EnerSys PowerSafe Data Safe Operation & Maintenance Manual
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EnerSys PowerSafe Data Safe Operation & Maintenance Manual

Flooded lead-acid batteries c, d, e, f and g
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Safety, Storage, Installation,
Operation & Maintenance Manual
Flooded Lead-Acid Batteries
C, D, E, F and G
Publication No. US-FL-IOM-002 January 2007

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  • Page 1 Safety, Storage, Installation, Operation & Maintenance Manual Flooded Lead-Acid Batteries C, D, E, F and G Publication No. US-FL-IOM-002 January 2007...
  • Page 2 Failure to observe the precautions as presented may result in injury or loss of life. This document is proprietary to EnerSys. This document cannot be copied or reproduced in whole or in part, nor can its contents be revealed in any manner or to any person except to meet...

  • Page 3: General Safety Instructions

    The explosion warning symbol is Explosion used to indicate locations and conditions where warnings molten, exploding parts may cause serious injury or death if the proper precautions are not observed. www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 4 10. Use proper lifting means when moving batteries and wear all appropriate safety clothing and equipment. 11. Do not dispose of lead acid batteries except through channels in accordance with local, state and federal regulations. www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 5 This manual contains important instructions for Flooded 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 the required precautions should perform servicing of the batteries. Keep unauthorized personnel away from batteries.

  • Page 6: Table Of Contents

    Installation Precautions ................. 19 7.2.2 Arrangement....................19 7.2.3 Spacing ......................19 Battery Installation..................... 20 Preparing and Installing Connections ............... 23 7.4.1 Terminal Posts ....................23 7.4.2 Intercell Connectors ..................23 7.4.3 Terminal Plates ..................... 26 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 7 Quality of Water......................40 Storage Battery Report - Battery in Float Service ...............41 12.6 Filling and Charging Moist-Charged Cells ..............42 13.0 TEST PROCEDURES ....................44 13.1 Procedure for Battery Capacity Tests................44 APPENDIX - HYDROGEN EVOLUTION CALCULATION............46 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 9: General Information

    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. Also, refer to all applicable federal, state and local regulations and industry standards.

  • Page 10: Safety

    MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM. You MUST understand the risk of working with batteries and BE PREPARED and EQUIPPED to take the necessary safety precautions. If not, contact EnerSys Reserve Power Service. Safety Equipment and Clothing...

  • Page 11: Safety Precautions

    3. Apply the solution until bubbling stops, then rinse with clean water. NOTE: In case of a sulfuric acid SPILL, bicarbonate of soda or an emergency spill kit should be within the battery room in accordance with OSHA regulation 1910.178g2. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 12: Explosive Gases

    2. If working on an assembled battery system, sectionalize (interrupt the battery in sections) into safe working voltage levels. 3. Check the battery system grounding. Grounding of the battery system is NOT recommended. However, grounding of the rack is recommended. Page 4 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 13 If you have ANY question concerning safety when working with the battery system, contact your local EnerSys sales/service representative to clarify any of the noted safety precautions, or, call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service.

  • Page 14: Inspecting Battery Shipment

    If damage is noted: 1. Make a descriptive notation on the delivery receipt before signing. 2. Request an inspection by the carrier. 3. File a damage report. Page 6 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 15: Concealed Damage

    REIMBURSEMENT FOR DAMAGES. Refer to the Bill of Lading, if, when performing the parts inventory, you are unsure about the appearance of a part. If you have questions concerning potential damages, contact your local EnerSys sales/service representative, or, call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service.

  • Page 16: Battery Storage Before Installation

    Make every effort to get the battery installed and connected to the charger before the expiration of the storage period, thereby avoiding the additional labor cost of preliminary freshening charges. WARNING FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S WARRANTY. Page 8 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 17: Installation Considerations

    READ THIS SECTION THOROUGHLY. INSTALLATION CONSIDERATIONS General If you have any questions concerning the installation considerations, contact your EnerSys sales/ service representative. The diagrams shown are general representations and may not depict all models and options. When planning the system space requirements for the EnerSys flooded stationary batteries, consider the following: •...
  • Page 18 It is recommended that the racks be grounded in accordance with NEC and/or local codes. Codes Building codes and fire codes may require a spill containment system for battery installations. Please consult local building codes. EnerSys offers spill containment systems. Contact your EnerSys sales/ service representative for more information. Floor Reasonably level.

