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Summary of Contents for OutBack Power EnergyCell 800RE
- Page 1 EnergyCell ® RE High Capacity Battery Installation Guide and Owner’s Manual...
- Page 2 Should you have ANY questions concerning how to perform the required maintenance or installation please contact Outback Power at the office number listed below and ask for Outback Power Tech Support. EnergyCell RE High Capacity Specifications...
- Page 3 Installation Manual PowerSafe DDM Modular Battery Systems Publication No. US-DDm-IM-003 November 2003...
- Page 5 Installation Manual PowerSafe DDm Modular Battery Systems IMPORTANT! Read safety information first See Safety, Storage, Operating and Maintenance Manual Publication No. US-DDm-IM-003 November 2003...
- Page 6 The installation manual is for reference only. To maximize safety and performance, read the accompanying Safety, Storage, Operating and Maintenance Manual thoroughly. It provides full instructions regarding safety, storage, operation and maintenance. Failure to observe the precautions as presented may result in injury or loss of life. Copyright ©2003 by EnerSys Inc.
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Page 7: General Safety Instructions
PowerSafe DDm GENERAL SAFETY INSTRUCTIONS Warnings in this manual appear in any of three ways: The danger symbol is a lightning bolt mark enclosed in a triangle. The danger symbol is used to indicate imminently hazardous situations, locations and Danger conditions which, if not avoided, WILL result in death, serious injury and/or severe property damage. - Page 8 IMPORTANT SAFETY INSTRUCTIONS A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working with batteries. 1. Verify that the Uninterruptible Power Supply (UPS) is off and that the power cord is disconnected from the power source.
- Page 9 PowerSafe DDm IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for PowerSafe DDm Lead-Acid Battery Systems that should be followed during the installation and maintenance of the battery system. Only a qualified EnerSys Inc. service representative who is knowledgeable in batteries and the required precautions should perform servicing of the batteries.
- Page 10 IMPORTANT! Read safety information first See Safety, Storage, Operating and Maintenance Manual Page iv Publication No. US-DDm-IM-003 www.enersysinc.com November 2003...
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Page 11: Table Of Contents
PowerSafe DDm TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS ................... i GENERAL INFORMATION......................2 RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES ..........4 SYSTEM LAYOUT ........................5 Anchor Spacing .........................6 FRAME ASSEMBLY AND INSTALLATION ..................7 Base Beams ..........................7 Vertical Channels ........................7 Horizontal Channels ........................8 Cell Support Shelves .......................10 BATTERY CELL INSTALLATION ....................11 Module Retainers ........................12 Electrical Bonding Instructions ....................12... -
Page 12: General Information
GENERAL INFORMATION PowerSafe DDm battery systems are modular units that can be installed in a SINGLE STACK (figure 1), a MULTI-STACK (figure 2), or a MULTI-STACK ZERO SEPARATION (Figure 3). Systems are available in 24, 48 and other voltage configurations. These systems allow for assembly at remote locations. - Page 13 PowerSafe DDm MULTI-STACK FIGURE 2 MULTI-STACK ZERO SEPARATION FIGURE 3 Publication No. US-DDm-IM-003 Page 3 November 2003 www.enersysinc.com...
