BAE OPzS Series User manual

STATIONARY BAE BATTERIES:
Vented Lead Acid (VLA) / Flooded
Installation and Operating Instructions
Important Documents - Do Not Discard
OPzS & OGi Series Batteries

Page 1 of 17 www.baebatteriesusa.com Rev: 0219
Stationary Vented Lead Acid (VLA) Batteries,
Installation andOperating Instructions
This publication defines the essential requirements for the proper storage,handling,
assembly, commissioning,operation, and maintenance of the BAE OPzS and OGi stationary
vented lead-acid batteries.
1.0 SAFETYPRECAUTIONS & WARNINGS
•Observe operating instructions and position them within sight of the battery!
•Work only on batteries under instruction of skilled personnel!
•When working on batteries wear safety glasses and protective clothing!
•Comply with accident prevention rules, local safety codes, as well as DIN VDE 0510, VDE
0105 part 1.
•No smoking! Do not expose the battery to an open flame, a glowing fire or sparks as
explosion and fire hazards exist.
•Acid splashes on the skin must be flushed with plenty of water.
•Acid splashes in eyes must be flushed thoroughly for at least 15 minutes with plenty of
water.
•Seek medical attention immediately!
•Remove clothing exposed to acid and wash with water immediately to avoid additional
contact with skin.
•Explosion and fire hazard due to explosive gases escaping from the battery.
•Caution! Metal parts of the battery are always live, therefore do not place items or tools on
the battery.
•Avoid short circuits!
•Caution! The electrolyte (diluted sulfuric acid) is extremely corrosive.
•Caution! Block batteries or cells are heavy!
•Ensure secure installation!
•Only use suitable transport equipment!
•Dangerous voltages!
•Shock hazard!
•Used batteries with this symbol are reusable goods and must be properly
recycled.
•Used batteries that are not recycled must be disposed of as special waste
in accordance with all local, state, and federal regulations.

Stationary VLA Batteries,
Installation and Operation Instructions
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1.1 ELECTROLYTE HAZARDS
The electrolyte is dilute sulfuric acid, which is harmful to skin, and eyes. It is
electrically conductive and corrodes unprotected metal surfaces.
PRECAUTIONS
a) When handling electrolyte wear full eye protection, rubber or plastic gloves, apron and
boots.
b) If electrolyte contacts skin, wash it off immediately with large amounts of water.
Remove contaminated clothing.
c) If it contacts the eyes, thoroughly flush with water and seek immediate medical
attention.
d) Neutralize any spilled acid with a weak alkaline solution of 1 pound of bicarbonate of
soda dissolved in 1 gallon of water.
1.2 ELECTRICAL HAZARDS
A filled and charged battery presents a high voltage, high current shock and short
circuit hazard.
PRECAUTIONS
Observe standard safety measures when working on batteries:
a) Remove watches, rings or metal jewelry.
b) Wear rubber gloves and boots.
c) Use insulated tools.
d) Never lay tools or other metallic objects on the battery/cell.
e) Before working on the system disconnect the charger and load prior to closing and/or
opening battery connections. Use appropriate lockout/tag-out procedures.
1.3 EXPLOSIVE GASES
Batteries can generate gases which, when released, can explode, causing
blindness and other serious personal injury.
PRECAUTIONS
a) Always wear protective clothing and use the correct safety tools.
b) Eliminate any potential of sparks, flames or arcing.
c) Provide adequate ventilation.
Using the correct tools and wearing the proper safety equipment will help prevent injury
should an accident occur.