  • Page 19: Considerations For Connecting The Battery System To Operating Equipment

    • as short as possible, • of equal lengths to the load (do not exceed cable ampacity), and • of sufficient ampacity. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 20: Unpacking And Handling For Installation

    Safety Equipment and Clothing Small Paint Brush Standard Allen Wrench Set NO-OX-ID Grease Be sure you have all the proper protective clothing and safety tools and equipment on hand before starting the installation. Page 12 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 21: Cell/Jar Handling

    Use a mechanical device, such as a hoist or crane, for lifting. Tilt the cell about 1 inch (25 mm) so as to position the lifting belt. See Figure 6.1. LIFTING MEDIUM SIZE CELL Figure 6.1 www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...
  • Page 22 Figure 6.2 Figure 6.2 Figure 6.2 Figure 6.2 LIFTING MEDIUM-SIZE CELL Figure 6.3 LIFTING MEDIUM-SIZE CELL LIFTING MEDIUM-SIZE CELL LIFTING MEDIUM-SIZE CELL LIFTING MEDIUM-SIZE CELL Figure 6.4 Figure 6.4 Figure 6.4 Figure 6.4 Page 14 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 23: Large Cell Handling (D And G)

    3. Fold the lifting belt in half and push each loop end Down between the cells/units until the loops touch the shipping pallet. See Figure 6.5. NOTE: Ensure that the straps are placed around the two sides of the cell/unit that will be positioned across LIFTING LARGE-SIZE CELL www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...
  • Page 24 Adjust the belt loop is even with the loops on the two free ends. See Figure 6.8. LIFTING LARGE-SIZE CELL Figure 6.8 Page 16 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 25 To prevent one end of the unit from "kicking out," assign one person to steady the unit on a level plane during the entire lifting procedure. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 26: System Installation

    SYSTEM INSTALLATION EnerSys flooded batteries are installed on racks that differ in type, size, seismic rating, and configuration. Refer to the RACK ASSEMBLY DRAWING and instructions included with the rack shipment for the details of your installation. System Layout Lay out the battery system before installation. Consult Section 5.0 for installation considerations.

  • Page 27: Installation Considerations

    Do not install where water, or any other foreign object or substances may get inside the Battery System. NOTE: Contact your nearest EnerSys sales/service representative when paralleling Battery Systems, to ensure compatibility of mating different batteries. Or, call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service.

  • Page 28: Battery Installation

    CELL/JAR PLACEMENT Figure 7.1 To lubricate the rack rails for sliding cells into position, use only EnerSys Pro-Slide or Dow Corning Silicon Compound #111. When sliding the cells on the lubricated rails, Do NOT push on the center of the cell/unit.
  • Page 29 Remove the belt loops (if used) from the lifting hook and pull the belt free from under the unit. Also remove any remaining protective packing covers. See Figure 7.4. Move cell into final position, observing spacing requirements. CELL/JAR PLACEMENT Figure 7.4 www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...
  • Page 30 Repeat Procedures 5 thru 7 until all units are installed on all tier/steps of the rack. See Figure 7.5. To lubricate the rack rails for sliding cells into position, use only EnerSys Pro-Slide or Dow Corning Silicon Compound #111. As soon as cells are unpacked and installed on the rack, remove the shipping vent plugs and immediately install the flame arrestors.

  • Page 31: Preparing And Installing Connections

    Very light brushing and cleaning with a cloth is generally sufficient. With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the contact surface of the intercell connector. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...
  • Page 32 (Figure 7.6b and the detail). Stamped flat washers may have one sharp edge. Install with this edge away from the plated copper intercell connector to avoid damaging the plating. Page 24 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 33 Apply a light coat of heated NO-OX-ID grease to the bolted connection with a small paintbrush in the area of the terminal post only. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 34: Terminal Plates

    Install the terminal connectors to cell posts. Tighten all connections according to the torque values in Table 7.1. TERMINAL PLATE CABLE CONNECTOR TERMINAL CONNECTOR WITH NEMA LUG L SHAPE OPTIONAL TERMINAL PLATE INSTALLATION Figure 7.7 Page 26 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 35 Section 12.1.3. Then remake the connection. NOTE: Do NOT recalculate the average resistance and do NOT repeat the cleaning procedure. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 36: Initial And/Or Freshening Charge

    Check the nameplate to determine whether the battery is of a lead-antimony type or a lead-calcium type. Connect battery positive (+) terminal to charger bus positive (+) terminal. Connect battery negative (-) terminal to charger bus negative (-) terminal. Page 28 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 37 C) , stop the charge immediately and allow the temperature to decrease below 100 F ( 38 C ). Failure to follow this warning may result in severe overcharge and damage to the cell/battery. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 38: Operation

    • one or more cells fall below the following critical voltages on float, corrected for temperature. (Refer to Section 9.4 for equalizing charge.) TABLE 9.2 MINIMUM TEMPERATURE – CORRECTED FLOAT VOLTAGES Nominal Specific Gravity Cell Voltage 1.215 2.13 1.250 2.14 Page 30 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 39: Hydrometer Readings - Specific Gravity

