other foreign objects.
5. Provide adequate ventilation as regulated by Federal,
State and Local codes and follow recommended
charging voltages.
6. Extinguishing media: Class ABC extinguisher. Note:
CO
2
may be used but not directly on the cells due to
thermal shock and potential cracking of cases.
7. Never remove or tamper with pressure relief valves.
Warranty void if vent valve is removed.
8. Inspect all flooring and lifting equipment for functional
adequacy.
Batteries, battery posts, terminals and related accessories
contain lead and lead compounds, and other chemicals known
to the state of California to cause cancer and birth defects or
other reproductive harm. Wash hands after handling.
California
Proposition 65
Warning
This manual is intended to be a guide to optimize battery performance for multiple cyclic & float applications. Consult applicable
User Manuals for additional parameters for specific systems. This manual is not intended for SLI or Vehicle related applications.
Vehicle / Equipment Owner’s Manual should be followed for SLI & Vehicle related applications.
®
DANGER
HIGH
VOLTAGE...
RISK OF SHOCK.
DO NOT TOUCH
UNINSULATED
TERMINALS OR
CONNECTORS.
DO NOT REMOVE VENT VALVE.
WARRANTY VOID IF VENT VALVE IS REMOVED.
SEE INSTALLATION, MAINTENANCE AND OPERATION
INSTRUCTIONS FOR IMPORTANT SAFETY PRECAUTIONS.
SHIELD EYES
EXPLOSIVE GASES
CAN CAUSE BLINDNESS
OR INJURY.
•
SPARKS
•
FLAMES
•
SMOKING
SULFURIC
NO.
ACID
CAN CAUSE
BLINDNESS OR
SEVERE BURNS.
VENTILATE WELL WHEN IN AN ENCLOSED
SPACE AND WHEN CHARGING.
REPAIR SHOULD BE PERFORMED ONLY
.BY A QUALIFIED SERVICE TECHNICIAN.
FLUSH EYES
IMMEDIATELY
WITH WATER.
GET
MEDICAL
HELP
FAST.
2
BATTERY ASSEMBLY
(Always wear eye protection.)
1. Set up the batteries so that the positive post (+) of one
battery is connected to the negative post (–) of the next
battery for all series connections.
2. All battery electrical contact surfaces shall be cleaned by
rubbing gently with a non-metallic brush or pad before
installing connectors. No-Ox-ID grease can be used but
is not required.
BATTERY ASSEMBLY
(con’t)
3. Install all electrical connectors / cables and bolting hardware loosely to allow for final alignment of batteries.
Torque to manufacturer recommendations.
4. After torquing, read the voltage of the battery string to
ensure the individual batteries are connected correctly.
The total voltage should be approximately equal to the
number of batteries times the measured voltage of one
battery (when connected in series). If the measurement
is less, recheck the connections for proper voltage and
polarity.
5. Read and record connection resistance and note the
method of measurement. This helps determine a satisfactory initial installation and can be used as a reference
for future maintenance requirements. See Appendix B,
recording forms, in the back of the manual. Clean,
remake and remeasure any connection having a
resistance measurement greater than 10% of the
average of all the same type of connections.
6. Battery performance is based on the output at the battery
terminals. Therefore, the shortest electrical connections
between the battery system and the operating equipment
results in maximum total system performance.
Cable size selection should be determined by current
carrying requirements as well as providing a minimum
voltage drop between battery system and operation
equipment. Proper techniques should be applied per
electrical standards, such as NEC and/or local codes.
Note: Excess voltage drop will reduce the support
time of the battery system.
SYSTEM OPERATION
State of Charge
Battery state of charge can be determined by measuring
the open circuit voltage. Consult the below table.
NOTE: Divide values in half for 6-volt battery(ies)
*The “true” O.C.V. of a battery can only be determined
after the battery has been removed from the load (charge
/ discharge) for 24 hours.
Charging
Consult Charger User Manual of specific application
for Safety and Operating requirements.
For cyclic applications it is important that the battery(ies)
be charged fully after each discharge. It is recommended
that 108% to 115% of the Ah (Amp Hour) capacity
removed from the battery(ies) be replaced after each
discharge. This additional Ah is to compensate for
any efficiency losses between the battery charger and
the battery(ies)
% Charge Gel AGM
100 12.85 or higher 12.80 or higher
75 12.65 12.60
50 12.35 12.30
25 12.00 12.00
0 11.80 11.80
State of Charge vs. Open Circuit Voltage
*
®
RECEIVING AND STORAGE
Receiving Inspection
Upon receipt, and at the time of actual unloading, each
package should be visually inspected for any possible
damage or electrolyte leakage. If either is evident, a
more detailed inspection of the entire shipment should
be conducted and noted on the bill of lading. Record
receipt date, inspection data and notify carrier of any
damage.
Unpacking
1. Always wear eye protection.
2. Check all batteries for visible defects such as cracked
containers, loose terminal posts, or other unrepairable
problems. Batteries with these defects must be replaced.
