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Summary of Contents for EnerSys PowerSafe
- Page 1 Battery Safety, Storage, Installation, Operation & Maintenance Manual RE Flooded Lead-Acid Batteries Publication No. US-RE-IOM-002 January 2012...
- Page 2 . 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 the purpose for which it was delivered, without the express written permission of EnerSys. www.enersys.com Publication No. US-RE-IOM-002...
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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-RE-IOM-002 January 2012... - 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-RE-IOM-002 January 2012...
- Page 5 Keep unauthorized personnel away from batteries. Misuse of this equipment could result in human injury and equipment damage. In no event will EnerSys be responsible or Caution 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
6.3.2 Six Cell Unit Handling (6RE) ................. 16 SYSTEM INSTALLATION ..................17 System Layout ......................17 Installation Considerations ..................18 7.2.1 Installation Precautions ................. 18 7.2.2 Arrangement ....................18 7.2.3 Spacing ......................18 Battery Installation ..................... 19 www.enersys.com Publication No. US-RE-IOM-002 January 2012... - Page 7 Adding Water ......................35 12.5 Quality of Water ......................36 STORAGE BATTERY REPORT - Battery in Float Service Sheet No. _________ ..37 APPENDIX ..........................38 HYDROGEN EVOLUTION CALCULATION OF RE CELLS ............38 www.enersys.com Publication No. US-RE-IOM-002 January 2012...
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Page 8: General Information
The RE range benefits from the square tubular plate when compared to both round tube and flat plate battery designs. The PowerSafe RE battery’s square tubes provide more surface area on the positive plate, exposing more positive plate active material to the electrolyte. The unique tube construction also prevents shedding of the active material –... -
Page 9: Range Summary
Lifting can be done with an overhead crane using specially ® designed lifting straps available from EnerSys . All intercell connections are made with welded lead connectors so only terminal connections must be made. Terminal connections of each unit are bolt-on, allowing easy cabling to the next unit or the DC bus. -
Page 10: Precautions
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 Service. www.enersys.com Publication No. -
Page 11: 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 Service. Safety Equipment and Clothing When working with any battery system, be sure you have the necessary tools and safety... -
Page 12: 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-RE-IOM-002 January 2012 Page 5... -
Page 13: 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, rack grounding is recommended. Page 6 www.enersys.com Publication No. US-RE-IOM-002 January 2012... - Page 14 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 Service. www.enersys.com Publication No.
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Page 15: 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 8 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 16: Concealed Damage
® 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 Service. -
Page 17: Battery Storage Before Installation
Following faulty use such as excessive over-discharge, bad maintenance, or by the • addition of non-demineralized water Temperature rise • Do NOT stack pallets. DAMAGE MAY OCCUR AND THE WARRANTY WILL BE VOIDED. Page 10 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 18: Storage Interval
Storage Interval ® PowerSafe RE batteries must be given a freshening charge at maximum storage times shown in the table below, or when open circuit voltage (“OCV”) approaches 2.06 VPC, whichever occurs first. Under higher temperature conditions, greater charging frequency is required. Use date of battery shipment to determine freshening charge requirements. -
Page 19: 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 PowerSafe... - Page 20 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. Shim up to 1/4 inch (6 mm) maximum to level battery front to rear and side to side.
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Page 21: Considerations For Connecting The Battery System To Operating Equipment
• cables from the batteries to the load must be: as short as possible, • of equal lengths to the load (do not exceed cable ampacity), and • of sufficient ampacity. • Page 14 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 22: Unpacking And Handling For Installation
Tape Measure (Nonmetallic) Safety Equipment and Clothing Small Paint Brush NO-OX-ID Grease Be sure you have all the proper protective clothing and safety tools and equipment on hand before starting the installation. www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 15... -
Page 23: Cell/Battery Handling
Lift and move these batteries manually. For cells heavier than 50 lbs, 2 people should be used to move and position cells. Optionally, a strap can be placed under the container and run through the handles for lifting with a crane. Contact your EnerSys sales/service representative for correct lifting strap and lifting instructions. 6.3.2... -
Page 24: System Installation
NOTE: The floor must be capable of supporting the weight of the Battery. 4. Batteries should be kept in the original shipping containers until installed. However, if you must remove the batteries before installation, see the procedures in Section 6.3, “Cell/Battery Handling.” www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 17... -
Page 25: 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 Service. -
Page 26: Battery Installation
Battery Installation ® To install an EnerSys battery system, follow the procedures below: 1. Clear area where battery will be placed, allow space for installation maneuvering. 2. Employ the appropriate lifting/handling method for the cells to be installed (as described in Section 6.3). - Page 27 Allowing too low a level defeats the flame arrestor function. Number the cells starting from the positive terminal of the battery for maintenance purposes. Pressure-sensitive ® adhesive labels are available from EnerSys . Before MULTI CELL UNITS (6RE) CONNECTIONS applying the cell numbers, clean surfaces according to Figure 7.2...
