GNB Industrial Power – The Industry Leader. SECTION 92.61 2013-09 Installation and Operating Instructions For ® GNB Industrial Power, a division of Exide Technologies, is a global leader in network power applications including communication/data networks, UPS systems for computers and control systems, electrical power generation and distribution systems, as well as a wide range of other industrial standby power applications.
INDEX Page SECTION 1.0 1 General Information.............................................................................................................. SECTION 2.0 2.1 2.2 2.3 2.3.1 2.4 2.5 2 Safety Precautions................................................................................................................ Sulfuric Acid Electrolyte Burns.............................................................................................. Explosive Gases........................................
SECTION 9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9 Connections.......................................................................................................................... Post Preparation................................................................................................................... Connections - System Terminals.......................................................................................... Connections - INTER-Module...........................................
LIST OF ILLUSTRATIONS Page 3 Fig. 1A-B Typical Systems - Top View 5 Fig. 2 Packed Modules 5 Fig. 3 Unpacking Modules 6 Fig. 4 Handling - Lifting Strap Placement 6 Fig. 6A-B-C Typical Horizontal Stack Arrangements - Front Views 7 Fig. 7 Typical Horizontal Stack Arrangements - Back to Back and End to End 7 Fig. 8 Hardware Installation for 2.67” Wide I-Beam Support 7 Fig. 9 Hardware Installation for 4.5” Wide I-Beam Support 7 Fig.
SECTION 1 1.0 significantly reduce hydrogen formation. Tests have shown that 99% or more of generated gases are recombined within the cell under normal operating conditions. Under abnormal operating conditions (e.g. charger malfunction), the safety valve may open and release these gases through the vent. The gases can explode and cause blindness and other serious injury.
Charge) at 6 month intervals thereafter. Storage at elevated temperatures will result in accelerated rates of self discharge. For every 18°F (10°C) temperature increase above 77°F (25°C), the time interval for Wearing a ground strap while working on a connected battery string is not recommended. 2.4 Safety Alert ! 2.5 the initial freshening charge and subsequent freshening charges should be halved.
FIGURE 1A - HORIZONTAL END TO END FIGURE 1B - HORIZONTAL BACK TO BACK FIGURE 1 - TYPICAL SYSTEMS (TOP VIEW) -3-
Annual Average Battery Temperature Maximum Battery Temperature 77°F (25°C) 86°F (30°C) 95°F (35°C) 104°F (40°C) 113°F (45°C) 122°F (50°C) 122°F (50°C) 122°F (50°C) 122°F (50°C) 122°F (50°C) 122°F (50°C) 122°F (50°C) Percent Reduction In Battery Life Four 9/16” (14.3 mm) holes are provided in each I-Beam support for anchoring. To maintain seismic certification, use four anchor bolts per horizontal support. Anchor design is the responsibility of the purchaser/installer. 0% 30% 50% 66% 75% 83% 5.
SECTION 6 6.0 6.3 Unpacking and Handling Recommended Installation Equipment and Supplies • Fork lift or portable boom crane • Chalk line • Line Cord • Torpedo level (Plastic) • Plywood straight edge 1/2” x 4” x 48” • Torque wrenches • Ratchet wrench with 10, 13, 17, 19 mm sockets and 2 and 15 mm deep sockets • Box wrenches of 10, 13, 15, 17 and 19 mm sizes • Vinyl electrical tape • Paper wipers • 3M Scotch Brite® scour-pads™† • Hammer drill (floor anchoring) † Trademark of 3M 6.
CAUTION! If a fork lift or portable crane is used to handle modules in a horizontal position, a piece of insulating material such as heavy cardboard, rubber insulating mats or plywood should be used between handling equipment and module tops to prevent shorting of module top connections with metal parts of lift equipment. Figure 6A NOTE: 1) Straps must be criss-crossed. 2) Lifting shackle orientation and proper channel hole use must be observed.
