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Deka SPACESAVER Interlock AVR45 Installation And Operation Manual

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AVR45, AVR75, AVR95, AVR125
™
HT45, HT95, HT125
Installation and Operation Manual
Proposition
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the
65
State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to
Warning:
the State of California to cause cancer. WASH HANDS AFTER HANDLING.
E.P.M. Form No. 1112 07/23
© 2023 by EPM Printed in U.S.A.

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Summary of Contents for Deka SPACESAVER Interlock AVR45

  • Page 1 Interlock AVR45, AVR75, AVR95, AVR125 ™ HT45, HT95, HT125 Installation and Operation Manual Proposition Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to Warning: the State of California to cause cancer.

  • Page 2: Table Of Contents

    Side Termination ...........a.15 Charge Current Limits Final Assembly Check Procedure ....a.19 Safety Shield Assembly ........a.19 APPENDIX H – Unigy II / Deka Fahrenheit HT 2V - Renewable Energy (Cyclic) Applications ..a.31 Top Protection Shield Installation ....a.20 Charging Parameters Voltage Compensation SYSTEM OPERATIONS APPENDIX I –...

  • Page 3: Safety Precautions

    10. The below IEEE Standards contain additional information. Other SAFETY PRECAUTIONS standards may be relevant to your specific application. Although all valve-regulated cells have the electrolyte immobilized IEEE 1184 - Guide for Batteries for UPS Systems within the cell, the electrical hazards associated with batteries still IEEE 1187 –...

  • Page 4: Installation

    (model), as called out in Appendix F for Unigy II & Appendix G for Deka Fahrenheit HT 2V. 8. All requested information on “Refresh Record Form” in Appendix B should be completed for each refresh charge.
  • Page 5 4. Anchor holes can be marked and drilled with bases in place. d. It is recommend to place an interstack connector on the Consult Appendix E for anchor hole pattern. All anchor holes system to ensure no stress will be placed on the cell posts. in base are required to be used to meet seismic requirements.
  • Page 6 b. Module connecting hardware is furnished with a dragon tooth d. Connect the module to the base with a maximum of six – washer in place of a lock washer and flat washer. 3/8-16 x 1.25" bolts & dragon tooth washers in the front The dragon tooth washer is used to enhance the electrical only.

  • Page 7: Safety Shield Bracket Assembly

    10. Module layout should be compared to battery string layout 2. Safety shield brackets are to be installed at the top of the diagram and all hardware should be checked for proper torque module in the same manner as detailed previously. Tighten, do before proceeding.

  • Page 8: Electrical Connection

    3. For multiple stack systems, joining plates are to be installed at Electrical Connection the front of the modules at the top of the stacks. One joining plate is to be used at the junction of two modules. Use the 3/8- Connector Assembly 16 x 2.50"...
  • Page 9 3. Installation and direction of the cell post hardware is 5 to 15 Plate important. Consult below diagram for clarification. 17 to 27 Plate 29 to 33 Plate...
  • Page 10 4. Unigy II & Fahrenheit HT 2V battery strings are typically supplied with connector package 1CU requiring one connector per post. 5. High rate applications will require multiple connectors to be used per cell post. A 2CU connector package will require 2 connectors per connection (1 per side), see example below.
  • Page 11 6. Some installations require a vertical “C” connector. This “C” 17 to 27 Plate connector is limited to a 2CU connector package. 1. Install “L” connector with vertical bolt as below. Bolt Consult below for proper installation for particular cell type being should be installed loosely for future adjustments.

  • Page 12: Terminal Assembly

    Terminal Assembly 29 to 33 Plate 1. Install “L” connector with vertical bolt as below. Bolts Top Termination should be installed loosely for future adjustments. Duplicate connection process at both connection points. Consult battery string layout diagram for termination location. 1.
  • Page 13 3. Install terminal plate to battery posts using 1/4-20 hardware 5. After confirming alignment safety shield bracket hardware should (consult battery string layout diagram & parts kit for specific be tightened, but not torqued. All remaining hardware should be length). torqued.
  • Page 14 8. Top terminal plates are designed to accept up to 0.50" dia. bolt and COMPLETED use a maximum 1.75" center, 2 hole lug. ASSEMBLY Lug and lug hardware not included. 7. Top terminal assembly will vary by battery plate size. 5 to 15 Plate 17 to...

