PowerSafe VGM, VGL Quick Reference Manual

RESERVE
POWER

VGM and VGL

Battery Installation and
Quick Reference Guide

Publication No: US-NiCd-QRG-001 - February 2014

Ni-Cd batteries are safe when operated and handled properly. It is vitally
important that you observe the precautions recommended in this installation
sheet. YOU SHOULD BE TRAINED IN HANDLING, INSTALLING,
OPERATING AND MAINTAINING BATTERIES BEFORE YOU WORK ON
ANY BATTERY SYSTEM.

When working on batteries wear safety glasses with side
shields, rubber gloves and protective clothing. All metallic
personal objects, such as rings, watches, bracelets etc. shall
be removed before starting work on the battery! Only use
insulated tools!

Electrolyte is corrosive.

In case of SKIN CONTACT with electrolyte, IMMEDIATELY

1. REMOVE contaminated CLOTHING

2. FLUSH the area THOROUGHLY with WATER

3. Get MEDICAL ATTENTION

In case of EYE CONTACT with electrolyte, IMMEDIATELY

1. FLUSH THOROUGHLY for at least 15 minutes with large
amounts of WATER.

2. Get MEDICAL ATTENTION.

In case of electrolyte CONTACT WITH CLOTHING OR

MATERIAL, IMMEDIATELY

1. REMOVE CONTAMINATED CLOTHING

2. Apply large amounts of water to affected area.

3. Wash clothing as soon as possible.

Batteries can generate gases which, when released, can
explode, causing blindness and other serious personal injury.

Warning: batteries remain live even though they are
disconnected. No rings or metal bracelets should be worn
during the assembly of the battery. Do not place electrically
conductive objects such as tools etc. on top of the battery!

Warning: cells are heavy, use proper lifting technique.

Do not allow flames, embers or sparks near the battery
due to the risk of explosion or fire!

The Battery Installation and Quick Reference Guide must be strictly
observed. Non-compliance with the Battery Installation and Quick Reference
Guide, use of non OEM spares or use of additives to the electrolyte or
unauthorized tampering will void the warranty

Spent batteries with this symbol are reusable products and
have to be put into a recycling system. Used batteries must
be disposed of as special waste in accordance with all
standards.

Ni-Cd

Cd

WARNING!

Never use sulfuric acid or acidic water for cleaning, this may damage
the battery.

Never recycle in the same container as lead acid batteries.

1. Receiving the battery

The cells are not to be stored in packaging,
therefore, unpack the battery immediately
after arrival. Do not tilt the package or turn it
upside down. The battery cells are equipped
with a blue plastic transport plug. The battery
will be delivered:

• Filled and charged: The battery is ready for
installation. Replace the transport plug with
the red vent cap included in the
accessories just before use. The battery
must not be charged with the transport
plug in the cells as this can damage the
battery.

2. Storage

The rooms provided for storing the batteries
must be clean, dry, cool 50ºF (10°C) to
86ºF (30°C) and well ventilated. Cells are not
to be stored in the transport packaging and
must not be exposed to direct sunlight or
UV-radiation

• If the cells are delivered in plywood

boxes, open the boxes before storage
and remove the packing material on the
top of the cells. If the cells are delivered
on pallets, also remove the packing
material on the top of the cells.

• Cells can be stored up to 12 months from
the day of delivery.

• Storage of cells at a temperature above
86ºF (30°C) will result in a loss of capacity.
This can be approximately 5% per 18ºF
(10°C)/year when the temperature exceeds
86ºF (30°C). It is very important that the
cells are sealed with the plastic transport
plugs tightly in place. This is to be checked
after receiving the goods.
In case of electrolyte loss during transport,
refill the cell up to the “MAX” mark with
genuine electrolyte before storage.

3. Installation

It is recommended that Ni-Cd batteries not be
operated or stored in the same room as lead
acid batteries. In addition to this, the charging
gases from lead acid batteries should be kept
away from Ni-Cd batteries by suitable
precautions such as ventilation or hermetic
isolation of the rooms.

