Valve-Regulated Lead Acid Batteries Installation and Operating Manual RS02044/1114/CD 1 www.cdtechno.
SAFETY PRECAUTIONS Only authorized and trained personnel familiar with 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. Be sure to discharge static electricity from tools and technician by touching a grounded surface near the batteries, but away from the cells and flame arresters. All tools should be adequately insulated to avoid the possibility of shorting connections.
Table of Contents Part 1: Introduction ............................................................................................................................... 5 1.1 Cell Characteristics ..................................................................................................................... 5 Part 2 – Recommended Technical References ...................................................................................... 6 Part 3 – Safety Precautions .......................................
9.2 Quarterly (including the above) .................................................................................................. 24 9.3 Semi-Annually (including the above) .......................................................................................... 24 9.4 Annually (including the above) ................................................................................................... 24 9.5 Module Assembly Adjustments ......................................................................
Part 1: Introduction The msEndur II batteries referenced in this document are stationary, lead-acid batteries. They are constructed with an absorbent glass mat (AGM) and are characterized as Valve Regulated Lead-Acid (VRLA). As VRLA, there is no free flowing electrolyte.
Part 2 – Recommended Technical References These instructions assume a certain level of competence by the installer/user. Installers must have the appropriate knowledge and experience to safely install the batteries. The design of the battery room, system wiring, protection, environmental, fire, and safety requirements must comply with applicable codes required by the governing enforcement agency. The following is a partial list of the codes that may have direct impact on your installation.
Part 3 – Safety Precautions This battery is designed for industrial, stationary use only and is not intended for application in vehicular, starting, lighting and ignition (SLI), and the operation of portable tools and appliances. Use in accordance with this manual or all IEEE battery procedures. Use of this product other than in accordance with these instructions may produce hazardous and unsafe operating conditions, leading to damage of equipment and/or personal injury.
3.3 Installation Tools and Supplies • • • • • • • • • • Lifting sling or appropriately sized platform – for lifting cells and modules. Insulated steel toed safety shoes & remove all metals, i.e. rings, etc – to ensure no short circuits. Sodium bicarbonate, 1 lb per gallon of water – to neutralize and clean up any electrolyte. Insulated tools – to ensure no short circuits between connections. Insulated torque wrench – to ensure no short circuits between connections.
Part 5 – Storage Prior to Installation 5.1 Storage Conditions Store batteries indoors in a cool, well ventilated, clean, dry location and place in service as soon as possible after receiving. 5.2 Storage Temperature and Duration The recommended temperature for storage is 50°F (10°C) to 77°F (25°C).
6.2 Ventilation Although the ATP and ATLP series of batteries are valve regulated, they do produce minimal gas emissions during normal operation. If exposed to abnormal high voltage charging, the cells may vent potentially explosive hydrogen gas. Hydrogen gas when accumulated in a confined area that exceeds four (4%) percent by volume in air is explosive. C&D recommends not allowing hydrogen gasses of greater than two (2%) percent by volume to accumulate.
6.5 Module Installation msEndur II battery systems are typically shipped with the cells pre-installed into the modules for ease of transportation and installation. In some cases it may be necessary to have the cells shipped separately, or to remove the cells from the modules prior to installation. It is essential and the responsibility of the customer/installer to be properly trained and have suitable equipment to handle these heavy products.
• • • NOTE: Handling of Individual Cells When removed, do not allow cells to drop. Cells must be laid down in a controlled manner. A battery dropped may be damaged by the impact of falling even short distances. Some damage may occur to internal components, not visible at installation. Batteries should not be laid, slid or dragged across pallets or rough floors. Nails, pebbles, floor imperfections and other obstructions can damage jar, cover or weld.
a) Align the cell side restraint plate against the cell while keeping the plate straight and parallel to the module side wall. Adjust bolts so they are both protruding approximately the same amount out from the side of the module. b) Turn each bolt one rotation at a time alternating between the two bolts, ensuring to keep the cell side restraint plate straight and parallel to the module’s walls and the protruding bolt length of the two bolts the same.
