C&D Technologies LIBERTY 1000 Series User manual

LIBERTY®SERIES 1000
Valve-regulated Lead Acid Batteries
Installation and Operating Instructions
RS-990

SAFETY PRECAUTIONS
Only authorized and trained personnel familiar with standby battery installation, preparation, charging and
maintenance should be permitted access to the battery.
WARNING
SHOCK HAZARD -DO NOT TOUCH UN-INSULATED BATTERY, CONNECTORS OR TERMINALS.
BE SURE TO DISCHARGE STATIC ELECTRICITY FROM TOOLS AND TECHNICIAN BY TOUCHING
AGROUNDED SURFACE IN THE VICINITY OF THE BATTERIES BUT AWAY FROM THE CELLS
AND FLAME ARRESTERS.
ALL TOOLS SHOULD BE ADEQUATELY INSULATED TO AVOID THE POSSIBILITY OF SHORTING
CONNECTIONS. DO NOT LAY TOOLS ON THE TOP OF THE BATTERY.
ALTHOUGH LIBERTY®SERIES 1000 BATTERIES ARE SEALED AND EMIT NO GAS DURING NOR-
MAL OPERATION, THEY CONTAIN POTENTIALLY EXPLOSIVE GASES, WHICH MAY BE RELEASED
UNDER ABNORMAL OPERATING CONDITIONS, SUCH AS A CHARGER MALFUNCTION. PROVIDE
ADEQUATE VENTILATION SO HYDROGEN GAS ACCUMULATION IN THE BATTERY AREA DOES
NOT EXCEED ONE PERCENT BY VOLUME. HOWEVER, NORMAL AIR CIRCULATION IN A VENTI-
LATED FACILITY WILL PRECLUDE ANY HYDROGEN BUILD-UP, EVEN DURING EQUALIZE CHARG-
ING. NEVER INSTALL BATTERIES IN A SEALED CABINET OR ENCLOSURE. IF YOU HAVE ANY
QUESTIONS, CONTACT YOUR LOCAL C&D TECHNOLOGIES AGENT.
THIS BATTERY CONTAINS SULFURIC ACID,WHICH CAN CAUSE SEVERE BURNS. IN CASE OF
SKIN CONTACT WITH ELECTROLYTE, REMOVE CONTAMINATED CLOTHING AND FLUSH
AFFECTED AREAS THOROUGHLYWITH WATER. IF EYE CONTACT HAS OCCURRED, FLUSH
FOR A MINIMUM OF 15 MINUTES WITH LARGE AMOUNTS OF RUNNING WATER AND SEEK
IMMEDIATE MEDICAL ATTENTION.
THIS BATTERY IS DESIGNED FOR INDUSTRIAL USE ONLY AND IS NOT INTENDED FOR
APPLICATION IN VEHICULAR STARTING, LIGHTING AND IGNITION AND/OR OPERATION OF
PORTABLE TOOLS AND APPLIANCES. USE ONLY IN ACCORDANCE WITH MANUFACTURER’S
WRITTEN INSTRUCTIONS. USE OF THIS PRODUCT OTHER THAN IN ACCORDANCE WITH
MANUFACTURER’S WRITTEN INSTRUCTIONS MAY PRODUCE HAZARDOUS AND UNSAFE
OPERATING CONDITIONS, LEADING TO DAMAGE OF EQUIPMENT AND/OR PERSONAL INJURY.
I
IM MP PO OR RT TA AN NT TFOLLOW MANUFACTURER’S PUBLISHED INSTRUCTIONS WHEN INSTALLING, CHARGING AND
SERVICING BATTERIES. THIS MANUAL IS TO BE USED FOR THE INSTALLATION AND
OPERATION OF C&D TECHNOLOGIES VALVE-REGULATED LIBERTY SERIES 1000 BATTERIES.

