RS-1476 Section 12-800
SAFETY PRECAUTIONS Only authorized and trained personnel familiar with standby battery installation, preparation, charging and maintenance should be permitted access to the battery. WARNING SHOCK HAZARD - DO NOT TOUCH UN-INSULATED BATTERY, CONNECTORS OR TERMINALS. BEFORE TOUCHING THE BATTERY, BE SURE TO DISCHARGE STATIC ELECTRICITY FROM TOOLS AND TECHNICIAN BY TOUCHING A GROUNDED SURFACE IN THE VICINITY OF THE BATTERIES BUT AWAY FROM THE CELLS AND FLAME ARRESTORS.
INTRODUCTION The batteries referenced in this document are C&D Technologies VLA (flooded) or stationary vented lead acid, with sulfuric acid electrolyte and pasted plate lead alloy electrodes. These batteries are designed for standby applications requiring an emergency dc power source. There are three major battery designs - long duration, short duration and general purpose.
STANDBY BATTERY, VENTED CELL INSTALLATION, OPERATION AND MAINTENANCE INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 TABLE OF CONTENTS. . . . . . . . . . . . . . . . . . . . . . . 2 PART 1 - RECEIVING AND INSTALLATION . . . . . . 3 SECTION 1 - RECEIVING . . . . . . . . . . . . . . . . . . . . . 3 1.1 General 1.2 Damage and Shortage Situations 1.3 Cell Type Identification SECTION 2 - STORAGE AND SHELF LIFE. . . . . . . 4 2.1 Storing Charged and Wet Batteries 2.
PART 1 RECEIVING AND INSTALLATION SECTION 1 - RECEIVING 1.1 General Every precaution has been taken to pack the battery for shipment to ensure its safe arrival. As soon as you receive the battery, check the packing material for evidence of damage in transit. If the packing material is physically damaged or wet acid stains are present, make a notation on the delivery receipt before you accept the shipment/delivery.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) 1.3 Cell type identification C&D presently produces lead calcium alloy and lead antimony alloy products. The distinction can be made by checking the cell type label (lead calcium white label, lead antimony green label), the operating instruction label, or the stamping on top of the post as calcium alloy may have “CA” and antimony alloy may be stamped with “SB.” SECTION 2 - STORAGE and SHELF LIFE 2.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) *Table 2 - Open Circuit Cell Voltages Specific Gravity of Cell Individual Cell Voltage 1.170 1.215 1.225 1.250 1.275 1.300 2.025 2.063 2.075 2.098 2.123 2.145 *Fully Charged with Electrolyte Between High & Low Level Lines Cell on Open Circuit for 24-72 Hours 2.2 Storing charged and dry batteries Storage of dry-charged batteries should be in a ventilated, weatherproof, cool and dry building.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) 3.1 Installation of Battery Rack(s), Overview NOTE: Standby Battery Rack assembly instructions and/or rack assembly drawings are supplied with C&D supplied racks and should be consulted for detailed instructions specific to your rack assembly prior to assembly. Remember that standby battery and rack systems will be in place for many years. Rack frames, rear cross bracing, bottom and rear support rails are assembled before any batteries are installed.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) SECTION 4 - INSTALLING CELLS* * These instructions apply to lead acid batteries configured as single cell containers or multi-cell containers. The term containers can apply to both configurations.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) Not using the correct cleaning solutions will void warranty on the battery. Consult the optional battery arrangement plan, if one was ordered from C&D. Cells may now be loaded onto the rack(s). Always lift cells by the bottom only. WARNING Storage batteries present both electrical and chemical hazards to those who install or service them. It is essential you exercise extreme care at all times to assure a safe working environment.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) WARNING Do not use wire pulling compounds, oils, grease or any other material not specifically authorized by C&D in writing, as these may contain additives that could damage the plastic containers. Use of any unauthorized solvents voids warranty. For seismic (EP) racks, spacers between cells are required.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) DO NOT REMOVE LEAD PLATING To maintain electrical contact integrity, C&D supplies NO-OX-ID grease (in the accessories package) as a corrosion resistant coating for all bolted electrical contacting surfaces.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) Tighten connections to the torque values shown in Table 3, using an insulated torque wrench and an insulated open-end wrench in countertorque, as shown in Figure 1.4.7. Refer to Table 3 to verify that your hardware is correct for the battery type being installed. Align cells so the inter-cell connectors match up with the holes of the terminal posts.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) When two inter-cell connectors are supplied for connecting cells they must be placed on opposite sides of the posts. Make the inter-cell connection (positive to negative) using the bolt assemblies supplied. Refer to Figure 1.4.5. High current batteries may use shorter piggy back inter-cell connectors applied over the top of the full length inter-cell connectors connecting all posts. See illustrations for four and six post cells, Figure 1.4.8.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) Terminal plates facilitate the connection of multiple power leads. They are made of heavy copper, tin or lead-plated and formed to permit connection to posts of various configurations. See Appendix A for details of the terminal plates supplied in the standard accessory kits. Caution Unsupported cables may cause excessive stress to terminal plates and posts. The maximum unsupported length of an inter-tier, inter-row or inter-rack cable should be 3 feet.