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Page 14: Recommended Installation Equipment And Supplies
RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES Before working with the battery system, be sure that you have the proper protective clothing, safety equipment and insulated tools as specified in the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery Systems. The following is a recommended list of equipment required for installation of a PowerSafe DDm Battery System. -
Page 15: System Layout
PowerSafe DDm SYSTEM LAYOUT Before installing the battery system, lay out available floor space including aisles for installation, maintenance and possible cell replacement. Consult the local installation considerations as determined in Section 5 of the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular D = DISTANCE BETWEEN BASES (VARIABLE) FRONT Battery Systems. -
Page 16: Anchor Spacing
Anchor Spacing TABLE 2 Base Beam Anchor Spacing Cell Multi-Stack w/ 2 Cells Wide 3 Cells Wide 4 Cells Wide 6 Cells Wide Model zero spacing L (in) L (cm) L (in) L (cm) L (in) L (cm) L (in) L (cm) M (in) M (cm) -
Page 17: Frame Assembly And Installation
PowerSafe DDm FRAME ASSEMBLY AND INSTALLATION To assemble and install the frame for the PowerSafe DDm battery system, follow the procedure below using the system layout determined in the “System Layout” section. Base Beams 1. LEVEL with customer-supplied floor shims, and anchor in place. -
Page 18: Horizontal Channels
Horizontal Channels NOTE: There may be two types of horizontal channels with your shipment: Rear – have four weld nuts Front – have more than four weld nuts The front horizontals are universal and, in most configurations, are substituted for the rear horizontals. Front horizontals are to be installed with the flange positioned with the holes facing up. - Page 19 PowerSafe DDm Starting at the bottom of the FRONT verticals: 1. Insert FRONT horizontal channels into the vertical channels. Center the horizontals between the verticals. See figures 13A & 13B. 2. Bolt horizontal channels to vertical channels. Refer to below list for hardware order and Figure 14.
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Page 20: Cell Support Shelves
Cell Support Shelves Starting at the bottom of the rack: 1. Place shelves over FRONT and REAR horizontals. See Figure 15. 2. Align holes of shelf with holes of horizontal channels. Bolt the shelf to the REAR horizontal using (2) M10x1.5 – 25mm Serrated Hex Bolts in the two OUTSIDE holes of the shelf. -
Page 21: Battery Cell Installation
PowerSafe DDm BATTERY CELL INSTALLATION DDm battery cells are designed for shipment and use in steel modules. USE CAUTION WHEN HANDLING THE DDm MODULES After a cell has been inserted into a module at the factory, a loose fit could develop because of recombination. -
Page 22: Module Retainers
NOTE: The larger modules are too heavy to lift onto the shelves manually. To avoid personal injury use appropriate lifting devices when lifting modules onto the shelves. 4. Slide the module back into a safe position. Remove the shipping retainer. 5. -
Page 23: Connections
PowerSafe DDm CONNECTIONS The cells are now positioned and ready to be connected. The cells must be connected according to the polarities on the ASSEMBLY DRAWING and the following instructions. Before preparing and making connections, heat NO-OX-ID grease in hot water as necessary to soften for application with a paintbrush. -
Page 24: Inter-Cell Connectors
Inter-Cell Connectors The connections are made by bolting the supplied lead-plated copper inter-cell and inter- module connectors to the cell posts of opposite polarity on adjacent cells. See ASSEMBLY DRAWING for details. 1. Clean the contact surface of the inter-cell connector using a stiff-bristle nonmetallic brush/pad. -
Page 25: Terminal Bars
PowerSafe DDm Terminal Bars Terminal bars are supplied with the battery system to provide a cell terminal-to-terminal plate connection. 1. Inspect the system to be assured that all cells are connected correctly – POSITIVE to NEGATIVE and according to the ASSEMBLY DRAWING. -
Page 26: Initial System Readings
INITIAL SYSTEM READINGS Measure the DC system voltage across the system terminals. Voltage should equal approximately 2.15 times the number of cells in the system (See Table 3). If the voltage is lower than 2.15 times the number of cells in the system, inspect the system to be assured that all cells are connected correctly —... -
Page 27: Safety Shields And Covers
PowerSafe DDm SAFETY SHIELDS AND COVERS Safety shields and covers are provided to help prevent accidental contact with connections after installation and during operations. Safety shields and covers should remain in place at all times during normal operation of the system. Terminal plate covers are provided as necessary to prevent accidental contact with the “live”... - Page 28 NOTES Page 18 Publication No. US-DDm-IM-003 www.enersysinc.com November 2003...
- Page 30 PRECAUTIONS* Do Not bring any heat or flame source near battery. Do Not remove pressure relief valves. DO NOT PUSH ON CENTER USE EDGE OF MODULE TO POSITION BATTERY WHEN POSITIONING BATTERY Do Not lift any cells by the terminal posts. Do Not tamper with seal nuts on the cell post.