1
FOR ADDITIONAL INFORMATION CONTACT:
C&D Technologies, Inc.
1400 Union Meeting Road, PO Box 3053
Blue Bell, PA 19422-0858
215-619-2700 or 1-800-543-8630, Fax [phone]
www.cdtechno.com
FOR TECHNICAL or WARRANTY ASSISTANCE CONTACT:
Technical Service Department located at:
1400 Union Meeting Road
Blue Bell, PA 19422
215-619-2700 or 1-800-543-8630, Fax [phone]
WARRANTY NOTICE
This instruction manual is not a warranty. Each standby battery is sold subject to a limited
warranty, which is in place of all other warranties, express or implied (including the warranties of
merchantability or fitness for a particular purpose) and which limits a purchaser’s (user’s)
remedy to the repair or replacement of a defective battery or parts thereof. The terms of the
limited warranty are incorporated herein and are available upon written request from C&D
Technologies, Inc., 1400 Union Meeting Road, PO Box 3053, Blue Bell, PA 19422-0858 or in
Canada C&D Technologies, Inc., Canada, 7430 Pacific Circle, Mississauga, ON
L5T 2A3.

2
INTRODUCTION
The batteries referenced in this document are valve-regulated lead acid Liberty Series 1000®.
They are constructed with pasted lead calcium plates with an absorbent glass mat and are
valve-regulated. They are designed to provide long, reliable service life with minimal
maintenance. The cells/units are shipped pre-assembled in 2-, 4-, 6- and 12-Volt modules to
enable quick and easy installation. When operated at the recommended float voltage and
temperature, the batteries emit virtually no gas or acid mist and do not need special
ventilation other than what is required by local building codes. This makes Liberty Series
1000 batteries an ideal reserve power source for many critical applications, including
telecommunications, switchgear and control, and uninterruptible power supply (UPS)
systems. The Liberty Series 1000 product brochure and additional information are available
on the C&D Technologies website at www.cdtechno.com.
Recombination: A More Efficient Design
In addition to eliminating the need for watering, the uniquely efficient recombination design
also makes Liberty Series 1000 batteries lighter and more powerful than conventional lead-
acid batteries.Oxygen evolves from the positive plates where it is converted back to water
by electro chemical recombination, eliminating the need for watering.
CAUTION: Do not remove vent covers, they must remain in place at all times. Removal
will void warranty.
Specifications are subject to change without notice. Contact your C&D Technologies sales
office for the latest specifications. All statements, information and data given herein
are believed to be accurate and reliable but are presented without guaranty, warranty, or
responsibility of any kind, express or implied. Statements or suggestions concerning possi-
ble use of our products are made without representation or warranty that any such use is
free of patent infringement, and are not recommendations to infringe any patent. The user
should not assume that all safety measures are indicated, or that other measures may not be
required.

3
RECOMMENDED TECHNICAL REFERENCES AND EXPERTISE
These instructions assume a certain level of competence by the installer/user. The following
recommended practices and codes contain relevant information, and should be consulted for safe
handling, installation, testing and maintaining standby batteries. Applicable state and local codes must
be followed.
IEEE Std. 485-1997, IEEE Recommended Practice for Sizing Large Lead Acid Storage Batteries for Generating
Stations and Substations (ANSI)
IEEE 1189-1996, IEEE Guide for Selection of Valve-Regulated Lead Acid (VRLA) Batteries for Stationary
Applications
IEEE 1188-1996, IEEE Recommended Practice for Maintenance, Testing, and Replacement of Valve Regulated
Lead-Acid Storage Batteries for Stationary Applications
IEEE 1187-2000, IEEE Recommended Practice for Installation Design and Installation of Valve Regulated Lead-
Acid Storage Batteries for Stationary Applications
IEEE - PAR-1375-1998 “Guide for Protection of Stationary Battery Systems”
NESC, National Electric Safety Code, ANSI C2-1993 (or latest revision)
Copies may be obtained by writing: The Institute of Electrical and Electronic Engineers, Inc.
345 East 47th Street, New York, NY 10017, USA
ANSI - T1.330-1997, Valve-Regulated Lead Acid Batteries Used in the Telecommunications Environment
NEC National Electrical Code NFPA -70 (latest version) available from:
National Fire Protection Association Batterymarch Park, Quincy, MA 02269
Federal Codes:
29CFR1926.441 “Safety Requirements for Special Equipment”
29CFR1910.151(c) “Medical Services and First Aid”
29CFR1910.268(g) “Telecommunications”
29CFR1910.305(j) “Wiring Methods, Components and Equipment”
STD 1-8.2(e)
“ OSHA Standing Directive”
IBC, International Building Code
This manual is divided into four parts: Receiving and Installation of the battery, Operation and Maintenance,
Reference and Trouble-Shooting section to assist the user should he require more detailed explanation of battery
performance and maintenance procedures, and the Appendix.
Before handling cells or storing cells for future installation take time to read this manual. It contains
information that could avoid irreparable damage to the battery and/or void product warranty.

