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Summary of Contents for EnerSys PowerSafe mP Series
- Page 2 © 2017 by EnerSys. All rights reserved. This document is proprietary to EnerSys. This document cannot be copied or reproduced in whole or in part, without the express written permission of EnerSys. Please check our website for literature updates.
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Page 3: General Safety Instructions
The explosion warning symbol Explosion is used to indicate locations and conditions where warnings molten, exploding parts may cause serious injury or death if the proper precautions are not observed. Publication No. US-MP-OM-001 March 2017 www.enersys.com... - 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. Publication No. US-MP-OM-001 March 2017 www.enersys.com...
- Page 5 Misuse of this equipment could result in human injury and C UTION equipment damage. In no event will EnerSys be responsible or liable for either indirect or consequential damage or injury that may result from the use of this equipment.
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Page 6: Table Of Contents
8.2 Frame Module Weldment ........... . . 18 Publication No. US-MP-OM-001 March 2017 www.enersys.com... - Page 7 22.2 Return to Service ............42 Publication No. US-MP-OM-001 March 2017 www.enersys.com...
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Page 8: General Information
1.0 GENERAL INFORMATION 1.1 Introduction EnerSys ® modular valve-regulated lead acid (VRL ) batteries have unique features that make them easy to install and maintain. These batteries are composed of absorbed glass mat ( GM) separators with flat plates and electrolyte. -
Page 9: Precautions
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. lso, refer to all applicable federal, state and local regulations and industry standards. -
Page 10: Safety
YOU SHOULD BE TRAINED IN H NDLING, INST LLING, OPER TING ND M INT INING B TTERIES BEFORE YOU WORK ON NY B TTERY 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 ®... -
Page 11: Safety Precautions
0.5 kg/5.0 liters of water) on the clothing or material. pply the solution until bubbling stops, then rinse with clean water. NOTE: In case of a electrolyte SPILL, bicarbonate of soda or an emergency spill kit should be within the battery room. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 12: Explosive Gases
Always wear protective clothing and use nonconductive or insulated safety tools when working with ANY battery system. Remove all jewelry that could produce a short circuit. BEFORE working on the system: 1. Disconnect LL loads and power sources to the battery. Use appropriate lockout/tagout procedures. Publication No. US-MP-OM-001 March 2017 www.enersys.com... - Page 13 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. Publication No. US-MP-OM-001 March 2017...
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Page 14: Inspecting The Battery Shipment
• wetness or stains, indicating electrolyte leakage. 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. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 15: Concealed Damage
REIMBURSEMENT FOR D M GES. Refer to the Bill of Lading, if, when performing the parts inventory, you are unsure about the appearance of a part. If you have any questions concerning potential damages, 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 16: Battery Storage Before Installation
Freshening charges are required before the end of the storage time period, or more frequently, as noted in Table 4.1. 7. FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S WARRANTY. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 17: Dvance Preparation
Make every effort to get the battery connected to the charger before expiration of the storage period, thereby avoiding the additional labor cost of freshening charges. WARNING Failure to charge as noted voids the battery’s warranty. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 18: Installation Considerations
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. -
Page 19: Considerations For Connecting The Battery System To Operating Equipment
VRL batteries may be installed next to electronic Equipment equipment, unless the equipment generates heat. Cell Identification/ EnerSys ® recommends battery one (1) be at the positive (+) output. Numbering Then label the cells in ascending sequential order as the cells are connected in series. -
Page 20: Considerations For Parallel Installation
• as short as possible (equal to the longest inter-cell connector). • of equal lengths to the load. • of sufficient ampacity (cable ampacity should not be exceeded). Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 21: Unpacking And Handling For Installation
Cell Number Set Labels ssembly Hardware Rack Parts NO-OX-ID Grease for Battery Posts ssembly Drawing Bill of Materials/Packing List Operation & Installation Manual Safety Shields and Standoffs Miscellaneous: • Cables • Side Termination Kits Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 22: Recommended Installation Equipment And Supplies
Stiff-Bristle Nonmetallic Brush/Pad Tape Measure (Nonmetallic) Safety Equipment and Clothing Small Paintbrush NO-OX-ID Grease CAUTION Be sure you have all the proper protective clothing and safety tools and equipment on hand before starting the installation. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 23: System Layout
3. Mark the floor with the location of the floor anchors. ll holes are to be used when anchoring to the floor. Dimension “L” in Figure 1 is to the outermost set of holes. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 24: Nchor Spacing
FIGURE 4 SINGLE STACK MULTI-STACK 4.00 in. TYP. 4.00 in. TYP. (10.2 cm) (10.2 cm) L + 4.00 in. 4.00 in. TYP. (10.2 cm) (10.2 cm) (2 x L) + 8.00 in. (20.3 cm) Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 25: Frame Assembly And Installation
75 ft-lbs. Cells may be installed at this time or the next FIGURE 5a frame module weldment may be fastened to the previously installed module. This manual will follow the method of installing cells next. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 26: Battery Cell Module Installation
4. Reinstall terminal safety caps. NOTE: ® Report any defects to your nearest EnerSys sales/service representative for resolution, or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service. -
Page 27: Module Retainers
See Figure 7a & 7b. 2. Torque to 20 ft-lbs. 3. Install cell modules and retainer plates as described until module is full. See Figure 7. FIGURE 7 Publication No. US-MP-OM-001 March 2017 www.enersys.com... - Page 28 Upper Frame Module Weldment Lower Frame Module Weldment FIGURE 8 FIGURE 8a 5. Install cell modules and retainer plates as described in Section 9.0 & 9.1. See Figures 9, 10, 11. FIGURE 9 FIGURE 10 FIGURE 11 Publication No. US-MP-OM-001 March 2017 www.enersys.com...