  • Page 15: Side Termination

    Side Termination Review the “Connector Packages” chart (pg a.9) to ensure the correct connector package has been supplied. Consult battery string layout diagram for termination location. 1. Remove module bolts (3/8-16 x 1.25") from the module where side 1CU / 2CU CONNECTOR PACKAGE termination is to be installed.
  • Page 16 4. Install side terminal plate to terminal plate bracket using 1/4-20 6. After all parts are installed and alignment is confirmed, safety x 1.00" hardware. Bolts should be installed loosely for future shield bracket hardware should be tightened, but not torqued. All adjustments.
  • Page 17 8. Depending on the termination location, side terminal plates may SIX TERMINAL PLATE BRACKET ASSEMBLY be adjacent to each other. The side terminal bracket attachment is different depending on the number of adjacent terminal plates. TWO TERMINAL PLATE BRACKET ASSEMBLY FOUR TERMINAL PLATE BRACKET ASSEMBLY EIGHT TERMINAL PLATE BRACKET ASSEMBLY (Installed in two sections)
  • Page 18 9. Side terminal plate is designed to use up to 0.50" dia. bolt and a maximum 1.75" centers, 2 hole lug. Plate is capable of handling 4 runs of cable. Lugs can be positioned on both sides of the terminal plate. Lug and lug hardware not included. Lug Positioning Options a.18...

  • Page 19: Final Assembly Check Procedure

    Final Assembly Check Procedure 1. For future identification, individual cells should be numbered in electrical connection sequence, beginning with number one (1) at the positive end of the battery string. NOTE: Following steps are to be followed with battery disconnected from any load or charge source. 2.

  • Page 20: Top Protection Shield Installation

    Consult Voltage Compensation Chart (Appendix F for Unigy II establishing a life history of the battery string and inform the user & Appendix G for Deka Fahrenheit HT 2V) for temperature if and when corrective action needs to be taken. Values should be recorded using “Battery Maintenance Report”...

  • Page 21: Acceptance Testing

    “Voltage Compensation Chart” in recommendations may not apply. Appendix F for Unigy II & Appendix G for Deka Fahrenheit HT 2V of this manual. Discharge and recharge affect voltage and ohmic values. These readings should be taken only after the battery string has been on continuous, To ensure the cells are fully charged within 24hrs;...

  • Page 22: Battery Cleaning

    Battery Cleaning 3. Remove connectors from cell being removed. 4. Remove cell retainer bar(s) from cell being removed. Batteries, cabinets, racks, and modules should be cleaned with clean water. If neutralizing is required use a mixture of 1 lb baking soda to 1 5.

  • Page 23: Cell Replacement Procedure

    Cell Replacement Procedure a. Thread non-metallic rope through two battery terminals and knot. 1. Cells develop internal pressure. Relieving this pressure from the cell will make it easier to install the cell into the module. Follow the steps of “Cell Removal Procedure” item 4. 2.
  • Page 24 APPENDIX A For Energy Storage Applications Following UL 1973 the following shall be reviewed: 1. Batteries and components shall be installed in accordance with Article 480 or Article 706 of NFPA 70 or Section 64 of CSA C22.1. 2. The charger shall comply with one of the following standards: UL 1012, UL 1741, UL 60335-2-29/CSA C22.2 No.
  • Page 25 EPM ORDER NUMBER WILL APPEAR ON THE SHIPPING LABEL ON THE CARTON COVERING EACH PALLET OF CELLS TO ENSURE CONTINUATION OF WARRANTY, SUBMIT FORMS TO: East Penn Mfg. Co, Inc., Reserve Power Division, Product Support & Warranty Dept. (reservepowerwarranty@dekabatteries.com) Form available as an Excel spreadsheet. Consult your EPM or Deka Services Representative a.25...

  • Page 26: Appendix C - Unigy Ii - Cell Weight And Volume

    APPENDIX C Unigy II - Cell Weight and Volume Electrolyte (per cell) Pure Acid (per battery) Cell Weight Battery Volume Weight Wieght Type liter AVR45-5 0.37 1.40 4.00 1.81 1.60 0.72 AVR45-7 0.52 1.96 5.60 2.54 2.24 1.02 AVR45-9 0.67 2.52 7.22 3.28...
  • Page 27 APPENDIX D Fahrenheit HT 2V - Cell Weight and Volume Electrolyte (per cell) Pure Acid (per battery) Cell Weight Battery Volume Weight Wieght Type liter HT45-5 0.37 1.40 4.00 1.81 1.60 0.72 HT45-7 0.52 1.96 5.60 2.54 2.24 1.02 HT45-9 0.67 2.52 7.22...
  • Page 28 APPENDIX E Unigy II / Deka Fahrenheit HT 2V - Interlock Base Anchor Hole Pattern 2 & 4 CELL MODULES 45 Ah. 75 Ah. 95 Ah. 125 Ah. 5.84 12.91 5.84 20.01 8.81 12.91 8.81 20.01 8.81 22.63 11.81 12.91 11.81...