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LIBERTY SERIES 1000
VALVE-REGULATED (SEALED) LEAD ACID BATTERIES
INSTALLATION AND OPERATING INSTRUCTIONS
TABLE OF CONTENTS PAGE
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Recombination: a more efficient design
Recommended Practices, Technical Sources
PART 1
RECEIVING AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 1 - RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 General Information and precautions
1.2 Safety
1.3 Packing, Inspection at time of delivery
1.4 Damage and shortage situations
1.5 Unpacking and handling
SECTION 2 - STORAGE and SHELF LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Storing charged batteries
SECTION 3 - INSTALLATION AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Location and preparation
3.2 Ventilation
3.3 Modular rack assembly
3.4 Relay rack assembly
3.5 Optional steel jackets for batteries/units operating in a demanding
environment
SECTION 4 - ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Preparing electrical contacting surfaces
4.2 Polarity inspection of assembled units and inter-row, inter-tier con-
nections
4.3 Connecting and torquing battery terminal posts
4.4 Checking connection integrity
4.5 Parallel battery strings
PART 2
CHARGING AND OPERATION OF BATTERY . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 1 - CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 General information and precautions
1.2 Initial charge
1.3 Constant voltage charging
1.4 Initial charge records
1.5 Warning labels

5
SECTION 2 - BATTERY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Float charging
2.2 Equalizing charge
2.3 Over-voltage
2.4 Voltmeter calibration
SECTION 3 - GENERAL INFORMATION AND MAINTENANCE. . . . . . . . . 20
3.1 Performance characteristics
3.2 Capacity and testing
3.3 Low cell voltages
3.4 Effects of temperature
3.5 High ambient temperature
3.6 Cleaning cell covers
3.7 Tap connections
3.8 Putting batteries into storage
3.9 Record keeping
PART 3
TROUBLE-SHOOTING and AVOIDING BATTERY DEGRADATION and
RECOGNIZING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 1 - HOW TO AVOID BATTERY DEGRADATION . . . . . . . . . . . . . 26
1.1 General information and precautions
1.2 Float versus cycle life
1.3 Low float voltage and sulfation
1.4 Hydration
1.5 Open circuit - late installations
1.6 Parallel battery strings
1.7 High temperature operation
APPENDIX A - MATERIAL SAFETY DATA SHEETS . . . . . . . . . . . . . . . . . . 29
APPENDIX B - WARRANTY PROVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . 35
APPENDIX C - VALVE REGULATED LEAD ACID BATTERY and
CHARGER INSPECTION REPORT FORM . . . . . . . . . . . . 36