Stationary VLA Batteries,
Installation and Operation Instructions
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TABLE OF CONTENTS:
INTRODUCTION ………………………………………………………………………………................................... 1
1.0 SAFETY PRECAUTIONS & WARNINGS ………………………..………………………………..……...……. 1
1.1 ELECTROLYTE HAZARDS ……………………………………………………...........……………………..…. 2
1.2 ELECTRICAL HAZARDS ……………………………………………………………………..…………………. 2
1.3 EXPLOSIVE GASES ………………………………………………………………………..……………………. 2
TABLE OF CONTENTS ………………………………………………………………………………………...……... 3
2.0 RECEIVING OF STATIONARY BATTERIES ………………………………………………....................…... 4
2.1 VISIBLE EXTERNAL DAMAGE………………………………………………………………….........……...….. 4
2.2 CONCEALED DAMAGE…………………………………………………………………………......………...….. 4
2.3 ACCESSORIES ………………………………………………………………………………………........……... 5
3.0 STORAGE AND MAINTENANCE ………………………………………………………….……...…......…..... 5
3.1 STORAGE AND MAINTENANCE: WET CHARGED BATTERIES …………………………………..…....... 5
3.2 STORAGE AND MAINTENANCE: BATTERIES REMOVED FROM OPERATION ……….………..…....... 5
4.0 UNPACKING & HANDLING ………………………………………………………………..…………......…..... 6
4.1 ACCESSORIES ………………………………………………………………………………………………....... 6
5.0 PRE-INSTALLATION PLANNING ……………………………………………………………………….....….. 6
5.1 RACKS (EXISTING RACK) ………………………………………………………………………..………....….. 7
5.2 RACKS (NEW RACK) ……………………………………………………...........………………..……...…...…. 7
6.0 BATTERY CELL/JAR INSTALLATION …………………………………………………………………....….. 7
6.1 TERMINAL PREPARATION …………………………………………………………………….………….……. 8
6.2 INTER-CELL CONNECTORS ……………………………………………………………………...…….………. 8
6.3 TERMINAL PLATES ……………………………………………………………………..………..……………… 9
6.4 FINAL INSTALLATION STEPS………………………………………………………………..………………….. 9
7.0 COMMISSIONING – SUPPLIED WET AND CHARGED ……………………………………………….…….. 10
7.0.1 COMMISSIONING WITH FLOAT CHARGE VOLTAGE – 2.23 VPC ……………………….….…… 11
7.0.2 COMMISSIONING WITH HIGHER CHARGING VOLTAGES – 2.33 TO 2.40 VPC ……...………. 11
8.0 INSTRUCTIONS FOR OPERATION …………………………………………………...………………………. 11
8.1 FLOAT CHARGING ………………………………………………………………………...…………………….. 11
8.2 EQUALIZATION CHARGING …………………………………………………………………..……………….. 11
8.3 CHARGING CURRENTS ………………………………………………………………………………...………. 12
8.4 TEMPERATURE-RELATED CHARGING VOLTAGE …………………………………………………...……. 12
8.5 OPERATING TEMPERATURE ………………………………………………………………………………….. 12
8.6 DISCHARGE CYCLE …………………………………………………………………………………………….. 12
8.7 RECHARGING CYCLE …………………………………………………………………………………………... 13
9.0 BATTERY MAINTENANCE …………………………………………………………….……………………….. 13
9.1 CLEANING OF BATTERIES ………………………………………………………………………….…………. 13
9.2 ADDITION OF WATER …..………………..………………………………………………………….………….. 13
10.0 PERIODIC INSPECTIONS ……………………………………………………………………………...………. 14
10.1 TOTAL SYSTEM VOLTAGE AND CURRENT ………………………………………………………...……… 14
10.2 INDIVIDUAL CELL VOLTAGES ………………………………………………………………………..………. 15
10.3 CELL TEMPERATURE ……..……………………………………………………………………………..……. 15