Figure 6-3 Base to Module Assembly MODULE TO MODULE BOLT, WASHER AND NUT FRONT CELL RESTRAINT BAR 1 4" BOLT SIDE RESTRAINT PLATE WASHER (WHERE APPLICABLE) SIDE RESTRAINT PLATE BOLT CELL SPACER PLATE CELL SIDE RESTRAINT PLATE msEndur II CELL Figure 6-4 Spacer and Front Cell Restraint Assembly RS02044/1114/CD 14 www.cdtechno.
Figure 6-4A Flange Nut Detail Figure 6-5 Module and Faceplate Assembly RS02044/1114/CD 15 www.cdtechno.
6.5.3 Cell Removal and Stack Disassembly If a requirement to disassemble a module stack arises, it is recommended to remove the cells before disassembly. Once the battery string has been removed from service, the technician must use properly insulated tools and all appropriate battery safety methods. If removing cells from a new system in preparation for installation, skip to step 5. 1. 2. 3. 4. Remove the faceplate from the subject module. Disconnect the system ground connection.
Figure 6-7 Removing a Cell Figure 6-6 Cell Removal Tool Figure 6-8 Cell Installation and Removal Using Lift Table RS02044/1114/CD 17 www.cdtechno.
6.6 Electrical Connections • • • • • Always use protective insulating equipment, such as gloves, shoes, eye and face protection. Wrenches and other tools must be properly insulated. Observe local, state, and national electric codes at all times. Always work with the battery ungrounded. Battery ground connections, if required, should be made last. To avoid working with high voltages, break the battery down into convenient lower-voltage modules, equal to or less than 48-volts.
Prior to installation, lightly brush with a brass brush or Scotch Brite ™ type pad the battery terminals and any contact surfaces of the inter-unit connections. Then apply a thin coating of NO-OX-ID type grease to both the battery terminals and contact surfaces of the inter-unit connectors prior to installation. The ATP and ATLP msEndur II series of battery terminals are made of a copper alloy with a thin lead coating.
Part 7 – Initial Charging General Information and Precautions To safely charge the msEndur II batteries and avoid damaging the battery and/or connected equipment, observe the following: • Use a constant voltage charger with only direct current (DC). AC ripple current from charger shall not exceed five (5%) percent of the 8-hour (ampere-hour) rating of the battery in amps. • Be sure charger is turned off before making electrical connections between the battery and system.
7.1 Initial Charge All cells are shipped fully charged from the factory with no need for an initial freshening or equalization charge. The cells should be constant voltage charged at the average float voltages as noted in Table 1 below. However, when in storage or transit for an extended period (especially at temperatures above 77°F/25°C) or when the number of cells is greater than 24 cells; it is recommended the battery system be given an initial freshening charge (see Table 1) at installation.
Battery identifications 1. Date of readings 2. Battery total float voltage 3. Ambient operating temperature 4. Date and description of initial or last equalizing charge 5. General observations from visual inspection 6. Individual cell voltages 7. Connection resistance measurement 8. *Optional: One of the following for cell ohmic testers: Impedance, Conductance or Resistance 9.
NOTE: Chargers should be current limited to 25 amperes per 100-Ampere Hour battery rating. Higher charging current could potentially destroy the battery by overheating that subsequently causes more current to flow creating a vicious cycle sometimes referred to as “thermal runaway”. NOTE: Use the equalize voltage setting shown in Table 1 for a period not exceeding 16 hours. Consult your C&D Technologies representative for answers to specific questions. 8.
Part 9 – Maintenance The msEndur II is a VRLA cell which does not require water addition and no specific gravities or water levels need to be checked throughout its life. However, it is recommended to properly follow the below maintenance procedure, this will assure that the batteries are well maintained and ready for operation when needed. A blank inspection report (RS-1992) is shown in Appendix E. 9.1 Monthly Inspection 1. Visual inspection of the battery for general appearance and connector conditions.
9.5 Module Assembly Adjustments A module assembly that has been incorrectly assembled in the field should be adjusted to ensure all cells, cell side restraint plates, cell spacer plates, connectors and hardware are properly aligned and installed. Common assembly issues (see Figure 9-1): 1. Connectors not plumb and vertical (due to large cell cover spacing) and the GAP is not within specifications noted in Table 2 in Appendix C 2. Side restraint bolts not straight 3.
If the side restraint plate or the cell cover spacing in a module needs to be adjusted follow the steps below. The technician must use properly insulated tools and all appropriate battery safety methods.