  • Page 29: Voltage Compensation Chart

    APPENDIX F Unigy II - Standby (Float) Application Charge Current Limits Voltage Compensation Chart AVR45 Series AVR75 Series Refresh / °C Float °F Max. Charge Min. Charge Max. Charge Min. Charge Equalize Cell Type Cell Type Current (A) Current (A)** Current (A) Current (A)** >35...

  • Page 30: Appendix G - Deka Fahrenheit Ht 2V - Standby (Float) Application

    APPENDIX G Deka Fahrenheit HT 2V - Standby (Float) Application Charge Current Limits Voltage Compensation Chart HT95 Series HT45 Series °C Float °F Max. Charge Min. Charge Max. Charge Min. Charge Cell Type Cell Type Current (A) Current (A)** Current (A) Current (A)** >35...

  • Page 31: Appendix H - Unigy Ii / Deka Fahrenheit Ht 2V - Renewable Energy (Cyclic) Applications

    APPENDIX H Unigy II / Deka Fahrenheit HT 2V - Renewable Energy (Cyclic) Applications Charge Parameters Max. Current Reference Bulk Charge (Amps) Below Chart Absorption (Regulation)Charge Constant Voltage 2.35 - 2.40 vpc Float Charge Constant Voltage 2.24 - 2.26 vpc...
  • Page 32 APPENDIX I Unigy II - Renewable Energy (Cyclic) Applications Maximum Charge Current AVR45 Series AVR75 Series Max. Charge Max. Charge Cell Type Cell Type Current (A) Current (A) AVR45-5 21.4 AVR75-5 35.5 AVR45-7 32.2 AVR75-7 53.2 AVR45-9 42.9 AVR75-9 70.9 AVR45-11 53.6 AVR75-11...
  • Page 33 APPENDIX J Deka Fahrenheit HT 2V - Renewable Energy (Cyclic) Applications Maximum Charge Current HT45 Series HT95 Series Max. Charge Max. Charge Cell Type Cell Type Current (A) Current (A) HT45-5 HT95-7 16.5 46.1 HT45-7 HT95-9 24.7 61.4 HT45-9 HT95-11 32.9...
  • Page 37 Non-Interlock AVR45, AVR75, AVR95 ™ HT45, HT95 Installation and Operation Manual Proposition Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to Warning: the State of California to cause cancer.

  • Page 38: Appendix I - Unigy Ii - Renewable Energy (Cyclic) Applications

    Charging Parameters Temperature Compensation..........b.19 Voltage Compensation Cell Voltage .................b.19 APPENDIX J – Deka Fahrenheit HT 2V - Cyclic Application Charge Current Limits ..b.32 Rectifier Ripple Voltage ............b.19 APPENDIX K – Battery Maintenance Report..............b.33 IN REFERENCE TO THIS MANUAL: – “Cell” is defined as an individual 2-volt unit.

  • Page 39: Safety Precautions

    SAFETY PRECAUTIONS 10. The below IEEE Standards contain additional information. Other standards may be relevant to your specific application. Although all valve-regulated cells have the electrolyte immobilized IEEE 1184 - Guide for Batteries for UPS Systems within the cell, the electrical hazards associated with batteries still IEEE 1187 –...

  • Page 40: Installation

    (model), as called out in Appendix F for Unigy II & Appendix G for Deka Fahrenheit HT 2V. 8. All requested information on “Refresh Record Form” in Appendix B should be completed for each refresh charge.
  • Page 41 8. Module connecting hardware is furnished with a dragon tooth 4. Anchor holes can be marked and drilled with bases in place. washer in place of a lock washer and flat washer. Consult Appendix E for anchor hole pattern. All anchor The dragon tooth washer is used to enhance the electrical holes in base are required to be used to meet seismic require- conductivity of the grounding system within a stack of modules.

  • Page 42: Safety Shield Bracket Assembly

    Safety Shield Bracket Assembly 1. Safety shield brackets are to be installed at the outside corners of every 2 modules starting from the bottom and working towards the top. This is to be repeated for each stack in the battery system. For stacks containing odd number of modules an additional set of safety shield brackets will be required to be installed at the top of the module.