PART 1
RECEIVING AND INSTALLATION
SECTION 1 - RECEIVING
1.1 General Information and Precautions
This battery is designed for industrial use only and is not intended for
application in vehicular starting, lighting, and ignition, and/or operation
of portable tools and appliances. Use only in accordance with
manufacturer’s written instructions. Use of this product other than in
accordance with manufacturer’s written instructions may produce
hazardous and unsafe operating conditions, leading to damage of
equipment and/or personal injury.
1.2 Safety
Charge only in accordance with manufacturer’s operating instructions.
Do not expose to open flame or electrical arc.
Do not tamper with cell covers that prevent access to vents.
Observe all precautions shown on the inside cover of this manual.
1.3 Packing, Inspection at time of delivery
Every precaution has been taken to pack the battery for shipment to
ensure its safe arrival. As soon as you receive the battery, check the
packing material for evidence of damage in transit. If the packing
material is physically damaged or wet acid stains are present, make a
notation on the delivery receipt before you accept the shipment/
delivery.
Note: Freight Carriers generally require that the carriers’
representative inspect concealed damage within 15 days
from date of delivery to determine responsibility. The
resolution of such claims may extend up to 9 months.
Verify the number of cartons and skids against the bill of lading and
verify the components against the packing lists.Keep a copy of the
verified lists for your installation records. It is important to verify that
the accessory package is present and the component quantity is
correct. If help is required call your local C&D Technologies
Representative or C&D Technologies Customer Service at 800-543-
8630 to report any discrepancies.
1.4 Damage and shortage situations
C&D Technologies ships FOB plant (ownership passes at our dock). If
shipments are damaged or if cartons or skids are damaged or miss-
ing, a claim must be filed with the carrier. Place an immediate
order for replacement with C&D Technologies and use the replace-
ment cost as the amount of freight that damages or shortages
involved. If individual components or parts are missing, a shortage
report should be filed immediately with C&D Technologies. Mail
(express mail recommended) or fax a copy of the VERIFIED compo-
6

7
nent packing list. This verified list should show both the name of the
packer, as well as the quantities of items checked off by the receiver.
Send the list to:
C&D Technologies, Inc.
Attn.: Customer Service
1400 Union Meeting Road
Blue Bell, PA 19422
SECTION 2 - STORAGE and SHELF LIFE
2.1 Storage of VRLA (valve regulated lead acid) Batteries
Store batteries indoors, preferably at 77°F (25°C) or in a cool 20°F to
90°F (-7°C to 32°C), dry location and place on charge by the date
found on the battery carton.
Note: Batteries that are not placed in service for several months will
self-discharge.
Storage time is based on storage at 77°F (25°C) and is six months for
Liberty Series 1000 valve regulated cells. Do not allow the electrolyte
to freeze, as this will destroy the battery and can cause a potentially
hazardous condition and leakage.
Refer to Table 1, for electrolyte freezing temperatures. Although the
specific gravity of a fully charged battery may present no freezing
problem, a discharged battery gravity may freeze at relatively mild
temperatures.
TABLE 1 - FREEZING TEMPERATURE VS SPECIFIC GRAVITY
Specific Gravity Freezing Temperature
at 77°F (25°C)
Celsius Fahrenheit
1.000 0.0 +32
1.050 -3.3 +26
1.100 -7.7 +18
1.150 -15 + 5
1.200 -27 -17
1.250 -52 -61
1.300 -70 -95
1.350 -49 -56
1.400 -36 -33
Note: Store cells upright in order to maximize electrolyte contact with
the plates.
2.2 Storage limitations
C&D Technologies Liberty Series 1000 valve-regulated (sealed) lead

8
acid batteries are warranted against defects in materials or manufac-
turing or both. To keep the warranty in effect, you must place the units
on charge by the date stamped on the shipping carton when stored at
77°F (25°C). If storage beyond this time is required or storage temper-
ature is in excess of 77°F (25°C), monitor battery voltage at monthly
intervals, if possible. A convenient measurement technique is to read
the open circuit voltage. If the open circuit voltage drops below 2.10
volts per cell from the nominal value, the cell(s) must be given a boost
charge at the “Initial/Equalize” voltage shown in Table 2. With the
exception of the LS 2-600 all units consist of multiple cells. Refer to
Table 2 for the nominal voltage and number of cells for a particular
Liberty Series unit. Never charge the cells at a higher voltage than the
equalize/ boost voltage recommended in Table 2, at 77°F (25°C). If
cell temperature is below 60°F (16°C), double the initial/equalize
charge time that is typically 12-16 hours at 77°F (25°C).
If this is not possible, contact C&D Technologies, Inc., Technical
Services Department for special instructions.
Always complete a record of initial charge, refresh charges during
storage, and float charge readings as described in “initial charge”
Part 2, Section 1.2 using RS-1511 of this manual and retain the
readings in your files for future reference. Clearly identify your installa-
tion location, application, C&D Technologies model number, the date,
and name of the person who took the readings.
The service life of the battery will depend on its ambient temperature,
frequency and depth of discharge, discharge rate, charge voltage, and
regulation of the battery charger.
SECTION 3 - INSTALLATION AND CONNECTION
3.1 Location and Preparation
Liberty Series 1000 batteries are best installed upright. Physical
dimensions for layout may be found in Table 2. Install battery in a cool,
dry location away from heat sources. The recommended operating
temperature is 65-77°F (18-25°C). The allowable temperature range
with performance degradation at the extreme temperatures is 32-90°F
(0-32°C). Float voltage compensation should be made for temperatures
other than 77°F (25°C).
Avoid sources of hot or cold air directed on a section of the
battery that could cause temperature variations within the
battery assembly. Such variations will compromise optimum
battery performance such as float voltages of individual cells.
When handling units never lift them by the terminals as this can
damage the post seals and cause acid leakage.