Part 10 – Battery Degradation 10.1 General Information and Precautions When properly maintained and charged, the ATP and ATLP series of msEndur II batteries should provide many years of trouble-free service. However, despite their inherent dependability, failure to operate and maintain them correctly can lead to damage, shortened service life and possible loss of service. The following sections address some of the most frequently encountered errors. 10.
10.4 Low Float Voltage and Sulfation Either because of incorrect charger voltage adjustment, excessive intermittent or static loads paralleling the charging source, low operating temperature or simply not fully recharged; a battery may not receive adequate charging voltage. In some cases, the charger may even be turned off, erroneously or by choice. The net result is a battery left in a partially discharged or undercharged condition. The first observable signs may be erratic cell voltages.
Appendix A - Connections A.1 Terminal Connections 1. Remove any remaining factory-applied grease coating from the terminals with a dry cloth. 2. Lightly brush the terminal, cable lug and terminal plates contact surfaces with the supplied brass bristle brush or scotch brite type pad. 3. Coat all electrical surfaces with NO-OX-ID. (Optional: Use heat gun or hot plate to melt and then apply the NO-OX-ID grease, no open flames). 4. (Optional) - Re-flow excess NO-OX-ID with heat gun and wipe excess. 5.
Appendix B – Installation and Operation of Cam Assemblies In some cases, the side restraint plate bolts will not be accessible once the battery stack has been installed. For these installations, C&D Technologies offers cam assemblies that mount to the side of the module and provides a way to tighten and loosen cell side restraint plates from the front of the module.
Figure B-2 Cam Assembly Detail Appendix C GAP and Module Assembly Details Table 2 – GAP and Module Assembly Details (Reference Figure C-1) Module Size 16 16 19 19 22 22 22 22 26 26 27 27 27 30 30 30 31 34 34 34 34 35 39 40 40 43 43 45 * 49 * 58 * 58 * RS02044/1114/CD Module Width (Reference) Cell Size # of Cells Wide Target GAP Range (inches) 0.50 to 0.88 AT(L)-07P 4 0.50 to 1.13 16.04" AT(L)-15P,-17P 2 0.63 to 1.25 19.32" AT(L)-07P 5 2.00 to 2.88 19.32" AT(L)-09P 4 0.88 to 2.00 22.61" AT(L)-07P 6 2.
GAP CELL SIDE SIDE RESTRAINT RESTRAINT PLATE PLATE BOLTS BOLTS Torque not to exceed 15 Ft-Lbs INTER-CELL CONNECTORS INTER-CELL VERTICAL WITH PROPER CONNECTORS INSTALLATION OF CELL VERTICAL WITH SIDE RESTRAINT PLATE PROPER INSTALLATION OF SIDE RESTRAINT PLATE SPACING BETWEEN CELLS SPACING BETWEEL CELLS REMOVED/ MINIMIZED REMOVED/MINIMIZED PROPER ASSEMBLY BYBY PROPER ASSEMBLY SIDE RESTRAINT PLATE OFOF CELL SIDE RESTAINT PLATE Figure C-1 Module Assembly Details RS02044/1114/CD 32 www.cdtechno.
Appendix E – Battery Inspection Report RS02044/1114/CD 33 www.cdtechno.
RS-1992 BATTERY CHARGE STATUS Open Circuit Float Equalize BATTERY BUS VOLTAGE Vdc Vdc Vdc LOCATION: Cell # Volts +2.000 RS02044/1114/CD Serial # Connection Resistance Internal Cell Conductance/ Impedance/ Resistance Cell # 34 Volts +2.000 Serial # Connection Resistance Internal Cell Conductance/ Impedance/ Resistance www.cdtechno.
Appendix F – Recycling Lead-acid batteries are recyclable and C&D Technologies currently has a low cost, convenient, and environmentally safe collection and recycling program. Visit the C&D Web site at www.cdtechno.com for further information. RS02044/1114/CD 35 www.cdtechno.
Figure & Table Index Figure 3-1 BCI warning label ................................................................................................................ 7 Figure 6-1 Installation Using Forklift .................................................................................................... 11 Figure 6-2 Installation Using Hoist and Straps ..................................................................................... 11 Figure 6-3 Base to Module Assembly .................................