- Page 31 Safety, Storage, Operating and Maintenance Manual VRLA Battery Systems mSeries, DDm, DDS, DGX, DDV and SC Publication No. US-VR-OM-002 March 2008...
- Page 32 Safety, Storage, Operating and Maintenance Manual VRLA Battery Systems mSeries, DDm, DDS, DGX, DDV and SC When working with any EnerSys ® Modular Battery System, be sure to refer to the Installation Manual specified for that system and Rack Assembly Instructions included in the rack shipment. Publication No.
- Page 33 This manual provides full instructions regarding safety, storage, operation, and maintenance for EnerSys valve-regulated lead acid batteries, as well as certain installation considerations. To ® maximize safety and performance, read the accompanying Installation Manual thoroughly. Failure to observe the precautions as presented may result in injury or loss of life. ©...
- Page 34 GENERAL SAFETY INSTRUCTIONS Warnings in this manual appear in any of three ways: The danger symbol is a lightning bolt mark enclosed in a triangle. The danger symbol is used to indicate imminently hazardous situations, locations and Danger conditions which, if not avoided, WILL result in death, serious injury and/or severe property damage.
- Page 35 IMPORTANT SAFETY INSTRUCTIONS DANGER A battery can present a risk of electrical shock and high short circuit current. The following precautions should be observed when working with batteries. 1. Verify that the Uninterruptible Power Supply (UPS) is off and that power cord is disconnected from the power source.
- Page 36 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for PowerSafe™ mSeries Lead-Acid Battery Systems that should be followed during the installation and maintenance of the battery system. Only a qualified EnerSys service representative who is knowledgeable in batteries and ®...
- Page 37 When working with any EnerSys Modular Battery System, be ® sure to refer to the Installation Manual specified for that system and Rack Assembly Instructions included in the rack shipment. Publication No. US-VR-OM-002 March 2008 www.enersys.com...
- Page 38 TABLE OF CONTENTS GENERAL SAFETY INSTRUCTIONS ........... . i GENERAL INFORMATION .
- Page 39 BATTERY TAPS ............. . . 22 10.0 PILOT CELL .
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Page 40: General Information
1.0 GENERAL INFORMATION 1.1 Introduction EnerSys ® modular valve-regulated lead acid (VRLA) batteries have unique features that make them easy to install and maintain. These batteries are composed of absorbed glass mat (AGM) separators with flat plates and/or gelled electrolyte with tubular positive plates. The AGM retains the acid between the plates to ensure long float service. -
Page 41: Service
1.3 Service Should you require installation supervision, service, parts, accessories or maintenance; EnerSys has a nationwide service organization to assist with your new battery purchase. ® Please call your nearest EnerSys sales/service representative for more information or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service. -
Page 42: Safety
2.0 SAFETY 2.1 General PowerSafe™ valve-regulated lead acid batteries are reduced-maintenance batteries that oper- ate on recombinant principles and are safer than conventional "wet cell" lead-acid batteries. Under NORMAL operating conditions and use, their design features: • minimize hydrogen gas release •... -
Page 43: Safety Precautions
2.3 Safety Precautions 2.3.1 Sulfuric Acid Burns Because VRLA cells are sealed, they normally do not present an acid danger. However, they do contain sulfuric acid, which can cause burns and other serious injuries. Always wear protective clothing AND use the correct safety tools. In case of SKIN CONTACT with sulfuric acid, IMMEDIATELY REMOVE contaminated CLOTHING FLUSH the area THOROUGHLY with WATER... -
Page 44: Explosive Gases
2.3.2 Explosive Gases Batteries can generate gases, which when released can explode, causing blindness and other serious personal injury. Always wear protective clothing and use the correct safety tools. Eliminate any potential of sparks, flames or arcing. IN CASE OF FIRE: To extinguish a fire in a battery room containing lead-acid batteries, use a , foam or dry-chemical extinguishing medium. - Page 45 IF BATTERY SYSTEM IS GROUNDED: (system is intentionally grounded by connecting a battery terminal to ground) An increased shock hazard exists between the terminal of opposite polarity and ground, (i.e., dirt and acid on top of battery cell touching rack). If an unintentional ground develops within the already grounded system, a short circuit may occur and cause explosion or fire.
