® SECTION 92.80 2008-07 Exide Technologies – The Industry Leader. Installation and Operating Instructions For GNB Industrial Power, a division of Exide Technologies, is a global leader in stored electrical energy solutions for all major critical reserve power applications and needs.
TABLE OF CONTENTS SECTION 1: GENERAL ...................................................................................................................................6 SECTION 2: SAFETY MESSAGES .................................................................................................................6 2.0 2.1 2.2 2.3 2.3.1 2.4 2.5 SECTION 3: 3.0 3.1 SECTION 4: 4.0 4.1 4.2 SECTION 5: 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.7.1 5.8 5.9 5.10 SECTION 6: 6.0 6.1 6.2 6.3 6.4 General Information.......
SECTION 7: SYSTEM ARRANGEMENTS.....................................................................................................11 SECTION 8: SYSTEM ASSEMBLY ................................................................................................................11 7.0 8.0 8.1.1 8.1.2 8.1.3 8.2 8.2.1 8.2.2 8.2.3 SECTION 9: 9.0 9.1 9.2 9.3 9.4 9.5 SECTION 10: 10.0 10.1 10.2 10.3 10.4 SECTION 11: 11.0 11.1 SECTION 12: 12.0 12.1 Module Arrangements..............................................
SECTION 13: 13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 SECTION 14: 14.0 14.1 14.2 SECTION 15: 15.0 15.1 15.2 BATTERY OPERATION ............................................................................................................19 Cycle Method of Operation........................................................................................................19 Floating Charge Method ............................................................................................................
PAGE LIST OF ILLUSTRATIONS FIGURE DESCRIPTION 10 Fig. 2 Packaged Modules 11 Fig. 4 8 11 11 11 Fig. 1 Fig. 3 Fig. 5 Fig. 6 12 Fig. 7 12 Fig. 9 12 13 13 13 13 13 14 14 14 14 15 16 18 23 PAGE 9 10 17 20 21 PAGE 25 26 27 Fig. 8 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig.
SECTION 1: GENERAL 1.0 Multi-cell systems attain high voltages, therefore, extreme caution must be exercised during installation of a battery system to prevent serious electrical burns or shock. General Information Interrupt the AC and DC circuits before working on batteries or charging equipment. CAUTION! Before proceeding with the unpacking, handling, installation and operation of this sealed lead-acid storage battery, the following information should be reviewed thoroughly.
SECTION 3: DELIVERY INFORMATION 3.0 NOTE: Storage in temperatures above 25°C (77°F) will result in loss of operating life. Receipt of Shipment Initial and freshening charge data should be saved and included with the battery historical records (see Section 15). Immediately upon delivery, examine packaging for possible damage caused in transit. Damaged packing material or staining from leaking electrolyte could indicate rough handling. Make a descriptive notation on the delivery receipt before signing.
TABLE A TEMPERATURE EFFECTS ON LIFE Maximum Annual Average Battery Temperature 25°C 30°C 35°C 40°C 45°C 50°C (77°F) (86°F) (95°F) (104°F) (113°F) (122°F) Maximum Battery Temperature 50°C 50°C 50°C 50°C 50°C 50°C (122°F) (122°F) (122°F) (122°F) (122°F) (122°F) The total battery weight will depend on the cell size, number of cells, as well as module configuration involved.
5.8 Stacking Limitations 6.1 NOTE: Check accessory package against packing list to assure completeness. Do not proceed with installation until all accessory parts are available. There are recommended limits on stacked (horizontal only) battery configurations, see Table B and consult your layout/wiring diagram.
6.3 Unpacking 4) Never lift more than one module with straps and hooks. Carefully remove bolts and protective shipping hood. See Figure 3. Remove the bolts holding modules to shipping pallet. Also remove hardware bolting upper channels of modules together. Do not remove modules at this time. Base supports for horizontally stacked modules are more easily attached before removing modules from pallet (see Section 8 System Assembly).
a module may have only one cell in a two-cell tray. For example, a 46 volt system will consist of eleven full modules and one single-cell module. Assemblies can be rotated 180° for proper polarity location. 8.1.1 8.1.2 Handling 8.1.3 Tip Over Procedure The module/I-beam assembly may now be removed from the pallet using methods outlined in Section 6.5. See Figures 4 and 5. Remaining modules may be removed in a similar manner.
bolts and nuts in open holes, finger tight. Use leveling shims to fill gaps between trays. See Figures 13, 14 and 15. TIP-OVER PROCEDURE Figure 10 B. At this time, check to see that the first two modules are plumb front to back and side to side using wooden or plastic level together with plywood straight edge. This is to insure proper alignment for module interconnection later on. Torque hardware to 47 Newton-meters (35 Ft-Lbs). C.
To achieve maximum stack stability, especially where seismic conditions may exist, as well as proper interfacing of inter-stack connections, metal tie plates are provided. The plates used on stacks end to end are 3” x 1” x 1/8” with two 9/16” holes. Use one tie plate at each interface to connect the module channels of adjacent stacks. See Figure 18. INSTALLING HARDWARE Figure 15 8.2 8.2.
Refer to layout/wiring diagram for connector placement and materials list. Figure 19 shows typical module connections, intrastack connections and interstack connections. Apply a thin film of NO-OX-ID “A” grease (supplied) to all terminal surfaces, bolts, and washers. This will preclude oxidation after connections are completed. 9.1 Connections - System Terminals Each system is supplied with a terminal plate assembly for the positive and negative terminations.