NOTE: The use of leveling shims is required when assembling any Absolyte system in order to meet seismic requirements. Failure to use the shims to level each module and to fill spaces between tray channels during module assembly will result in the assembly not meeting seismic certification criteria. Similarly, install the remaining I-beam support on the other side of the module (see Figure 10).
8.1.2 Handling E. Where floor anchoring is required, position module/base assembly in desired location. Mark floor through I-beam holes and remove module/base assembly. Install floor anchoring and reposition module/base assembly over anchoring. Prior to installing nuts and washers, check that assembly is level in both axes. Level using shims provided. Torque anchor hardware to manufacturer’s recommended value.
TIP-OVER PROCEDURE Figure 12B NOTE: ! MODULE WITH BASE ASSEMBLY AFTER TIP-OVER Figure 13 1) Straps must be criss-crossed 2) Lifting shackle orientation and proper channel hole use must be observed. 3) See Figure 4 for handling modules in vertical orientation. 4) Lift single modules only.
H. Proceed with stacking of remaining modules, checking that stack is plumb in both axes as stacking progresses before torquing hardware. Be certain to check the layout/wiring diagram for correct horizontal orientation to provide proper polarity interconnection as stacking progresses. See Figure 17B. COMPLETED HORIZONTAL STACK Figure 17B 8.
SEISMIC SHIM INSTALLED UNDER TIE PLATE WHERE APPLICABLE HORIZONTAL STACKS — BACK TO BACK POSITIONING Figure 19A TIE PLATE BOTTOM MODULES Figure 20A COMPLETED HORIZONTAL STACKS — SIDE BY SIDE Figure 19B M10 SERRATED FLANGE BOLT 8.2.1 Stack Tie Plate To achieve maximum stack stability, especially where seismic conditions may exist, as well as proper interfacing of interstack connections, metal tie plates are provided. The plates used on stacks end to end are 3” x 1” x 1/8” with two 9/16” holes.
SECTION 9 9.0 Connections 9.1 Post Preparation Cells are interconnected with connectors and hardware as shown in Figures 21A and 21B 9.4 Using either a brass bristle suede shoe brush or 3M Scotch Brite scouring pad, brighten the flat copper terminal surfaces to ensure lowest resistance connections. Apply a thin film of NO-OX-ID “A” grease (supplied with battery) to all terminal mating surfaces. This will preclude oxidation after connections are completed. 9.
FOUR POST CELLS INTER-MODULE CONNECTION B TWO POST CELLS INTER-MODULE CONNECTION A TWO POST CELLS INTER-STACK CONNECTION FOUR POST CELLS INTER-STACK CONNECTION C D 1) See Section 9 - Connections 2) Torque hardware to 11.3 Newton-meters (100 in-lbs). 3) C onsult layout/wiring diagram received with battery system 4) Curved edge of washer should face the connector.
Figure 22 - 14 -
CABLE LUGS (NOT SUPPLIED) MODULE CHANNELS Figure 23 - 15 -
TO ASSEMBLE THE ABSOLYTE GP MODULE COVER, THE FOLLOWING ARE NEEDED: ITEM CLEAR COVER STANDOFF LEG KEY TOP CLOSEOUT QUANTITY 1 4 4 1* *TOP MODULE COVER ONLY TOP MODULE COVER 7 INSTALL TOP CLOSEOUT ON TO CLEAR COVER OF TOP MODULE: CUT TO ALLOW FOR TERMINAL PLATE AS REQUIRED 8 INSTALL COVERS ONTO STANDOFF LEGS.
9.8 Cell Numerals A set of pressure sensitive cell numerals and system polarity labels are supplied and should be applied at this time. Cell numerals should be applied to the top of the module and as close to the cell being identified as possible. Suggest application to cell restraint bars or to module channels. Designate the positive terminal cell as #1 with succeeding cells in series in ascending order. The system polarity labels should be applied next to the positive and negative terminals. 9.