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Page 28: Preparing And Installing Connections
WARNING Make sure that all bolted battery connections are torqued to the recommended values. The increased resistance of a loose connection can generate heat and become a fire hazard. www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 21... -
Page 29: Terminal Plates
With a small paintbrush, apply a light coating of heated NO-OX-ID grease to contact areas. With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the electrical contact areas of the terminal plate. TERMINAL PLATE INSTALLATION Figure 7.3 Page 22 www.enersys.com Publication No. US-RE-IOM-002 January 2012... - Page 30 Inspect the cell connections of the system to ensure that all cells are connected correctly, POSITIVE (+) to NEGATIVE (-), Measure the voltage across the system terminals. Voltage of the battery should equal approximately 2.10 times the number of cells in the string. www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 23...
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Page 31: Initial And/Or Freshening Charge
20 to 40°C 2.45V 2. Add demineralized water if cells to not reach maximum level. Allow an additional 3 days of charge for stirring of the electrolyte if water is added. Page 24 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 32: Operation
As a rule, installations will be equipped with a regulator whose voltage threshold values will protect against deep discharge: TABLE 9.2 DISCHARGE TIME 120h 240h Low voltage alarm 1.92V 1.92V 1.95V Disconnect 1.80V 1.85V 1.90V voltage www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 25... -
Page 33: Hydrometer Readings - Specific Gravity
To take a specific gravity reading, use the level indicator’s center funnel. Access this funnel flipping over the flame arrestor top. ® A long stemmed hydrometer can be purchased form EnerSys for measurements (Cat. 81332). The long stem of the hydrometer can be cut down so it reaches the separator protector when the hydrometer is fully inserted. - Page 34 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. www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 27...
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Page 35: Equalizing Charge
Alternatively, if an outside charging source is available, the batteries may be constant current equalized at 4.5%, in amps, of the battery’s nominal amp hour rating (C Page 28 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 36: Operating Temperature
1350 1115 5584 2992 1987 1452 1163 4814 2580 1713 1252 1003 Batteries for renewable energy applications Derating factor for number of cycles vs. average cell temperature Temperature in °C Figure 9.2 www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 29... -
Page 37: Battery Taps
Because a small amount of electrolyte may be lost in taking hydrometer readings, you should select a different cell as the pilot cell annually. Read and record the pilot cell voltage on a monthly basis between regularly scheduled individual cell readings. Page 30 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 38: Maintenance
(4l) of water with 1 lb. (500g) of bicarbonate of soda]. Follow with a cloth dampened with clear water. 3. Dry with a clean cloth. 4. With a small paintbrush, apply a light coat of heated NO-OX-ID grease to the entire bolted connection. www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 31... -
Page 39: Heavy Corrosion Cleaning
These materials may cause permanent damage to the battery jar and cover and will void the warranty. Page 32 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 40: 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 Service. - Page 41 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 34 www.enersys.com Publication No. US-RE-IOM-002 January 2012...
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Page 42: Corrective Actions
In cold climate with unheated battery rooms, water should be added only when the battery temperature is 50 F (10 C), or above. Never add any special types of powders, solutions or jellies to the batteries. www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 35... -
Page 43: 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 36 www.enersys.com Publication No. US-RE-IOM-002 January 2012... -
Page 44: Storage Battery Report - Battery In Float Service Sheet No
VOLTS Notes Quarterly ADDING WATER (when required) Add water after completing hydrometer readings. Date Quantity _____________ ______________ Qts. Annually Connector Bolts Retorqued Acceptance Test Results — Date Performance Test Results — Date www.enersys.com Publication No. US-RE-IOM-002 January 2012 Page 37... -
Page 45: Appendix
C). The cfm values will double for every 15 F (8 C) of temperature rise. If the temperature drops, the cfm values will be halved for every 15 F (8 C) decrease. Page 38 www.enersys.com Publication No. US-RE-IOM-002 January 2012... - Page 46 Do Not clean cell with anything other than water/bicarbonate of soda. Do Not over torque connections. Do Not exceed EnerSys recommended storage intervals without refreshing charge. * These are only a few of the precautions. Please read this manual thoroughly for complete details.
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