3. Check the contents of the package against the packaging
list. Report any missing parts or shipping damage to your
MK Battery agent or MK Battery immediately.
4. Never lift batteries by the terminal posts.
5. Always lift batteries by the bottom or use the lifting handles.
Storage
1. Batteries should be stored indoors in a clean, level, dry
and cool location. Recommended storage temperature is
0°F to 90°F (– 18°C to 32°C).
2. Stored lead-acid batteries self discharge and must be
given a charge six months from date of manufacture to
prevent permanent performance degradation. Record
dates and conditions for all charges during storage.
3. Recommended charge during storage is at a constant
voltage of 13.80V (6.90V for 6V battery) for 24 hours at
77°F (25°C).
4. Do not store beyond 12 months.
INSTALLATIONS
General
Caution should be taken when installing batteries to
insure no damage occurs. The battery cabinet, tray, rack,
etc. shall be inspected for sharp edges that could cause
damage to the battery casing. Batteries shall not be
dropped, slid, placed on rough or uneven surfaces such
as tray lips or grated flooring. Mishandling of batteries
could result in equipment damage or human injury.
MK Battery will not be liable for damage or injury as a
result of mishandling or misuse of the product.
Grounding
When grounding the battery system, proper techniques
should be applied per electrical standards, such as NEC
and/or local codes, as well as User Manual of specific
application.
3
RECORD KEEPING
Voltages, Temperatures & Ohmic Readings
Consult User Manual of specific application for
additional Safety & Operating requirements.
Record keeping is an important part of battery maintenance and warranty coverage. This information will help
in establishing a life history of the battery and inform the
user if and when corrective action needs to be taken.
(Refer to Appendix B, Battery Maintenance Report).
After installation and the batteries are at a fully charged
condition, the following data should be recorded:
Depending on application, some of the following
recommendations may not apply.
• Battery and/or string terminal voltage
• Charger voltage
• Individual battery float / charge voltages
• Individual battery ohmic readings**
• Ambient temperatures
• Terminal connections should be checked to verify all
connections are properly torques. Micro-ohm readings
should be taken across every connection. Refer to meter
manufacturer’s instructions for proper placement of
probes. If any reading differs by more than 20% from its
initial installation value, re-torque the connections. If the
reading still remains high, clean contact surfaces
according to installation portion of this manual.
** Note: To provide accurate / consistent values,
battery(ies) must be fully charged, at same temperature
and probes placed at same location each time readings
are taken.
®
SYSTEM OPERATION
(con’t)
Charge Voltage
For both 8A & 8G batteries the following voltage settings
should be followed:
Charge / Absorption / Equalize
13.80V to 14.60V @ 77°F (25°C)
Float / Standby
13.50V + .01 @ 77°F (25°C)
The charger must be able to maintain the system voltage
within ± 0.5% of the desired level at all times.
Note: Divide values in half for 6-volt battery(ies).
Temperature Compensation
Battery voltage should be adjusted for ambient
temperature variations.
3mV per °C (1.8°F) per cell
18mV per 12V battery
9mV per 6V battery
For temperatures above 77°F (25°C) subtract and
for temperatures below 77°F (25°C) add.
Consult Voltage Compensation Chart in
Appendix A for temperature compensation voltage
maximum and minimum limits.
The average battery operating temperature should not
exceed 95°F (35°C) and should never exceed 105°F
(40.5°C) for more than an eight-hour period. Operating at
temperatures greater than 77°F (25°C) will reduce the
operating life of the battery. If operating temperatures
are expected to be in excess of 95°F (35°C), contact
MK Battery for recommendations.
Discharging at temperatures less than 77°F (25°C) will
reduce the capacity of the battery.
Charge Current
To properly determine the amount of charge current
required the following variables are to be considered:
• DoD (Depth of Discharge)
• Temperature
• Size & efficiency of the charger
• Age and condition of battery(ies)
Maximum charge current should be limited to 30% of the
C20 Ah rate for the battery(ies) being used in the system.
Example: 8G24 C20 rate – 73.6Ah
Consult Charging Current vs Charging Time chart in
Appendix A as a guide line to determine recharge time
from 0% to 90% state of charge at an initial charge current.
Max. recharge rate: 73.6Ah x 0.3 = 22.1A
Discharge Voltage Curve
To estimate battery voltage during a constant current
discharge at various DoD (Depth of Discharge) consult
chart Discharge Voltage Curve in Appendix A.
NOTE: Battery voltage can vary depending on
temperature, age, and condition of battery.
4
MAINTENANCE
Always wear eye protection when working on or near
batteries. Keep sparks and open flames away from
batteries at all times.
Consult User Manual of specific application for
additional Safety & Operating requirements.
Annual Inspection
Depending on the application, some of the following
recommendations may not apply.