C. Proceed to Step 3. TEMPERATURE CORRECTION V corrected = V25°C - (( T actual-25°C) x ( .0055V/°C)) or V corrected = V77°F - ((T actual-77°F) x (.003V/°F)) STEP 3 The initial charge is complete. Charger voltage can now be reduced to float voltage setting per Section 12.2. For a target float charge of 2.25 VPC on a 24-cell system, you would set the charger voltage to 54 volts. See Appendix A for standard values.
12.6 Effects of Float Voltage “Reference” ohmic values are of dubious value because so many factors can affect the way the readings are made and displayed by the devices. Connector configuration and AC ripple as well as differences between readings of temperature and probe placement will prevent the ohmic devices from generating consistent and meaningful data. The meters work better with monoblocs and small capacity VRLA products and less well with large (>800-Ah) VRLA and flooded battery designs.
C. Individual cell(s) float is more than +/- 0.05 volts from average. charge, monitoring cell voltages hourly, until the lowest cell voltage ceases to rise. D. Accurate periodic records (See Section 15) of individual cell voltages show an increase in spread since the previous semi-annual readings. C. Proceed to Step 3. STEP 3 An annual equalize charge is recommended to help ensure uniform cell performance. 13.2 The Equalize charge is now complete.
SECTION 16 16.0 SECTION 19 Tap Connections 19.0 Tap connections should not be used on a battery. This can cause overcharging of the unused cells and undercharging of those cells supplying the load, thus reducing battery life. Battery terminals and intercell connections should be corrosion free and tight for trouble-free operation. Periodically these connections should be inspected. SECTION 17 17.0 ! Temporary Non-Use CAUTION! DO NOT WORK ON CONNECTIONS WITH BATTERY CONNECTED TO CHARGER OR LOAD.
Figure 25.1 - 22 - Volts TYPE: Conn. Ohmic Resist. C / R / I ADDITIONAL COMMENTS: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 No. Cell SYSTEM VOLTAGE: No. of CELLS: ADDRESS: COMPANY: DATE: Tem p 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 No. Cell Volts TEMPERATURE: Tem p 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 No.
Figure 25.2 - 23 - Volts TYPE: Conn. Ohmic Resist. C / R / I ADDITIONAL COMMENTS: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 No. Cell SYSTEM VOLTAGE: No. of CELLS: ADDRESS: COMPANY: DATE: Temp 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 No. Cell Volts TEMPERATURE: Temp 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 No.
APPENDIX A Temperature Corrected Float Voltages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 2.23 2.35 2.35 2.34 2.34 2.33 2.33 2.32 2.32 2.31 2.31 2.30 2.30 2.29 2.28 2.28 2.27 2.27 2.26 2.26 2.25 2.25 2.24 2.23 2.23 2.22 2.22 2.21 2.21 2.20 2.20 Float Voltage at 25°C 2.24 2.25 2.26 2.35 2.35 2.35 2.34 2.34 2.33 2.33 2.32 2.32 2.31 2.31 2.30 2.29 2.29 2.28 2.28 2.27 2.27 2.26 2.26 2.25 2.24 2.24 2.23 2.23 2.22 2.22 2.21 2.21 2.20 2.20 2.35 2.
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APPENDIX C BONDING & GROUNDING OF BATTERY RACK INTRODUCTION 1. To insure personnel safety, and equipment protection, operation, and reliability, the battery rack should be connected to the Common Bonding Network (CBN). 2. E lectrical continuity between modules is provided through the use of serrated hardware. If continuity between the horizontal supports (I-beams) and the bottom module is desired, the use of a grounding kit (GNB P/N: K17ABSGPGRND) is required.
G G G G G G G G G G G G G G G G G G - 27 - G G G G G G G G G G G G G G G G G G
GNB Industrial Power – The Industry Leader. SECTION 92.61 2013-09 Installation and Operating Instructions For ® GNB Industrial Power, a division of Exide Technologies, is a global leader in network power applications including communication/data networks, UPS systems for computers and control systems, electrical power generation and distribution systems, as well as a wide range of other industrial standby power applications.