  • Page 43: Electrical Connection

    2. Safety shield brackets are to be installed at the top of the Electrical Connection module in the same manner as detailed previously. Tighten, do not torque hardware. Connector Assembly 1. The contact surfaces of each individual post on every cell have been cleaned and coated with a thin film of No-Ox-ID “A”...
  • Page 44 5 to 15 Plate 17 to 27 Plate 29 to 33 Plate...
  • Page 45 4. Unigy II & Fahrenheit HT 2V battery strings are typically supplied with connector package 1CU requiring one connector per post. 1CU Package Detail 5. High rate applications will require multiple connectors to be used per cell post. A 2CU connector package will require 2 connectors per connection (1 per side), see example below.
  • Page 46 6. Some installations require a vertical “C” connector. This 17 to 27 Plate “C” connector is limited to a 2CU connector package. 1. Install “L” connector with vertical bolt as below. Bolt Consult below for proper installation for particular cell type should be installed loosely for future adjustments.

  • Page 47: Terminal Assembly

    Terminal Assembly 29 to 33 Plate 1. Install “L” connector with vertical bolt as below. Bolts Top Termination should be installed loosely for future adjustments. Duplicate connection process at both connection points. Consult battery string layout diagram for termination location. 1.
  • Page 48 3. Install terminal plate to battery posts using 1/4-20 hardware 5. After confirming alignment safety shield bracket hardware should (consult battery string layout diagram & parts kit for specific be tightened, but not torqued. All remaining hardware should be length). torqued.
  • Page 49 8. Top terminal plates are designed to accept up to 0.50" dia. bolt COMPLETED and use a maximum 1.75" center, 2 hole lug. ASSEMBLY Lug and lug hardware not included. 7. Top terminal assembly will vary by battery plate size. 5 to 15 Plate 17 to...

  • Page 50: Side Termination

    Side Termination 4. Install side terminal connector to battery posts using 1/4- 20 bolts. Bolts should be installed loosely for future adjustments. Consult battery string layout diagram for termination location. 1. Remove module bolts (3/8-16 x 1.25") from the module where side termination is to be installed.
  • Page 51 4CU / 6CU CONNECTOR PACKAGE 4CU / 6CU CONNECTOR PACKAGE (double connector) (1/4-20 x 1.25” hardware required) 7. After all parts are installed and alignment is confirmed, safety shield bracket hardware should be tightened, but not torqued. All remaining hardware should be torqued Consult “Hardware 5.
  • Page 52 SIX TERMINAL PLATE BRACKET ASSEMBLY 9. Depending on the termination location, side terminal plates may be adjacent to each other. The side terminal bracket attachment is different depending on the number of adjacent terminal plates. SLEEVE SPACER TWO TERMINAL PLATE BRACKET ASSEMBLY SLEEVE SPACER SLEEVE...
  • Page 53 10. Side terminal plate is designed to use up to 0.50" dia. bolt and a maximum 1.75" centers, 2 hole lug. Plate is capable of handling 4 runs of cable. Lugs can be positioned on both sides of the ter- minal plate.

  • Page 54: Final Assembly Check Procedure

    Final Assembly Check Procedure 1. For future identification, individual cells should be numbered in electrical connection sequence, beginning with number one (1) at the positive end of the battery string. NOTE: Following steps are to be followed with battery disconnected from any load or charge source. 2.

  • Page 55: Top Protection Shield Installation

    Consult Voltage Compensation Chart (Appendix F for Unigy II maintenance and warranty coverage. This information will help in & Appendix G for Deka Fahrenheit HT 2V) for temperature establishing a life history of the battery string and inform the user compensation voltage maximum and minimum limits.

  • Page 56: Acceptance Testing

    “Voltage Compensation Chart” in following recommendations may not apply. Appendix F for Unigy II & Appendix G for Deka Fahrenheit HT 2V of this manual. Discharge and recharge affect voltage and ohmic values. These readings should be taken only after the battery string has been on To ensure the cells are fully charged within 24hrs;...

  • Page 57: Battery Cleaning

    Battery Cleaning c. Unscrew valve ¼ turn using 17mm hex key (pressure will release). Batteries, cabinets, racks, and modules should be cleaned with d. Tighten valve immediately and torque to 12-14 in lb with clean water. If neutralizing is required use a mixture of 1 lb baking 17mm hex key.