Tools for lead acid batteries must not be
used for Ni-Cd batteries.

The installation should be carried out in
accordance with the manufacturer’s
instructions.

• Location - Install the battery in a dry and
clean room. Avoid in any case direct

sunlight and heat. The battery will give the
optimal performance and maximum service
life if the ambient temperature ranges
between 50ºF (10°C) to 86ºF (30°C).

• Ventilation - During the last phase of
charging, a mixture of oxygen and
hydrogen is released. Ventilation is
necessary, even if the generation of gas is
very low during float charging. Ventilation
should be carried out in accordance with
the manufacturer’s instructions.

• Setup - Always follow assembly drawings,
circuit diagrams and other separate
instructions. The transport plugs have to be
replaced with the red vent caps included
with the accessories.

Cell connectors and/or flexible cables
should be checked to ensure they are
tightly seated.

Terminal nuts, screws and connectors
must be tightly seated.

Torque loading for:
M10: 71 in-Lb

Female thread:
M8: 177 – 221 in-Lb
M10: 221 – 265 in-Lb

Connectors and terminals should be
protected by a thin coating of the anti­corrosion grease, NO-OX.

• The electrolyte for Ni-Cd batteries consists
of a diluted potassium hydroxide (KOH)
and lithium hydroxide solution with specific
gravity of 1.200 ± 0.01 kg/litre. The
potassium hydroxide solution is prepared in
accordance with factory regulations.
The specific gravity of the electrolyte does
not indicate the state-of-charge of the
battery. It changes insignificantly during
charging and discharging and is only
minimally related to the temperature.

When checking the electrolyte levels, a
variation in level between cells is not
abnormal and is due to the different
amounts of gas held in the separators of
each cell. Before the battery is put into
service for the first time, check that the
electrolyte level is not lower than 0.4 in
(10 mm) below the “MAX” mark. There is
normally no need to adjust it. Do not open
or remove the low pressure vents during
normal operation.

If the electrolyte level is lower than the
upper edge of the plate block during
service, the battery should not be
disconnected from the charger for more
than 24 hours.

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Battery Installation and Quick Reference Guide

4. Commissioning

The following instructions are valid for commissioning
between 68ºF (20°C) and 86ºF (30°C). For different
conditions please contact EnerSys
constant current is the preferred method.

According to IEC 62259, 0.1 C

0.1 I

A. The reference test current It is expressed as:

t

CnAh

It A =

1 h

Example:

0.1I

A means:

t

10 A for a 100 Ah battery or
50 A for a 500 Ah battery

• Commissioning with constant current

Cells stored up to 6 months:

A commissioning charge is required prior to putting the
cells in service. If full performance is necessary
immediately, a commissioning charge of 10 hours at

0.1 I

A is required.

t

This procedure is carried out without the low-pressure
red vents installed (no vent in place).

During the charge the temperature should be
checked (section 6).

Cells stored more than 6 months and up to 1 year:

A commissioning charge of 15 hours at 0.1 I
necessary.

This procedure is carried out without the low-pressure
red vents installed (no vent in place).

During the charge the temperature should be
monitored (section 6).

• Commissioning with constant voltage

If the charger´s maximum voltage setting is too low to
supply constant current charging, divide the battery into
two parts and charge them individually.

Cells stored up to 6 months:

A commissioning charge is recommended prior to putting
the cells in service. If full performance is necessary
immediately, a commissioning charge of 20 hours at

1.65 V/cell with current limited to 0.1 I

This procedure is carried out without the low-pressure
red vents installed (no vent in place).

During the charge the temperature should be
checked (section 6).

Cells stored more than 6 months and up to 1 year:

A commissioning charge of 30 hours at 1.65 V/cell with
current limited to 0.1 I

This procedure is carried out without the low-pressure
red vents installed (no vent in place).