Stationary VLA Batteries,
Installation and Operation Instructions
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10.4 FLOAT CURRENT ………………………………………………………………………………………....……. 15
10.5 SPECIFIC GRAVITY (ELECTROLYTE DENSITY) ………………………………….…….…..………………15
10.6 CONNECTION RESISTANCE MAINTENANCE READINGS ………………………….……..……………… 16
11.0 IN-SERVICE CAPACITY TESTS …………………………………………………………………..………….. 16
SUPPLEMENT A: DRY CHARGED BATTERIES INSTRUCTIONS (Optional – may not be attached)
SA1.0 STORAGE AND MAINTENANCE: DRY CHARGED BATTERIES …………………………..…........ SA-1
SA2.0 FILLING AND FINAL INSTALLATION - FOR DRY CHARGED BATTERIES ………………………. SA-1
SA2.1 FILLING WITH SULFURIC ACID – FOR DRY CHARGED BATTERIES ………………..….…..……. SA-1
SA2.2 FINAL INSTALLATION STEPS …………………………………………………………....…..……….…. SA-2
SA3.0 COMMISSIONING – DRY CHARGED BATTERIES …………...………………………….………..…. SA-3
SA3.1 COMMISIONING OF DRY CHARGED BATTERIES IN NORMAL CONDITIONS ……………...…... SA-3
SA3.1.1 COMMISSIONING VIA FLOAT CHARGE VOLTAGE - 2.23 VPC ……………..….…..……. SA-3
SA3.1.2 COMMISSIONING VIA HIGHER CHARGING VOLTAGES - 2.35 to 2.40 VPC ……...…… SA-3
SA3.2 COMMISSIONING OF DRY CHARGED BATTERIES WITH EVIDENCE OF SELF DISCHARGE ... SA-4
SA3.3 COMMISSIONING OF DRY CHARGED BATTERIES WITH EVIDENCE OF EXCESSIVE SELF
DISCHARGE ………………………………………………………………………..……………….……… SA-4
SA3.4 COMPLETION OF COMMISSIONING …………………………………….……………..…………..…… SA-5
2.0 RECEIVING OF STATIONARY BATTERIES
Every precaution has been made in packaging the batteries for shipment to assure their
safe arrival. IMMEDIATELY upon delivery (while carrier delivering the shipment is still on
site) please check the packaging materials for evidence of damage in transit and the Bill
of Lading to assure all parts are being delivered, including the accessories.
2.1 VISIBLE EXTERNAL DAMAGE
•Wet acid stains may indicate spillage or leakage of electrolyte on wet supplied cells
•Crushed “Do Not Stack” cones or damaged boxes could be evidence of rough
handling during transit and damage to cells.
If any of the above are observed, make a note of it on the bill of lading before signing.
NOTE: Shipping damage must be handled with the carrier -- not BAE Batteries USA
2.2 CONCEALED DAMAGE
It is recommended that the cells be unpacked and checked for concealed damage as
soon as possible. Freight carriers generally require that concealed damage be inspected
by the carriers representative within 10 days from date of delivery to determine
responsibility.
It is the receiving facility’s responsibility to notify the freight carrier of concealed damage.
If cells need to be unpacked, see Section 4.0

Stationary VLA Batteries,
Installation and Operation Instructions
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2.3 ACCESSORIES
If possible, upon receiving the battery systems, check the accessory packages against
the included packing list for contents making certain that all the parts ordered with your
system are included.
3.0 STORAGE AND MAINTENANCE
BAE USA supplies lead-acid batteries in a fully charged, ready to use state.
Alternatively, the cells may be provided in a dry-charged (unfilled) state for either pro-
longed storage or export, refer to Supplement A of this manual for dry-charge battery
details.
Packaging depends on transit routes (domestic or export) and varies from simple shrink
wrapping on a pallet to seaworthy crating for export or special request.
Store batteries indoors in a clean, dry and cool location.
DO NOT stack pallets. Damage may occur and the warranty will be voided.
3.1 STORAGE AND MAINTENANCE: NEW WET CHARGED BATTERIES
Batteries provided filled (wet) and charged may be stored without further charging for a
limited period because of self-discharging and related chemical processes.
After a maximum storage period of 12 weeks at 25°C (77°F) or less (or 6 weeks at
ambient temperatures above 25°C (77°F)) the batteries must be charged by connecting
to a proper charger providing a continuous float charge of 2.23 volts per cell or providing
an equalization (boost) charge to the cells (See Section 8.2). Storage at high
temperatures results in accelerated rates of self-discharge and increases the frequency
of required boost charging if the cells are not on constant float charge.
Storage times exceeding the above maximums may result in plate sulfation which may
adversely affect electrical performance and expected life.
Adequate freeze protection must be met for low temperature storage, as this will damage
the battery and cause potentially hazardous leaking. A fully charged battery is more
resistant to freezing than a discharged one. As a battery loses charge, its specific gravity
decreases causing it to have a higher freezing temperature. The freezing temperature
versus specific gravity is shown in the table below. BAE VLA batteries have a specific
gravity of 1.240 kg/l at 68°F.
Specific Gravity
(68°F)
Freezing point
Specific Gravity
(68°F)
Freezing point
°C
°F
°C
°F
1.000
0.0
32.0
1.225
-39.8
-39.0
1.150
-15.1
5.0
1.250
-54.3
-65.0
1.175
-20.2
-4.0
1.275
-70.0
-93.0
1.200
-28.0
-18.0
1.300
-71.1
-95.0
3.2 STORAGE AND MAINTENANCE: BATTERIES REMOVED FROM OPERATION
Batteries that have been in service and taken out of operation must be maintained on
permanent float charge or must receive a periodic equalize charge not to exceed every 6
weeks at ambient temperatures at 25°C (77°F). Other conditions listed in Sections 3.0
and 3.1 apply. For extended storage periods please contact BAE USA or your local
representative for recommendations.