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Page 46: Inspecting The Battery Shipment
3.0 INSPECTING THE BATTERY SHIPMENT 3.1 General Precautions have been taken to pack the battery units, individual cells or cabinets containing batteries for shipment to ensure their safe arrival. However, upon receipt, you should inspect for evidence of damage that may have occurred during transit. WARNING During inspections, take precautions against electrical shock. -
Page 47: Concealed Damage
3.3 Concealed Damage Within 15 days of receipt, unpack the cells/batteries and check for concealed damage. Remember, you are handling a LIVE battery. Take precaution against a shock hazard. Follow all safety precautions as noted in Section 2.0. Note any: •... -
Page 48: Battery Storage Before Installation
4.0 BATTERY STORAGE BEFORE INSTALLATION 4.1 General Batteries should be unpacked, installed and charged as soon as possible after receipt. However, if this is impractical, follow the instructions below for storing the battery before installation. 4.2 Storage Location 1. Store batteries indoors in a clean, dry and cool location. Storage at higher temperatures will result in accelerated rates of self-discharge and possible deterioration of battery performance and life. -
Page 49: Advance Preparation
4.3 Advanced Preparation If storage time is likely to be exceeded, make advance preparation to have an adequate charger available and adjacent to an appropriate AC supply voltage. Positioning of the cells to accept temporary intercell connectors is another consideration of advance planning. -
Page 50: Installation Considerations
BEFORE INSTALLATION READ THIS SECTION THOROUGHLY. 5.0 INSTALLATION CONSIDERATIONS 5.1 General If you have any questions concerning the installation considerations, contact your EnerSys ® sales/service representative for clarification or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service. When planning the system space requirements, consider the following: •... -
Page 51: Considerations For Connecting The Battery System To Operating Equipment
TABLE 5.1 (continued) CONSIDERATION RECOMMENDATION Ventilation No special battery room or ventilation is required. However, do NOT install in an airtight enclosure. Grounding It is recommended that the modules or racks be grounded in accordance with NEC and/or local codes. Floor Reasonably level. -
Page 52: Considerations For Parallel Installation
To select the proper cable size: 1. Determine the cable size necessary to carry the design load. 2. Calculate the voltage drop of the cable between the battery terminal plate and the operating equipment. 3. Increase cable size to achieve the allowable voltage drop. Cable selection should provide no greater voltage drop than required between the battery system and the operating equipment as determined by the equipment/system supplier. -
Page 53: Unpacking And Handling For Installation
6.0 UNPACKING AND HANDLING FOR INSTALLATION 6.1 General Battery modules are shipped upright on pallets. All accessories for installation and use are supplied as optional prepackaged kits and are shipped on separate pallet(s) and/or in box(es). Cells may be packed in wooden boxes, which must be opened completely and carefully. The cells must then be handled as described in the appropriate Installation Manual. -
Page 54: Recommended Installation Equipment And Supplies
6.3 Recommended Installation Equipment and Supplies Before working with the battery system, be sure that you have the proper protective clothing, safety equipment and insulated tools as specified in Section 2.0. The following is a list of equipment typically recommended for installation of a PowerSafe™ VRLA Battery System. -
Page 55: Initial And/Or Freshening Charge
7.0 INITIAL and/or FRESHENING CHARGE Batteries lose some initial charge during shipment and storage. Depending on storage time, a battery may require a freshening charge. See Section 4.0 for battery storage times. Constant voltage is the ONLY charging method allowed. Confirm that your charger bus is a constant voltage type. -
Page 56: Operation