  • Page 58: Cell Replacement Procedure

    8. Pull cell from module onto lifting device. Care should be taken so lifting device does not come in contact with cell posts. Cell Replacement Procedure 1. Cells develop internal pressure. Relieving this pressure from the cell will make it easier to install the cell into the module. Follow the steps of “Cell Removal Procedure”...
  • Page 59 APPENDIX A For Energy Storage Applications Following UL 1973 the following shall be reviewed: 1. Batteries and components shall be installed in accordance with Article 480 or Article 706 of NFPA 70 or Section 64 of CSA C22.1. 2. The charger shall comply with one of the following standards: UL 1012, UL 1741, UL 60335-2-29/CSA C22.2 No.
  • Page 60 EPM ORDER NUMBER WILL APPEAR ON THE SHIPPING LABEL ON THE CARTON COVERING EACH PALLET OF CELLS TO ENSURE CONTINUATION OF WARRANTY, SUBMIT FORMS TO: East Penn Mfg. Co, Inc., Reserve Power Division, Product Support & Warranty Dept. (reservepowerwarranty@dekabatteries.com) Form available as an Excel spreadsheet. Consult your EPM or Deka Services Representative b.24...
  • Page 61 APPENDIX C Unigy II - Cell Weight & Volume Electrolyte Pure Acid Cell (per cell) (per battery) Battery Weight Volume Weight Weight Type liter AVR45-5 0.37 1.40 4.00 1.81 1.60 0.72 AVR45-7 0.52 1.96 5.60 2.54 2.24 1.02 AVR45-9 0.67 2.52 7.22 3.28...
  • Page 62 APPENDIX D Deka Fahrenheit HT 2V - Cell Weight & Volumes Electrolyte (per cell) Pure Acid (per battery) Cell Weight Battery Volume Weight Weight Type liter HT45-5 0.37 1.40 4.00 1.81 1.60 0.72 HT45-7 0.52 1.96 5.60 2.54 2.24 1.02 HT45-9 0.67...

  • Page 63: Appendix E - Non-Interlock Base Anchor Hole Pattern

    APPENDIX E Unigy II / Deka Fahrenheit HT 2V Non-Interlock Base Anchor Hole Pattern b.27...

  • Page 64: Appendix F - Unigy Ii - Standby (Float) Application

    APPENDIX F Unigy II - Standby (Float) Application Charge Current Limits Voltage Compensation AVR45 Series AVR75 Series Refresh / °C Float °F Max. Charge Min. Charge Max. Charge Min. Charge Equalize Cell Type Cell Type Current (A) Current (A)** Current (A) Current (A)** >35 2.230...

  • Page 65: Appendix G - Deka Fahrenheit Ht 2V - Standby (Float) Application

    APPENDIX G Deka Fahrenheit HT 2V - Standby (Float) Application Charge Current Limits Voltage Compensation HT45 Series HT95 Series °C Float °F Max. Charge Min. Charge Max. Charge Min. Charge Cell Type Cell Type Current (A) Current (A)** Current (A) Current (A)** >35...

  • Page 66: Appendix H - Unigy Ii / Deka Fahrenheit Ht 2V

    APPENDIX H Unigy II / Deka Fahrenheit HT 2V - Renewable Energy (Cyclic) Renewable Energy (Cyclic) Charge Parameters Max. Current Reference Bulk Charge (Amps) Below Chart Absorption (Regulation)Charge Constant Voltage 2.35 - 2.40 vpc Float Charge Constant Voltage 2.24 - 2.26 vpc...
  • Page 67 APPENDIX I Unigy II - Renewable Energy (Cyclic) Maximum Charge Current AVR45 Series AVR75 Series Max. Charge Max. Charge Cell Type Cell Type Current (A) Current (A) AVR45-5 21.4 AVR75-5 35.5 AVR45-7 32.2 AVR75-7 53.2 AVR45-9 42.9 AVR75-9 70.9 AVR45-11 53.6 AVR75-11 88.7...

  • Page 68: Appendix J - Deka Fahrenheit Ht 2V - Cyclic Application Charge Current Limits

    APPENDIX J Deka Fahrenheit HT 2V - Cyclic Application Charge Current Limits Max. Charge Max. Charge Cell Type Cell Type Current (A) Current (A) HT45-5 HT95-7 16.5 46.1 HT45-7 24.7 HT95-9 61.4 HT45-9 32.9 HT95-11 76.8 HT45-11 41.1 HT95-13 HT45-13 49.4...
  • Page 72 e-mail: reservepowersales@dekabatteries.com East Penn Manufacturing Co. Lyon Station, PA 19536-0147 Phone: 610-682-6361 Fax: 610-682-4781 www.dekabatteries.com All data subject to change without notice. No part of this document may be copied or repro- E.P.M. Form No. 1112 07/23 © 2023 by EPM Printed in U.S.A. duced, electronically or mechanically, without written permission from the company.

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