PART 1 RECEIVING AND INSTALLATION (CONTINUED) AC Ripple Commercial battery chargers convert ac electrical energy to dc. The conversion, however, is not perfect, and some voltage variation remains in the output voltage and current. This is known as ac ripple. The frequency and magnitude of the ripple depends on the design of the charger and the filtering included in the supply. Lead acid batteries act as a filter for ac ripple, and any variable energy delivered to the batteries is converted to heat.
PART 2 CHARGING AND OPERATION OF BATTERY (CONTINUED) Lead Calcium Cells Maximum Average Volts Per Cell VPC (see note) 2.38 2.43 2.50 Nominal Specific Gravity See Part 4, Sec. 1.3) 1.215 1.250 1.300 Time in Hours at maximum cell voltage 24 - 100 24 - 100 24 - 100 Note: Applies to average cell voltage.
PART 2 CHARGING AND OPERATION OF BATTERY (CONTINUED) (1) Setpoint: Recommended float voltage setpoint range for the system when read at the battery terminals. Charger settings can be calculated by multiplying the recommended target voltage times the number of series cells in the battery system.
PART 2 CHARGING AND OPERATION OF BATTERY (CONTINUED) Additional deep and/or frequent discharges can shorten service life, even with proper maintenance and operation. This section will consider batteries that are used in full float service. They will not be exposed to service in which the standby power system is not capable of supporting peak loads. In such cases the battery would be exposed to numerous partial discharges.
PART 2 CHARGING AND OPERATION OF BATTERY (CONTINUED) Single Cell Equalize: Some equipment may not have the required equalizing potentials available thereby lengthening the charging period. As an alternative, a single-cell charger with ac line isolation may be paralleled across the affected cell while still part of the overall battery to provide an over-voltage to the subject cell. Set points similar to system equalize should be used.
PART 2 CHARGING AND OPERATION OF BATTERY (CONTINUED) 5.
PART 2 CHARGING AND OPERATION OF BATTERY (CONTINUED) Note: D istilled or de-ionized water is preferred for adjusting e lectrolyte levels If you intend to use public water and question the suitability of the local water supply for use in lead acid batteries, consult your nearest C&D representative. If he does not have a recent analysis report available, you may wish to conduct your own analysis in-house or at a convenient laboratory.
PART 3 DRY-CHARGED BATTERIES, PREPARATION & CHARGING NOTE: Please refer to RS02208 for dry-charge batteries, preparation and charging. PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE SECTION 1 - REFERENCE INFORMATION A battery used in full float service that has been properly installed and not subjected to frequent discharges and recharges, floated at the recommended charging voltages and maintained in accordance with recommended practices will require minimal attention.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) Lower than normal temperatures have the opposite effects. In general, at recommended float voltage, a battery in a cool location will last longer and require less maintenance than one in a warm location.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) 1.4 Battery Performance Tests Batteries are rated on their ability to deliver a certain number of amperes or watts to the load for a specified amount of time before the battery voltage drops to a final cut off voltage. It is important to recognize that the performance of a cell or battery depends on several factors: 1. the discharge rate 2. electrolyte temperature at the start of the discharge 3. state of charge 4.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) 1.6 Connection voltage drop The importance of the integrity of inter-cell, inter-aisle and inter-row connections has been stated. Loose, dirty, or oxidized connections have higher than normal resistance and increased voltage drop resulting in less reserve time. Typically, the designed voltage drop between cells should be 30 millivolts or less.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) 1.9 Cell type identification C&D cells may be identified by looking at the label placed on the cover of each cell. The label contains valuable information such as: 1. cell type 2. nominal specific gravity 3. rated discharge time, current and final cell voltage (an average of all cells in the battery) 4. date of manufacture 5. plant of manufacture 6.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) CAUTION RECHARGE BATTERIES AS SOON AS POSSIBLE AFTER A DISCHARGE. Failure to recharge batteries promptly after a discharge may lead to sulfation or, in the case of deep discharge, to a complete battery failure due to hydration. If charging at equalize voltage is not practical, recharge battery at float voltage. 2.3 Batteries retained on open circuit stand As soon as a battery is removed from a charger, self-discharge begins.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) 2.5 Cleaning cell containers Wipe the outside of the cells as necessary with a cloth moistened with water to remove dust and ordinary dirt. If electrolyte is spilled on the covers, neutralize it with a cloth moistened with a solution of sodium bicarbonate and water mixed in the proportion of one pound of sodium bicarbonate to one gallon of water.