Stationary VLA Batteries,
Installation and Operation Instructions
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4.0 UNPACKING-HANDLING
Single cells and multi-cell blocks may be received packed in individual Styrofoam
containers with shrink-wrap or packing cases, surrounded by foam, shrink-wrap and
attached to a wooden pallet. Carefully open the cases or carton to avoid possibly
damaging any of the cells or blocks.
NOTE: When removing the blocks or cells from the containers or cases always lift cells
from the bottom, never from the connectors or cell posts as this can damage cell
covers or post seals and void your warranty.
NOTE: A BAE lifting sling may be used on the larger capacity
cells and blocks - slip the lifting sling under the cell and
use the loops in the sling for hoisting the cell. Four
battery lift sizes are available based jar dimensions. .
•Small Block Lift Kit, L = 272 mm (10.7 in)
•Large Block Lift Kit, L = 385 mm (15.16 in)
•Small Cell Kit, H < 620 mm (24.4 in)
•Large Cell Kit, min: L x W x H, 145 x 205 x 700 mm
(5.71 x 8.07 x 27.56 in)
max: L x W x H, 220 x 580 x 855 mm
(8.66 x 22.83 x 33.66 in)
weight: 250 kg (551.1 lbs)
See the specific battery lifting sling operating instructions for details on use.
NOTE: A mechanical battery lift may also be used to move the cells.
If the cells were ordered wet (filled), immediately check the electrolyte level in each cell
or block. The electrolyte level should be between the maximum and minimum level lines
on the container. If the level is below the minimum line, check the container for damage.
If your visual inspection, after unpacking, indicates damaged posts, cell covers or jars, or
electrolyte levels are below the minimum line immediately contact BAE USA or your local
representative.
4.1 ACCESSORIES
When unpacking the cells, place the accessories along with the installation and operating
instructions in a safe location to avoid misplacement or loss. If you find any of the items
listed on the packing list are missing please contact BAE USA or your local
representative.
5.0 PRE-INSTALLATION PLANNING
We recommend batteries not be installed in battery rooms that are still under
construction; this avoids the risk of damage to the batteries during construction.
The installation of the individual cells is dependent on the size and type of cell and the
intended application of the battery. Standard designs provide for installation in battery
cabinets, conventional steel racks or seismic (earthquake resistant) racks.
For all installation options, the ideal designs should include acid-resistant coatings and
rail insulation to ensure that the required insulation between the rack and battery is
present over the life of the batteries.

Stationary VLA Batteries,
Installation and Operation Instructions
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All racks should be properly aligned and all the bolted parts tightened thoroughly before
placing the cells on them. Use levelers/shims to compensate for irregularities in the floor
surface.
5.1 RACKS (EXISTING RACK)
If the cells are to be installed on an existing battery rack, the following inspection should
be made prior to installation to avoid any possibility of damage to the new battery.
a) Inspect all bolted connections to make sure that all are properly aligned and tight.
b) Check all painted surfaces making sure everything is clean and free of corrosion.
c) Make sure the rail insulation is clean and in place.
d) If the existing rack is not designed for the new batteries being installed this could
affect your seismic rating and battery warranty. Please contact BAE USA or your
local representative with questions.
If deficiencies are found with the existing rack - DO NOT INSTALL THE NEW CELLS
UNTIL CORRECTIVE ACTIONS ARE TAKEN.
If your inspection indicates that no corrective action is required, proceed with the cell/jar
installation (go to Section 6.0).
5.2 RACKS (NEW RACK)
Carefully unpack rack materials using care not to scratch the coated surfaces. Check
received parts against the Bill of Materials for the individual rack. If you find damage to
the rack components, file a claim against the carrier.
NOTE: If rack specific spill containment systems are used, then their installation will
likely have to be done while installing the rack. Refer to the manufacturer’s
recommended installation procedures.
Refer to the rack assembly drawing and installation instructions and proceed with rack
assembly.
•When assembled, battery racks must be level and in conformance with the rack
manufacture’s drawings and specifications supplied with the equipment. This will
ensure that neither individual cells nor rack assembly can topple, twist or overturn.
Use levelers to compensate for irregularities in the floor surface.
•Do not place battery cells on the rack until the rack has been completely assembled
with all bolts having been tightened. Otherwise, the weight of the cells may cause the
rack to shift and collapse.
•Never remove or loosen braces from a loaded battery rack, removal of braces could
allow the rack to shift or collapse.
If the new rack is not designed for the new batteries being installed this could affect your
seismic rating and battery warranty. Please contact BAE USA or your local
representative with questions.
6.0 BATTERY CELL/JAR INSTALLATION
SAFTEY REMINDERS – see Section 1 for details:

Stationary VLA Batteries,
Installation and Operation Instructions
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The electrolyte is dilute sulfuric acid, which is harmful to skin, and eyes. It is
electrically conductive and corrodes unprotected metal surfaces.
A filled and charged battery presents a high voltage, high current shock and
short circuit hazard.
Batteries can generate gases which, when released, can explode, causing
blindness and other serious personal injury.
To position the cells on the rack special auxiliary equipment, such as lifting straps
(Section 4.0) or other mechanical lifting gear, may be required. If necessary, this
equipment may be obtained from BAE Batteries USA.
An alignment guide should be used to aid in placing the cells properly on the rack.
Properly aligned cells will aid in connecting the cells together.
It is recommended that cells installation begin in the middle of the bottom tier with the
distance between the cells being determined from the center of the rack. In this way, it is
possible to make allowances toward the end of the rack(s). Planning the layout based on
cell dimensions and spacing ahead of time will prevent having to move cells on the rack
later.
Standard spacing between battery cells is 10 mm (0.394 in).
For a seismic rated rack, if cell spacers have been provided, install the spacers between
the cells during placement of each cell, otherwise insufficient spacing may be left to insert
them later. Install the remaining seismic battery rails for these racks once all cells are in
the proper position.
6.1 TERMINAL PREPARATION
Prior to assembling the inter-cell connectors to the cells, the plastic post covers should
be removed and the post contact surfaces should thoroughly cleaned by using the
provided wire brush and a clean cloth.
NOTE: Caution should be taken when using the wire brush as not to make contact with
other exposed metal areas to prevent short circuits.
Once clean, the post contact surfaces should have a light layer of no-ox grease applied.
These steps will insure the very best possible connection surface; once these surface
preparation steps are completed the connector to cell assembly can be performed.
6.2INTER-CELL CONNECTORS
The individual cells are connected by either using the included thermoplastic-insulated
copper connectors or the lead plated copper connectors (type is dependent on cell type
and customer preference). The connectors are bolted to the threaded insert post using
either a stainless steel M10 Allen head bolt or a 17 mm hex head bolt (bolt type is
dependent on cell type).
All bolted connections should be made using a calibrated torque wrench to insure proper
tightness of the connection without causing any damage to the battery posts. The torque
settings for both of BAE bolt types (M10 Allen and 17mm Hex) is:
•22 Newton-meters or 195 (194.7 actual) inch-pounds.

Stationary VLA Batteries,
Installation and Operation Instructions
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6.3 TERMINAL PLATES
For multi-terminal cell strings, terminal plate assemblies are provided standard for the +/-
customer connection cells. For single terminal cell strings the terminal plates are
purchased as an optional item. The standard terminal plates allow for customer
connection with either single hole or 2-hole 3/8” lugs with 1” spacing.
These terminal plate assemblies are to be bolted together using the following torques for
the terminal plate/bracket connection and the bracket to battery post connection.
Terminal plate covers are included as part of the terminal plate kit for safety.
If the cells were received Dry Charged (unfilled), go to Supplement A, Section SA2.0, Filling
and Final Installation – for Dry Charged Batteries.
6.4 FINAL INSTALLATION STEPS
Once the cells have been installed and the connections completed, the following items
should be completed.
•Clean the battery room with all installation debris being removed.
•Although already done during unpacking, check the electrolyte level in each cell or
block to assure spillage has not happened during handling and installation. The
electrolyte level should be between the maximum and minimum level lines on the
container. If for any reason electrolyte was lost during installation, contact BAE USA
or your local representative.
•Once the battery room has been cleaned, all of the cells should be wiped down and
cleaned using a damp cloth – dampen the cloth with clear (distilled) water. See
Section 9.1 on cleaning of cells.
NOTE: DO NOT use cleaners or chemicals to clean the cells without prior written
approval from BAE.
•Once the cells have been thoroughly cleaned, apply the supplied cell numbering
stickers to the upper left or right hand corner of the face of the cells as desired.
oPlease note the cells should always be numbered from the most positive cell to
the most negative cell.
•Apply the provided polarity labels as appropriate to the most positive and most
negative cell in the system.
Connection
Type
Torque setting for
BAE SS Hardware
N-m (in-lbs)
Angle Bracket to
Battery Post 22 N-m (195 in-lbs)
Terminal Plate to
Angle Bracket 28 N-m (247 in-lbs)