BILL OF MATERIALS — TOP TERMINAL PLATE ASSEMBLY ITEM DESCRIPTION 1 PLATE, TOP TERMINAL 2 BRACKET, TERMINAL SUPPORT 3 LOCK WASHER, M10 4 FLAT WASHER, M10 5 NUT, M10 X .8D 6 BOLT, M10 X 40 7 COVER, FRONT 8 COVER, BACK 9 NUT, M6 X .
10.2 System Polarity Labels 10.3 Warning Label 10.4 Battery Nameplate Determine the maximum voltage that may be applied to the system equipment. This voltage, divided by the number of cells connected in series, will establish the maximum volts per cell (VPC) that is available. Table C lists recommended voltages and charge times for the initial charge. Select the highest voltage the system allows to perform the initial charge in the shortest time period.
BILL OF MATERIALS — MODULE CLEAR COVER MATERIALS ITEM 1 2 3 DESCRIPTION Cover Standoff Leg Standoff Key QTY PER SYSTEM 1 4 4 Assembly Instructions: Install standoff legs and standoff keys to module channel as shown. The cover is then installed by grasping it so that the GNB logo is upright. Locate slots at bottom of cover to bottom standoff legs and slide in place. Locate holes at top of cover and install to top standoff legs.
STEP 3 TEMPERATURE CORRECTION 1. The initial charge is complete. Charger voltage can now be reduced to float voltage setting per Section 13.2. For a target float charge of 2.25 VPC on a 24-cell system, you would set the charger voltage to 54 volts. V corrected = V25°C - (( T actual-25°C) x ( .0055V/°C)) or V corrected = V77°F - ((T actual-77°F) x (.003V/°F)) See Appendix A for standard values. SECTION 13: BATTERY OPERATION 13.
13.5 Effects of Float Voltage 13.8 Ohmic Measurements Float voltage has a direct effect on the service life of your battery and can be the cause of thermal instability. Impedance, resistance and conductance testing is collectively known in the industry as ohmic measurements. Each measurement is derived using a manufacturer-specific and proprietary algorithm and / or frequency. This means that one type of measurement cannot be converted or related easily to another.
ations in cell temperatures greater than 5°F (2.78°C) in the series string at a given time, due to environmental conditions or module arrangement, can cause low cells. 14.1 STEP 2 A. Continue the charge for the time listed in Table E depending on the charger voltage setting. The time is IN ADDITION to the time spent charging in Step 1. Equalizing Frequency An equalizing charge should be given when any of the following conditions exist: Example, charge for 12 hours if the charger voltage is set to 2.
damp with electrolyte or show signs of corrosion, contact your local GNB representative. • • • • Individual cell voltages Overall string voltage Ambient temperature immediately surrounding battery Battery temperature at several places throughout the string. Recommend 1 reading per battery stack. More data points are recommended for larger batteries and to check for temperature gradients. Readings on the tray, cell cover or negative terminal are good places to measure battery temperature.
Volts TYPE: Conn. Ohmic Resist. C / R / I Temp ADDITIONAL COMMENTS: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 No. Cell SYSTEM VOLTAGE: No. of CELLS: ADDRESS: COMPANY: DATE: Figure 22.1 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 No. Cell Volts TEMPERATURE: 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 No.
Volts TYPE: Conn. Ohmic Resist. C / R / I Temp ADDITIONAL COMMENTS: 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 No. Cell SYSTEM VOLTAGE: No. of CELLS: ADDRESS: COMPANY: DATE: Figure 22.2 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 No.
APPENDIX A Temperature Corrected Float Voltages 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 2.23 2.35 2.35 2.34 2.34 2.33 2.33 2.32 2.32 2.31 2.31 2.30 2.30 2.29 2.28 2.28 2.27 2.27 2.26 2.26 2.25 2.25 2.24 2.23 2.23 2.22 2.22 2.21 2.21 2.20 2.20 Float Voltage at 25°C 2.24 2.25 2.26 2.35 2.35 2.35 2.34 2.34 2.33 2.33 2.32 2.32 2.31 2.31 2.30 2.29 2.29 2.28 2.28 2.27 2.27 2.26 2.26 2.25 2.24 2.24 2.23 2.23 2.22 2.22 2.21 2.21 2.20 2.20 2.35 2.
APPENDIX B MAXIMUM STORAGE INTERVAL BETWEEN FRESHENING CHARGES VERSUS AVERAGE STORAGE TEMPERATURE Maximum Storage Interval Months Days 25 6 0 77 6 0 26 5 18 78 5 23 27 5 7 79 5 17 28 4 26 80 5 10 29 4 16 81 5 4 30 4 7 82 4 29 31 3 29 83 4 23 32 3 21 84 4 18 33 3 13 85 4 12 34 3 7 86 4 7 35 3 0 87 4 3 36 2 24 88 3 28 37 2 18 89 3 23 38 2 13 90 3 19 39 2 8 91 3 15 40 2 4 92 3 11 41 1 29 93 3 7 42 1 25 94
APPENDIX C BONDING & GROUNDING OF BATTERY RACK INTRODUCTION 1. To insure personnel safety, and equipment protection, operation, and reliability, the battery rack should be connected to the Common Bonding Network (CBN). 2. Electrical continuity between modules is provided through the use of serrated hardware. Testing has shown that standard systems are compliant with the GR-1089-CORE, Issue 4, Section 9 requirements of the Bonding and Grounding tests. GROUNDING KIT INSTALLATION (OPTIONAL) 1.
® SECTION 92.80 2008-07 Exide Technologies – The Industry Leader. Installation and Operating Instructions For GNB Industrial Power, a division of Exide Technologies, is a global leader in stored electrical energy solutions for all major critical reserve power applications and needs.