1. Conduct a visual inspection of the battery(ies).
2. Record battery and /or string voltage. The accuracy of
the DMM (Digital Multimeter) must be 0.05% (on dc
scale) or better. The DMM must be calibrated to NIST
traceable standards. Because voltage readings are
affected by discharge and recharges, for cyclic applications, the battery(ies) must be in a fully charged
condition prior to taking readings. Batteries should be
within ± 0.30 volts (+ 0.15 volts for 6V) of the average
battery float voltage.
3. Record charger voltage.
4. Record the ambient temperature.
5. Record individual battery ohmic readings.***
6. Record all interunit and terminal connection resistances.
Micro-ohm readings should be taken during this inspection. If any reading is greater than 20% from initial
readings, retorque the connection. Recheck the microohm reading. If the reading remains high, clean contact
surface according to installation portion of this manual.
*** Note: To provide accurate / consistent values,
battery(ies) must be fully charged, at same temperature and probes placed at same location each
time readings are taken.
®
MAINTENANCE
(con’t)
Rectifier Ripple Voltage
FREQUENCY
Ripple that has a frequency greater than 667Hz
(duration less than 1.5ms) is acceptable, unless it
is causing additional battery heating.
Ripple that has a frequency less than 667Hz (duration
greater than1.5ms), must meet the following voltage
specification to be acceptable.
VOLTAGE
Ripple voltage shall be less than .5% peak to peak
of the manufacturer’s recommended string voltage.
Battery Cleaning
Batteries, cabinets, racks, and modules should be
cleaned with clean water. If neutralizing is required, use
a mixture of baking soda and water. Use clean water to
remove baking soda residue. Never use solvents to
clean the battery(ies).
Capacity Testing
Capacity tests should not be run unless the battery’s
operation is questionable. Do not discharge the
battery(ies) beyond the specified final voltage. When
discharging at higher rates, extra connectors may be
required to prevent excessive voltage drop. When
performing capacity testing and recording data use
applicable standard and/or User Manual.
Should it be determined any individual battery(ies)
or cell(s) need to be replaced, contact your nearest
MK Battery agent or MK Battery.
5
APPENDIX A
≥35 13.32 13.62 14.40 ≥95
34 13.34 13.64 14.42 93.2
33 13.36 13.66 14.44 91.4
32 13.37 13.67 14.45 89.6
31 13.39 13.69 14.47 87.8
30 13.41 13.71 14.49 86.0
29 13.43 13.73 14.51 84.2
28 13.45 13.75 14.53 82.4
27 13.46 13.76 14.54 80.6
26 13.48 13.78 14.56 78.8
25 13.50 13.80 14.58 77.0
24 13.52 13.82 14.60 75.2
23 13.54 13.84 14.62 73.4
22 13.55 13.85 14.63 71.6
21 13.57 13.87 14.65 69.8
20 13.59 13.89 14.67 68.0
19 13.61 13.91 14.69 66.2
18 13.63 13.93 14.71 64.4
17 13.64 13.94 14.72 62.6
16 13.66 13.96 14.74 60.8
≤15 13.68 13.98 14.76 ≤59
ºC Float
Charge/Absorption
ºF
Min. Max.
Voltage Compensation Chart
Note: 1. Above values based on 12-volt battery.
2. Divide above values in half for 6-volt battery.
®
APPENDIX A
DISCHARGE VOLTAGE CURVE
CHARGING CURRENT VS. CHARGING TIME
*
6®7
APPENDIX B
Charger Output ____________________Amp Air Temperature ____________________°F
Total Battery String Voltage _______________ Panel Meter Volts ____________________
Year _______________________ Year _______________________ Year _______________________ Year _______________________
Unit Ohms or Unit Ohms or Unit Ohms or Unit Ohms or
Number Volts Mhos Number Volts Mhos Number Volts Mhos Number Volts Mhos
BATTERY MAINTENANCE REPORT
Inspection Date_______________________________________________________________ No. of Units/String _________________
Company ___________________________________________________________________ Type ____________________________
Address ____________________________________________________________________ Date New ________________________
Battery location and/or number __________________________________________________ Date Installed _____________________
Readings Taken By ____________________________ Remarks/Recommendations __________________________________________________________
Readings should be taken at installation and annually thereafter.
_________________________________________________________________________________
1111
2222
3333
4444
5555
6666
7777
8888
9999
10 10 10 10
11 11 11 11
12 12 12 12
13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20
21 21 21 21
22 22 22 22
23 23 23 23
24 24 24 24
25 25 25 25
26 26 26 26
27 27 27 27
28 28 28 28
29 29 29 29
30 30 30 30
31 31 31 31
32 32 32 32
33 33 33 33
34 34 34 34
35 35 35 35
36 36 36 36
37 37 37 37
38 38 38 38
39 39 39 39
40 40 40 40
Avg. Voltage Avg. Voltage Avg. Voltage Avg. Voltage
Individual
Battery Readings
®
DISTRIBUTED BY:
E.P.M. Form No. 1833 © 2012 by EPM Printed in U.S.A.
No part of this document may be copied or reproduced, electronically
All data subject to change without notice.
or mechanically, without written permission from the company.
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