Model LS 12-25* LS 6-50* LS 12-55 LS 12-80
Nominal voltage 12 Volts 6 Volts 12 Volts 12 Volts
Number of cells in 6/unit 3/unit 6/unit 6/unit
module
Rated 8 hr. 25 Ah 50 Ah 52 Ah 80 Ah
Capacity (Ampere- to to to to
hours to 1.75 Vpc) 10.50 Volts 5.25 Volts 10.50 Volts 10.50 Volts
Rated 15-min. capacity 0.092 0.185 0.172 0.275
(kiloWatts to 1.67 Vpc)
Internal resistance/cell 0.0017 Ohms 0.0008 Ohms 0.00157 Ohms 0.00094 Ohms
Short circuit current 1155 A 2310 A 1274 A 2128 A
Unit height 7.11 in 7.11 in 9.20 in 9.20 in
(181 mm) (181 mm) (234 mm) (234 mm)
Unit length 7.64 in 7.64 in 10.20 in 13.94 in
(includes handles) (194 mm) (194 mm) (234 mm) (354 mm)
Unit width 5.20 in 5.20 in 6.80 in 6.80 in
(132 mm) (132 mm) (173 mm) (173 mm)
Weight 23 lbs 23 lbs 56 lbs 79 lbs
(10 kg) (10 kg) (25 kg) (36 kg)
Terminal 0.55 in (14 mm) 0.55 in (14 mm) 0.55 in (14 mm) 1.00 in (25 mm)
Characteristics diameter threaded diameter threaded diameter threaded diameter threaded
brass insert, 0.50 brass insert, 0.50 brass insert, 0.50 brass insert, 0.75
in (13 mm) deep. in (13 mm) deep. in (13 mm) deep. in (19 mm) deep.
Fasten with 10-32 Fasten with 10-32 Fasten with 10-32 Fasten with 1/4-20
stainless steel stainless steel stainless steel stainless steel
hex bolt/washer hex bolt/washer hex bolt/washer hex bolt/washer
Tightening torque 45 in-lbs (5.1 N*m) 45 in-lbs (5.1 N*m) 45 in-lbs (5.1 N*m) 110 in-lbs (12.4 N*m)
Re-torque 40 in-lbs (4.5 N*m) 40 in-lbs (4.5 N*m) 40 in-lbs (4.5 N*m) 100 in-lbs (11.3 N*m)
Boost charge voltage 2.33 +/-.02 Vpc 2.33 +/-.02 Vpc 2.33 +/-.02 Vpc 2.33 +/-.02 Vpc
Nominal float voltage 2.26 +/-.01 Vpc 2.26 +/-.01 Vpc 2.26 +/-.01 Vpc 2.26 +/-.01 Vpc
Electrolyte at 77°F 1.300 Specific 1.300 Specific 1.300 Specific 1.300 Specific
(25°C) nominal value Gravity Gravity Gravity Gravity
*These units have been discontinued
9
TABLE 2 - BATTERY SPECIFICATIONS
(Characteristics subject to change without notice. Refer to current specifications 12-373)

