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Summary of Contents for Rolls 8HHG2IP
- Page 1 RAILROAD & DIESEL STARTER BATTERY USER MANUAL Installation, charging and maintenance procedures for Rolls fl ooded lead-acid Railroad & Diesel Starter batteries.
- Page 2 RAILROAD & DIESEL STARTER...
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Page 3: Table Of Contents
TABLE OF CONTENTS 02 Equipment & Safe Handling Procedure, Inspection 03 Quick Check List, Disposal Procedure 04 Safety 05 Provisions Against Electrolyte Hazard 06 Installation 08 Charging 09 Recommended Float Voltage Specific Gravity Effect of Electrolyte Level On Specific Gravity Maintenance Electrolyte - Adding Distilled Water Watering Intervals... -
Page 4: Equipment & Safe Handling Procedure, Inspection
This manual provides the recommended setup, charging, Equalization and preventive maintenance procedures necessary to maximize the life of your Rolls batteries. If you have battery-related questions beyond the contents of this manual, we encourage you to visit our online Technical Support Desk (support.rollsbattery.com) for additional information or file a support ticket and our... - Page 5 QUICK CHECK LIST SHIPPING/RECEIVING (MUST INSPECT PRIOR TO DRIVER RELEASE!) • All parts are included • No acid spills • No visual damage to the batteries • Verify electrolyte levels INSTALLATION • Protective equipment should be worn • All electrical components should be turned off •...
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Page 6: Safety
SAFETY Follow your company’s safety instructions when working with or near locomotive starting batteries. Observe the warning label affixed to the battery. Thoroughly familiarize yourself with industry and government guidelines (OSHA, ANSI) for charging, handling and maintaining locomotive starting batteries. •... -
Page 7: Provisions Against Electrolyte Hazard
PROVISIONS AGAINST ELECTROLYTE HAZARD Electrolyte and water Electrolyte used in lead-acid batteries is an aqueous solution of sulphuric acid. Electrolyte used in NiCd and NiMH batteries is an aqueous solution of potassium hydroxide. Distilled or demineralised water is used when topping up the cells. Protective clothing In order to avoid personal injury from electrolyte splashes when handling electrolyte and/or vented cells or batteries, protective clothing shall be worn, such as:... -
Page 8: Installation
Maintenance tools such as funnels, hydrometers, thermometers which come in contact with electrolyte shall be dedicated either to the lead-acid or NiCd-batteries and shall not be used for any other purpose. INSTALLATION BLOCKING When installed, locomotive batteries must be properly blocked in the battery compartment as shifting or movement may occur which could cause damage to the battery. - Page 9 Failure to use or properly install the provided sensor may cause damage due to over/undercharge which is not covered under Rolls Battery manufacturer warranty. As a precaution, this sensor may also trigger a programmed safety charge cut-off as the battery should not exceed an operating temperature of 52ºC (125ºF).
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Page 10: Charging
CHARGING INITIAL REFRESHER CHARGE Rolls Railroad & Diesel Starter batteries are fully charged and tested as part of the quality assurance processes before shipping. Like other lead-acid batteries, it is normal for these models to self-discharge slightly during transit. The battery will also self-discharge at any time it is not maintained on a float charge or has been disconnected and placed in storage. -
Page 11: Recommended Float Voltage
shorten the life of the battery considerably. Undercharge is indicated by a decrease in specific gravity readings. Overcharge is commonly identified by faster and/or excessive water loss due to off-gassing, dark electrolyte due to burning oxide paste or very high specific gravity readings. -
Page 12: Specific Gravity
SPECIFIC GRAVITY The specific gravity of electrolyte in a battery cell is the most accurate measurement of actual state-of-charge. Specific gravity decreases during discharge and increases again as the battery is charged. To determine if a battery has reached full charge, test a sample of the electrolyte in each cell using a hydrometer or refractometer. -
Page 13: Effect Of Electrolyte Level On Specific Gravity
EFFECT OF ELECTROLYTE LEVEL ON SPECIFIC GRAVITY Varying electrolyte levels will affect the specific gravity reading of electrolyte. The specific gravity reading will decrease as distilled water is added to cells and will increase as the electrolyte level decreases. Over time, it is normal for the electrolyte level in each cell to drop as water evaporates during the charging process. -