8.0 OPERATION 8.1 General The sealed design of the VRLA batteries makes it impossible to measure specific gravity as a state-of-charge indicator. The state-of-charge can be identified to some degree by the amount of charging current going to the battery exceeding 2.35 volts per cell. 8.1.1 Determining the State-of-Charge The following method can be used to determine the state-of-charge of the battery. -
Page 57: Float Operation
8.2 Float Operation In this type of operation, the battery and the critical load circuits are continuously connected in parallel with a constant voltage charger. The charger should be capable of: • charging the battery from the discharged condition while supplying the DC power to the connected DC load •... -
Page 58: Float Charge Method
8.2.1 Float Charge Method A float charge is given after the battery has been given its initial charge. To perform a float charge, follow the procedure below after the battery has been given its initial charge: 1. Determine that the VOLTS PER CELL nominal value is within the 2.23 to 2.27 range. This can be done by measuring the total battery string voltage and dividing by the number of cells in the string. -
Page 59: Equalizing Charge
8.3 Equalizing Charge Under NORMAL conditions an equalizing charge is NOT required. An equalizing charge is a special charge given to a battery when nonuniformity in voltage has developed between cells. It is given to restore all cells to a fully charged condition. Nonuniformity of cells may result from: •... -
Page 60: Equalizing Charge Method
8.3.1 Equalizing Charge Method Constant voltage charging is the method for giving an equalizing charge. To perform an equalizing charge, follow the procedure below: 1. Determine the maximum voltage that may be applied to the system equipment. 2. Divide this voltage by the number of cells connected in a series. This is the MAXIMUM VOLTS PER CELL to be used for the equalizing charge. -
Page 61: Battery Taps
9.0 BATTERY TAPS Connections made to a battery for tapping a certain group of cells to provide a voltage other than the total battery voltage is NOT recommended and can void the warranty. Tapping results in an imbalance of the system during charging and discharging, causing unsatisfactory operation. -
Page 62: Corrosion Cleaning
11.1.2 Battery Taps To clean mild corrosion from the battery: Disconnect the battery. Remove corrosion by wiping with a cloth dampened with bicarbonate of soda solution [mix 1 gallon (4l) of water with 1 lb. (500g) of bicarbonate of soda]. Follow with a cloth dampened with clear water. -
Page 63: Test Procedures
11.2 TEST PROCEDURES 11.2.1 Procedure for Battery Capacity Tests Use the following test procedure or use the test procedure described in IEEE std. 1188. An equalizing charge, as described in Section 8.3, must have been given within the last 7 days. - Page 64 K TABLE TABLE 11.1 Initial Temperature Factor K ( ˚ C ) ( ˚ F ) 16.7 1.098 17.2 1.092 17.8 1.086 18.3 1.080 18.9 1.072 19.4 1.064 20.0 1.056 20.6 1.048 21.1 1.040 21.7 1.034 22.2 1.029 22.8 1.023 23.4 1.017 23.9...
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Page 65: Maintenance Records
11.3 Maintenance Records A complete recorded history of the battery operation is essential for obtaining satisfactory performance. Good records will show when corrective action may be required to eliminate possible charging, maintenance or environmental problems. Should you have ANY questions concerning how to perform the required maintenance, contact your nearest EnerSys ®... -
Page 68: Temporary Non-Use (Extended Outage)
12.0 TEMPORARY NON-USE (EXTENDED OUTAGE) 12.1 Installed/Out-of-Service System If an INSTALLED battery is expected to STAND IDLE longer than the storage period recommended for the storage temperature (see Table 4.1 on page 9), treat as follows: Before taking the battery out of service, give it an equalizing charge according to Section 8.3.1. - Page 69 NOTES Publication No. US-VR-OM-002 March 2008 www.enersys.com...
- Page 70 PRECAUTIONS* 1. Do not bring any heat or flame source near battery. 2. Do not remove pressure relief valves. 3. Do not lift any cells by the terminal posts. 4. Do not tamper with seal nuts on the cell post. 5.