Model LS 12-100 LS 6-200 LS 4-300 LS 2-600
Nominal voltage 12 Volts 6 Volts 4 Volts 2 Volts
Number of cells in 6/unit 3/unit 2/unit 1/unit
module
Rated 8 hr. 100 Ah 200 Ah 300 Ah 600 Ah
capacity (Ampere- to to to to
hours to 1.75 Vpc) 10.5 Volts 5.25 Volts 3.5 Volts 1.75 Volts
Rated 15-min capacity 0.344 0.688 1.032 2.063
(kiloWatts to 1.67 Vpc)
Internal resistance/cell 0.0008 Ohms 0.0004 Ohms 0.0003 Ohms 0.0001 Ohms
Short circuit current 2545 A 5089 A 7634 A 15267 A
Unit height 9.20 in 9.20 in 9.20 in 9.20 in
(234 mm) (234 mm) (234 mm) (234 mm)
Unit length 16.58 in 16.58 in 16.58 in 16.58 in
(includes handles) (421 mm) (421 mm) (421 mm) (421 mm)
Unit width 6.84 in 6.84 in 6.84 in 6.84 in
(174 mm) (174 mm) (174 mm) (174 mm)
Weight 95 lbs 95 lbs 95 lbs 95 lbs
(43 kg) (43 kg) (43 kg) (43 kg)
Terminal 1.00 in (25 mm) .00 in (25 mm) 1.00 in (25 mm) 1.00 in (25 mm)
characteristics diameter threaded diameter threaded diameter threaded diameter threaded
brass insert, 0.75 brass insert, 0.75 brass insert, 0.75 brass insert, 0.75
in (19 mm) deep. in (19 mm) deep. in (19 mm) deep. in (19 mm) deep.
Fasten with 1/4-20 Fasten with 1/4-20 Fasten with 1/4-20 Fasten with 1/4-20
stainless steel stainless steel stainless steel stainless steel
hex bolt/washer hex bolt/washer hex bolt/washer hex bolt/washer
Tightening torque 110 in-lbs
(12.4 N*m) 110 in-lbs (12.4 N*m) 110 in-lbs (12.4 N*m) 110 in-lbs (12.4 N*m)
Re-torque 100 in-lbs (11.3 N*m) 100 in-lbs (11.3 N*m) 100 in-lbs (11.3 N*m) 100 in-lbs (11.3 N*m)
Boost charge voltage 2.33 +/-.02 Vpc 2.33 +/-.02 Vpc 2.33 +/-.02 Vpc 2.33 +/-.02 Vpc
Nominal float voltage 2.26 +/-.01 Vpc 2.26 +/-.01 Vpc 2.26 +/-.01 Vpc 2.26 +/-.01 Vpc
Electrolyte at 77°F (25°C) 1.300 Specific 1.300 Specific 1.300 Specific 1.300 Specific
nominal value Gravity Gravity Gravity Gravity
10
TABLE 2 (CONTINUED)
3.2 Ventilation
The Liberty Series 1000 battery is a valve-regulated, low-maintenance battery, which, under normal float
conditions, requires only normal room ventilation. Therefore, under normal float operation, Liberty batteries
can be installed in proximity to electronic equipment and in computer rooms with personnel present.
However, should the battery be subjected to excessive overcharge, hydrogen and oxygen can be vented to
the atmosphere. Therefore, the battery should never be installed in an airtight enclosure. Sufficient
precautions must be taken to prevent excessive overcharge and containment of potential gases.