Page 14: Electrolyte - Adding Distilled Water
PH reading of 7 or less and no Total Dissolved Solids (TDS < 5 PPM). A TDS meter may be used to test and determine an accurate measure of water purity. Contact Rolls Battery Technical Support or your local Dealer if you have questions or are unsure of your water quality. -
Page 15: Automatic Watering Systems
Designed to eliminate the need to lift or remove a battery for watering, the Rolls Locomotive Single-Point Watering System is the only watering system with internal fl ame arrestors and includes a de-gas chamber to allow normal release of gasses. -
Page 16: Locomotive Smart Battery Monitoring System
Proper charging and maintenance is key to maximizing battery performance including capacity, starting crank Amps and cycle life. Utilizing a simple and easy-to- read LED visual indicator and audible alerts, Rolls integrated Locomotive Smart Battery Monitor offers maintenance crews supportive information relating to battery health as well as state-of-charge and engine starting ability. -
Page 17: Sulfation
Ensuring adequate charging and avoiding heavy discharge will maintain battery capacity and cranking performance. Using a combined LED indicator and continuous audible alarm, Rolls Locomotive Smart Battery Monitor alerts operators during incidents of abnormally low discharge which may lead to a fail- to-start event, suggesting a restorative maintenance charge &... -
Page 18: Other Causes Of Sulfation
When hard sulfate is present, the battery shows a false voltage, higher than its true voltage, fooling the voltage regulator into thinking that the battery is fully charged. This causes the charger to prematurely lower current output, leaving the battery discharged. Charging at a higher-than-normal voltage and low current may be necessary to break down the hardened sulfate. -
Page 19: Treating Sulfated Batteries That Do Not Respond To Charging At A Low Rate
HIGH TEMPERATURE – High operating temperatures will also accelerate sulfation buildup. This is often noticeable in an idle, partially discharged battery. TREATING SULFATED BATTERIES THAT DO NOT RESPOND TO CHARGING AT A LOW RATE 1. Follow regular charging procedures at the recommended charge voltage & charge rate. -
Page 20: Storage
6. On the cell to be removed, with # 53 hollow post drill bit, drill a hole where the connectors join the cell on each side to disconnect. Using a 3/16 polypropylene rope, make a sling by slipping the rope under all connectors of the cell to be removed. - Page 21 TESTING: Spare charged batteries should be checked quarterly to determine the specific gravity. Batteries should be charged when the specific gravity drops thirty (.030) points below the specified fully charged reading. Self-discharge is affected by ambient temperature. When not in use, it is normal to expect 10-12% self-discharge per month at 25ºC (77ºF) for flooded models.
- Page 22 4. Record the time at which the voltage of each cell reaches 1.75 VPC until the terminal voltage of the battery (7.0V for 8-volt models, 28.0V for 32-volt models) is reached. 5. Stop the test discharge when the average of the cell voltages have reach 1.75 VPC and termination value (7.0V for 8-volt models, 28.0V for 32-volt models) and before any single cell goes below 0.5 volts.
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Page 23: Warranty
NOTE: ALL SHIPMENTS SHOULD BE THOROUGHLY INSPECTED FOR DAMAGE BEFORE SIGNING THE DELIVERY SLIP. The Company will replace or, at its option, repair any Rolls Battery sold by it that fails to conform to the warranty stated above on a NO CHARGE BASIS. For warranty terms, conditions and model-specific details, please refer to the warranty document found on the Rolls Battery website. - Page 24 ROLLS RAILROAD BATTERIES - RR CROSS REFERENCE GUIDE R A I L R O A D M O D E L C R O S S - R E F E R E N C E RO LL S MODEL...
- Page 25 R E PL AC E S FIRST CROWN EAST PENN NATIONAL LP-817 LP-819 LP-821 LP-825 JMA-M4513 DL-3000S 4 DS 280 DL-3000L DL-4000 4 DS 390 MD-517 JMA-M4517 DL-4500 4MIL15DS DL-5000 DL-6000 MD-525 JMA-M4525 DL-6500 4MIL25DS 40125224 40105253 UD-519 JMA-U519 DL-U500 40020109 UD-525 JMA-U525...
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Page 26: Contacts
CONTACTS Surrette Battery Company Ltd. PO Box 2020, 1 Station Road Springhill, Nova Scotia, Canada B0M 1X0 PHONE: 1 902 597 3767 (local) 1 800 681 9914 (toll free) FAX: 1 902 597 8447 (local) 1 800 681 9915 (toll free) CUSTOMER SERVICE: 1 902 597 4005 customerservice@rollsbattery.com... - Page 28 CAUTION ONE MEAN BATTERY ROLLSBATTERY.COM...
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