During the charging the temperature should be
checked (refer to the periodic maintenance section
of this document for details).

In case of variable charging conditions, please consult
your EnerSys representative.

®

. Charging with

A is also expressed as

5

A is necessary.

t

A is

t

A is required.

t

5. Charging in Operation

Do not open or remove the low pressure vent caps during
operation. The charging current limit should be 0.1 I
maximum in general.

A

t

To reduce water consumption it is recommended to
compensate using the coefficient of -1.7mV per cell per
degree F (-1.7mV/ºF) if the ambient temperature is at or
above 95ºF (35ºC).

For operation at low temperatures, i.e. below 68ºF (20ºC),
there is a risk of poor charging and it is recommended to
adjust the charging voltage (-1.7mV/ºF).

Recommended charging voltages for ambient temperatures
from 68ºF (20°C) to 95ºF (35°C) are:

Two step charge:

Float charge: 1.40 - 1.42 V/cell
Boost charge: 1.45 - 1.46 V/ cell
Current limit: 0.1 I

A

t

Single step charge: 1.42 - 1.44 V/ cell
Current limit: 0.1 I

A

t

6. Periodic Maintenance

Powersafe®VGL and VGM batteries are extreme low
maintenance batteries

The following is recommended:

• The battery must be kept clean using only water.
Do not use a wire brush or solvents of any kind.

• Visually check the electrolyte level. Refilling is
recommended when the filling level reaches the “MIN“
mark. However it must never drop below the “WARNING
LEVEL” mark. Use only distilled or deionized water to
top-up the cells.

NOTE: Once the battery has been filled with the correct
electrolyte at the factory, there is no need to regularly check
the electrolyte density.

• Check regularly (approximately every 24 months) that all
connectors, nuts and screws are correctly torqued.
All metal parts of the battery should be corrosion­protected by a thin layer coating of anti-corrosion grease.

Do not coat any plastic part of the battery.

• It is required that the recommended charging voltage
remains unchanged. If a single-cell voltage of below 1.35
V is detected during float charging, it is recommend to
charge the cell(s) separately pursuant to the information
provided in Commissioning section of this document.

• High water consumption of the battery is usually caused
by improper voltage setting of the charger.

• The temperature of the electrolyte should never exceed
114ºF (45°C), as higher temperatures have a detrimental
effect on the performance and lifetime of the cells. During
charging, an electrolyte temperature of ≤95ºF (≤35°C)
should be aimed for. On exceeding 114ºF (45°C) the
charging should be temporarily interrupted until the
electrolyte temperature drops to 95ºF (35°C).

The temperature measurements are to be made at one cell
in the middle of the battery. Low ambient or electrolyte
temperatures down to -13ºF (-25°C) do not have any
detrimental effect on the battery; they just cause a
temporary reduction of capacity.

7. Capacity testing

If capacity testing is required it must be carried out
according to the IEC procedure 62259.

Publication No: US-NiCd-QRG-001 - February 2014

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8. Layout details: inter unit connection

Battery Installation and Quick Reference Guide

A. Nut connection

1 Cell container
2 Cell connector
3 Spring washer
4 Nut
5 Connector cover

Bolt connections

1 Cell case
2 Cell connector
3 Terminator connector
4 Spring washer
5 Bolt
6 Cover
7 Angle terminal connector
8 End terminal cover

B. Bolt connection

1 Cell container

5

4

3

2

1

2 Cell connector
3 Spring washer
4 Bolt
5 Connector cover

5

4

3

2

1

7

6

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EnerSys World Headquarters
EnerSys EMEA
EnerSys Asia

© 2014 EnerSys. All rights reserved.
Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted.
Subject to change without prior notification. E.&O.E.

Publication No: US-NiCd-QRGs-001 - February 2014

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152 Beach Road, Gateway East Building #11-03, Singapore 189721 Tel: [phone]

2366 Bernville Road, Reading, PA 19605, USA Tel: [phone] / [phone]