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Page 29: Top Module Weldment Installation
• Top module weldment • Frame module weldment • Flat washer • Hex nut FIGURE 12a 2. Install top row of retainer plates as described in Section 9.1. See Figure 13. FIGURE 13 FIGURE 12 Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 30: Electrical Bonding Instructions
Figure 15, 15a, 16 & 16a. 3. Torque all bolts to 15 ft-lbs. Hand tighten red insulators (cherries). FIGURE 16 FIGURE 16a Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 31: Connections
Lead Plated Parts — Be careful not to remove the lead plating with excessive brushing. pply a light coat of NO-OX-ID grease to the contact surfaces of the inter-cell connector and terminal post. FIGURE 17 Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 32: Terminal Connections
FIGURE 18 pply a light coat of NO-OX-ID grease to the terminal bar contact area. 4. Install terminal bar as described in Section 13.1 and as shown in Figure 18a. FIGURE 18a Publication No. US-MP-OM-001 March 2017 www.enersys.com... - Page 33 8. For the final system connection, bolt the L-Bracket to the terminal plate as shown in Figure 18e. 9. Torque bolts to 85 in-lbs. FIGURE 18d FIGURE 18e Publication No. US-MP-OM-001 March 2017 www.enersys.com...
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Page 34: Initial System Readings
EnerSys ® sales/service representative, or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service. 4. Make a copy of the Battery Maintenance Report found in the Safety, Storage, Operating and Maintenance Manual. -
Page 35: Terminal Plate Covers And Safety Shields
2. Starting with bottom row, hang safety shields on standoffs as shown in Figure 21a. FIGURE 21 NOTE: The bottom of each safety shield will overlap, on the outside, the top of the shield below it. FIGURE 21a Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 36: Initial And/Or Freshening Charge
Monitor the battery temperature during the charge. If the cell/battery temperature exceeds 105˚F (40˚C) stop the charge immediately and allow the temperature to decrease below 90˚F (32˚C). Failure to follow this warning may result in severe CAUTION overcharge and damage to the cell/battery. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 37: Operation
3. When the current level remains constant for three consecutive hours, the state-of- charge is approximately 95 to 98%. Full charge can be assumed. For most requirements, the battery is ready for use. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 38: Float Operation
Constant voltage output charging equipment is recommended. This type of charger, properly adjusted to the recommended float voltages, and the following recommended surveillance procedures will assist in obtaining consistent serviceability and optimum life. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 39: Float Charge Method
(When the mP Series cells are new, expect to see variations in float voltage from cell to cell within a string. These cell voltages should be within ±0.05 volts of the nominal setting). Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 40: Equalizing Charge
Do NOT equalize mP Series cells if they are within the following voltage limits: ±0.09 volts of the nominal value, as determined in Section 17.2.1, Procedure No.1. AFTER ±0.05 volts of the nominal value, as determined in Section 17.2.1, oNE YEAR Procedure No.1. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 41: Equalizing Charge Method
During charge, if the cell/battery temperature exceeds 105˚F (40˚C) stop the charge immediately and allow the temperature to decrease below 90˚F (32˚C). Failure to follow this warning may result in severe overcharge and damage to the cell/battery Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 42: Battery Taps
Do NOT use any type of oil, solvent, detergent, petroleum-based solvent or ammonia solution to clean the jars or covers. These materials will have an adverse affect and cause permanent damage to the battery jar and cover and will void the warranty. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 43: Mild Corrosion Cleaning
ST MPED FL T W SHERS M Y H VE ONE SH RP EDGE. INST LL THE W SHER WITH THE SH RP EDGE W Y FROM THE INTER-CELL CONNECTOR TO VOID D M GING THE PL TING. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 44: Test Procedures
® sales/service representative or call the corporate office number listed on the back of this manual and ask for EnerSys Reserve Power Service. ccumulate and permanently record the following data for review by supervisory personnel so that any necessary remedial action may be taken: 1. - Page 45 Then corrective actions can be ® taken to avoid a battery system failure. EnerSys recommends that you follow IEEE-1188 standards for internal ohmic measurements for VRL cell types.
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Page 48: Cell Reading
21.0 CELL READING The square post terminal on this product allows for direct access to the terminal when taking cell readings. The diagrams below are meant as a reference guide when taking readings. Publication No. US-MP-OM-001 March 2017 www.enersys.com... -
Page 49: Temporary Non-Use (Extended Outage)
To return the battery to normal service: Reconnect the battery, the load and charger. If any cells OCV’s are below 2.11 V, give the battery an equalizing charge as described in Section 17.3.1. Return the battery to float operation. Publication No. US-MP-OM-001 March 2017 www.enersys.com... - Page 50 Fax: +1-610-372-8613 Gateway East Building #11-03 www enersys com © 2017 EnerSys. All rights reserved. Singapore 189721 Trademarks and logos are the property of Tel: +65 6508 1780 EnerSys and its affiliates, except ISO™, which is not the property of EnerSys.
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