    When taking hydrometer readings, hold the hydrometer stem in an upright position so that the hydrometer floats freely and does not touch at either the top or the sides (See Figure 9.1). www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...
  • Page 40 C) , add one point (.001) to the hydrometer reading. For every 3 ( 1.67 C) of temperature below 77 F ( 25 C), subtract one point (.001) from the hydrometer reading. Page 32 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 41: Equalizing Charge

    NOTE: The voltage of a warm cell will be lower than the average. Its voltage can be corrected for temperature by adding 0.003V for each degree Fahrenheit (0.005 V/ that the cell temperature is above the average temperature of the other cells. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 42: Operating Temperature

    TABLE 9.5 – RELATIONSHIP OF TEMPERATURE TO BATTERY LIFE % of 8-Hr. Capacity Antimony Flat Plate Calcium Flat Plate Approx. number of cycles ― at 80% discharge Average operating Temp. Life Expectancy in Full Float Application (years) Page 34 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 43: Battery Taps

    Read and record the pilot cell voltage on a monthly basis between regularly scheduled individual cell readings. 12.0 MAINTENANCE EnerSys also recommends to follow IEEE Std. 450 for the battery maintenance in addition to the following: 12.1 Battery Cleaning Observe the battery for cleanliness at regular intervals.

  • Page 44: Corrosion Cleaning

    5. Recoat the contact surfaces with a thin application of the NO-OX-ID grease, heated to a liquid form and applied with a small paintbrush. 6. Reinstall and tighten connections to appropriate retorque value in Table 7.1. Page 36 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 45: Cleaning Flame Arrestors

    Should you have ANY questions concerning how to perform the required maintenance, contact your nearest EnerSys sales/service representative or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service.
  • Page 46 For system protection and to suit local conditions/requirements, more frequent readings (quarterly) are desirable. A sample record chart is provided. Make a copy of the chart to use for your permanent records. Page 38 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 47: Corrective Actions

    The mixing of the water with the electrolyte is a very slow process, especially with the low float currents of lead-calcium cells. In these cases realistic specific gravity readings may be obtained only after six or more weeks of charging at float voltages. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 48: Quality Of Water

    Fixed Solids* 200.0 Organic and Volatile* 150.0 Iron Chloride 25.0 Ammonium (NH Nitrates (NO 10.0 Nitrates (NO 10.0 Manganese 0.07 Calcium and Magnesium 40.0 * ASTM Spec. D-1888 Method A or equal Page 40 www.enersys.com Publication No. US-FL-IOM-002 January 2007...

  • Page 49: Storage Battery Report - Battery In Float Service

    _________________ _________ Qts. Annually Connector Bolts Retorqued Record contact resistance readings and any calculations. Date Range of Resistance Values Intercell Connectors _____________ ________________________ Acceptance Test Results — Date Performance Test Results — Date www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 50: Filling And Charging Moist-Charged Cells

    If cell temperatures exceed 110 F (43 C), interrupt the charge and wait until the temperature has dropped to 100 F (38 C). Then the charging may be resumed. Page 42 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 51 Nickel (Ni) 0.00004 0.00003 Manganese (Mn) 0.000008 0.000006 Nitrates (NO 0.0002 0.00016 Ammonium (NH 0.0004 0.0003 Chloride (Cl) 0.0004 0.0003 Fixed Residue 0.012 0.009 For test method — See Federal Specification 0S-801 (latest issue) www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 52: Test Procedures

    Where Ta = test discharge time to specified voltage. Where Ts = rated discharge time to specified voltage. 8. Recharge the battery, preferably using an equalizing charge (Section 9.4) to minimize the recharge time. Page 44 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 53 1.006 25.0 1.000 25.6 0.994 26.1 0.987 26.7 0.980 27.2 0.976 27.8 0.972 28.3 0.968 28.9 0.964 29.4 0.960 30.0 0.956 30.6 0.952 31.1 0.948 31.6 0.944 32.2 0.940 32.8 0.938 33.4 0.936 www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...

  • Page 54: Appendix - Hydrogen Evolution Calculation

    The values will double for every 15 F (8 C) of temperature rise. If the temperature drops, the current value will be halved for every 15 F (8 decrease. Antimony ranges indicate current increases due to cell aging. Page 46 www.enersys.com Publication No. US-FL-IOM-002 January 2007...
  • Page 55 320 cu. ft. (9.06 cu. m.). At the above hydrogen evolution rate of 0.538 cu. ft. (0.0152 cu. m.) per minute, it would require 10 hours to reach 2% concentration. Thus with one air change every 10 hours, the hydrogen concentration could be maintained below 2%. www.enersys.com Publication No. US-FL-IOM-002 January 2007 Page...
  • Page 56 Do Not clean cell with anything other than water/bicarbonate of soda. Do Not over torque connections. Do Not store EnerSys Lead Antimony batteries for over three months without charge – EnerSys Lead Calcium for over six months without charge, at normal temperatures.

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