TECHNICAL MANUAL 41-7525 VRLA Batteries 26-206 Ampere-Hour Capacity Battery Installation And Start up Guide (For Rack Mounted Systems) 41-7525/0514/CD www.cdtechno.
Table of Contents Page 12V VRLA Battery System Description ........................................................................................... 3 Series Connected Batteries .................................................. Fig. 1 .................................. 3 Two strings of Batteries Connected in Parallel....................... Fig. 2 .................................. 3 VRLA Battery Safety Hazards ...............................................................................................
12V VRLA BATTERY SYSTEM OPEN RACK INSTALLATION AND SYSTEM CHECKOUT GUIDE General Information This document provides a guide for use during receiving, installation and checkout of the 12V VRLA batteries of 25 through 200 ampere-hours capacity on open rack systems. This guide may not be complete within itself and should be used in conjunction with the following: 1. Rack Installation Drawing (M16285) 2. Specification Sheet for individual battery 3.
VRLA Battery Safety Concerns Installation and servicing of the 12V VRLA battery should only be performed and supervised by personnel knowledgeable of lead acid batteries and required personal and equipment safety precautions. Keep unauthorized personnel away from the batteries and installation activity. Electrical Hazards Battery systems present a risk of electrical shock and high short circuit currents. The following precautions should be observed when installing and maintaining VRLA batteries: 1.
Required Installation Tools & Equipment At a minimum, the following tools and equipment are required to install the 12V VRLA battery. 1. Digital voltmeter. 2. Socket wrench, insulated. 3. Torque wrench calibrated in inch-pounds, insulated. 4. Box end wrench, insulated. 5. Battery lifting equipment (handles) and fork lift to lift pallets of batteries. 6. Rubber gloves. 7. Full face shield. 8. Plastic apron. 9. Portable eyewash. 10. Spill kit. 11. Fire extinguisher (class C).
Storage Instructions Store batteries in a clean, dry cool area away from radiant heat sources. Elevated storage temperatures increase the self-discharge rate of the batteries and reduces the storage time between required freshening charges. Fully charged batteries with an electrolyte specific gravity of 1.280 or higher can be safely stored at temperatures as low as -20 degrees F. Batteries in storage should be given a freshening charge at 2.
Figure 4 - 1 Two Tier Rack with (10 each) 12 VDC VRLA Batteries for 120 VDC Figure 5 - 2 Four Tier Racks with (40 each) 12 VDC VRLA Batteries for 480 VDC 41-7525/0514/CD 7 www.cdtechno.
Locating the Batteries on the Rack The individual batteries should be placed on the rack tier/shelf with 1/2" (1.27 cm) spacing between the units. This is important to assure the inter-unit connecting cables properly align with the adjacent battery terminals and to allow air space for proper cooling of the batteries. When the batteries are being placed side to side, all the batteries should be placed with the terminals of the same polarity (POS. or NEG.) to the front of the tier/shelf.
If the measured voltage is not as expected, determine the cause and correct before proceeding. If a battery is installed with reverse polarity, the measured voltage for the tier of batteries will be reduced from the expected value by twice the open circuit voltage of the individual battery. Intertier, Interrow and Interrack Connections Cables used to interconnect tiers, rows and racks of batteries should be of at least the same size as the interunit connecting cables.
Figure 6 -INTERUNIT CABLE CONFIGURATIONS 0.5 Figure 6-1 Typical 6V VRLA Single Cable Connection CABLE 32668 4/0 FLEX 150-17771 32631 #2 FLEX 150-16550 32394 2/0 FLEX 150-19485 0.5 Figure 6-2 Typical 12V VRLA Single Cable Connection DUAL C ASSEM 32394 2 150-148 0.5 Figure 6-3 Typical 12V VRLA Dual Cable Connection 41-7525/0514/CD 10 www.cdtechno.
Figure 6 - (Continued) INTERUNIT CABLE CONFIGURATIONS CABLE ASSEMBLY PART NUMBER 32677 #6 FLEX CABLE 150-16601 0.5 Figure 6-4 UPS12-100MR DUAL CABLE ASSEMBLY PART NO. 12466 2/0 FLEX CABLE 150-20496 0.5 Figure 6-5 Typical 6V VRLA Dual Cable Connection 41-7525/0514/CD 11 www.cdtechno.
FIGURE 7 - INTERTIER CABLE CONFIGURATIONS Figure 7-1 - Typical Single Cable Intertier Connection for Flag Terminal Batteries Figure 7-2 - Typical Dual Cable Intertier Connection for 6V Threaded Insert Terminal Batteries 0.5 Figure 7-3 - Typical Single Cable Intertier Connection for Batteries with Threaded Insert Terminals 41-7525/0514/CD Figure 7-4 - Typical Large BCI Group Size Intertier Connection Using 4/0 Cable 12 www.cdtechno.
Figure 8 - INTERROW CABLE CONNECTIONS BETWEEN RACKS INSTALLED BACK TO BACK 0.5 Figure 8-2-Typical Dual Cable Interrow Connection for Batteries with Threaded Insert 0.5 Figure 8-3-Typical Single Cable Interrow Connection for Batteries with Flag Terminals 41-7525/0514/CD 13 www.cdtechno.
Figure 9 - INTERRACK CABLE CONFIGURATIONS BETWEEN RACKS PLACED END TO END WITH 4” SPACING 0.5 0.5 Figure 9-1 - Typical Dual Cable Interrack Connection for Batteries with Threaded Insert Terminals 0.5 0.5 0.5 Figure 9-2 - Typical Single Cable Interrack Connection for Batteries with Threaded Insert Terminals 41-7525/0514/CD 0.5 Figure 9-3 - Typical Single Cable Interrack Connection for Batteries with Small “Flag” Terminals 14 www.cdtechno.
Battery Connection to the Load/Charger Select the proper size and type of cable per the NEC or other applicable code which can handle the charge and discharge current related to the battery. The cable size selected should also consider the cable resistance per foot and the voltage drop allowed between the battery output terminals and the load.
After the battery system has been on float for approximately 24 hours, the float current acceptance should be approximately to .005 amperes or less per rated ampere hour capacity of the battery string but greater than zero. The individual battery float charging voltages should be within the following range: • 12 volt batteries 13.3 min. to 14.5 max. • 10 volt batteries 11.10 min. to 12.1 max. • 6 volt batteries 6.65 min. to 7.25 max. • 4 volt batteries 4.43 min. to 4.85 max.