PART 4 REFERENCE INFORMATION, TROUBLE SHOOTING & EXTENDED MAINTENANCE (CONTINUED) However, some users of vented batteries have chosen to use the impedance, conductance or resistance measurement technique for additional analytical data. It is important that readings be taken periodically in exactly the same location. The readings can only be compared if the cell electrolyte temperature is similar to that of previous readings.
APPENDIX A-Terminal Plates PT00448A TYPE “L” CELLS WITH (4) 1’’ SQUARE SINGLE HOLE POSTS PT00449A TYPE “L” CELLS WITH (6) 1’’ SQUARE SINGLE HOLE POSTS PT00450 TYPE “K” SINGLE & “L” MULTI-CELLS WITH 1’’ SQUARE POST PT00494 TYPE “K” CELLS WITH 1’’ SQUARE POST PT00496 TYPE “XTJ”, “K” & “L” MULTI-CELLS WITH FLAG TERMINALS PT00515A TYPE “L” CELLS WITH (4) 1’’ SQUARE DOUBLE HOLE POSTS PT00516A TYPE “L” CELLS WITH (6) 1’’ SQUARE DOUBLE HOLE POSTS PT00539A TYPE “L” 2-CELL & LARGE 4-CELL WITH 1’’ SQUARE DOUBL
APPENDIX B - material safety data sheet Please refer to C&D’s website at www.cdtechno.com/resource/msds.html for the latest material safety data sheet information; 14-324 Flooded Lead-Calcium Batteries and 14-326 Sulfuric Acid, Battery Electrolyte. APPENDIX C - SPILL CONTAINMENT Introduction: Spill containment systems are used to contain and absorb/ neutralize the release of battery electrolyte from damaged lead acid batteries used in stationary applications.
APPENDIX D FIGURE 4.1.3 - Battery capacity versus operating temperature. FIGURE 4.1.4 - Battery Life versus ambient temperature RS1476/0215/CD 31 www.cdtechno.
Inspected By: 1400 UNION MEETING ROAD BLUE BELL, PA 19422 Inspected Date: STATIONARY BATTERIES AND CHARGERS INSPECTION REPORT User: Contact: Battery Location: Phone No: Other: OEM: Installed By: BATTERY INFORMATION USER INSPECTION C&D INSPECTION C&D Order No. Appearance of Following: Date Mfg. Pos. Post Date Installed Pos. Strap Model Pos. Plate Cells x Strings Neg. Post Application Neg. Strap Electrolyte Level Neg.
Required Maintenance Documents for Warranty BATTERY STATUS OPEN CIRCUIT Office: Cell No. FLOAT Model: EQUALIZE Date: Volts Temp. Sp.Gr. Serial or Cell Volts Temp. Sp.Gr. Serial or +2.000 Deg. F +1.000 Work Order No. No. +2.000 Deg. F +1.000 Work Order No. Add measure and record string charge current (amps) after 96 and 100 hours equalization or 68 and 72 hours float. .
1400 Union Meeting Road P.O. Box 3053 • Blue Bell, PA 19422-0858 (215) 619-2700 • Fax (215) 619-7899 • (800) 543-8630 customersvc@cdtechno.com www.cdtechno.com Any data, descriptions or specifications presented herein are subject to revision by C&D Technologies, Inc. without notice. While such information is believed to be accurate as indicated herein, C&D Technologies, Inc.