11
VRLA batteries when subjected to extreme overcharge (above the
recombinant ability of the cell) can release hydrogen gas at a
maximum rate of 0.000269 cubic feet per minute per ampere of
charging current at 77°F (25°C) at atmospheric pressure.
3.3 Rack Assemblies
Liberty Series 1000 batteries may be installed in a variety of
mounting assemblies
• Modular Rack assembly (Figure 3.1) - battery units may be assem-
bled in a floor mounted module or rack. One modular rack available
from C&D Technologies, Inc. is designed to mount the units in a
sturdy open frame that is stackable. They are available in 29" and
43" (74 cm and 109 cm) lengths. Optional panels are available to
enclose the racks, providing a cabinet-like appearance. (Figure 3.2)
For additional information refer to specification 12-373 and 12-380.
• When large numbers of batteries are required for the application
and a dedicated battery room may be provided, conventional tiered
racks may be appropriate.
3.4 Relay Rack Assembly
• Battery units can be mounted in standard 19" and 23" (48 cm and
58 cm) relay rack frames.A typical C&D Technologies “tray layout” is
shown in Figure 3.3. Specially designed trays/fixtures should be
ordered for relay rack applications.
3.5 Optional Steel Jackets for Batteries/Units operating in a
demanding environment
Although a metal jacket cannot change the thermal degradation or
electro/chemical properties of the battery exposed to elevated
temperatures, it will physically contain the cells exposed to elevated
temperatures by retaining compression on the positive and negative
plates and absorbent glass mat between the plates. The net effect and
purpose is that the plates are provided with a uniform exposure to the
contained electrolyte.
Note: Optional steel jackets are recommended if the batteries are
expected to experience frequent periods of operation at
temperatures in excess of 90°F (33°C).
FIGURE 3.1 - Modular Rack Assembly
FIGURE 3.2 - Modular Rack With Panels
FIGURE 3.3 - Relay Rack Trays

12
SECTION 4 - ELECTRICAL CONNECTIONS
WARNING
• Always use protective insulating equipment, such as gloves,
shoes and eye and face protection. Wrenches and other tools
must be insulated.
• Observe local, state, and national electric codes at all times.
• Always work with the battery ungrounded. Battery ground
connections, if required, should be made last.
• To avoid working with high voltages, break the battery down
into convenient lower-voltage modules, i.e., equal to or less
than 48-Volts.
•Always maintain a firm grasp on tools and hardware when
working on the battery. Dropped hardware can cause a short
circuit, possibly resulting in serious personal injury and/or
damage to the equipment.
•Before working on the battery, be sure to discharge static
electricity that can build up on tools or the technician by touching
a grounded surface in the vicinity of the battery but far enough
away from the cells and flame arresters. Avoid creating sparks or
exposing cells to open flames that could ignite the gasses
produced by a charging battery.
4.1 Preparing electrical contacting surfaces
All electrical contacting surfaces must have a clean and electrolyte
free finish. Any tarnish or discoloration should be carefully removed.
Do not use steel brushes or other abrasive tools to clean the tin plated
battery posts and intercell connectors.The posts and intercell
connectors are plated with a thin layer of tin. Cable lugs are tin
plated. It is important that the electro-plating must not be
damaged or removed.
1. With a dry cloth, remove any factory-applied grease or oil coating
from the contact surfaces or posts.
2. Brush the contacting surfaces of battery posts/terminals and
intercell connectors to a clean corrosion free finish using a fine
brass plater’s wire brush (multiple 0.010 diameter brass wire
construction).
3. After brushing connections with a fine brass plater’s brush,
terminals and interface can be coated with NO-OX which prevents
oxidation between connections.

13
CAUTION
Do not use steel brushes, steel wool, sandpaper or emery cloth
to clean surfaces, as these will damage the plating. Do not use
cleaning solvents. Solvents can cause crazing or cracking of
the plastic cell containers or covers. Use of solvents will void
the warranty.
4. Attach intercell connectors or cable/lugs from the positive post of
one unit to the negative post of the next cell or unit for series
connection. If the units are mounted on more than one tier make
certain to follow the polarity convention, positive post to negative
post. Inter-tier and inter-row connections are typically made with
cables with lugs on both ends. Do Not Use Steel or Cadmium
Plated Lugs.
5. Large batteries may use “Terminal Plates” to accommodate
multiple cable connections. There are a variety of optional terminal
plates available from C&D Technologies, Inc., Inc. Terminal plates
should be clean and prepared in the same manner as the intercell
connectors.
4.2 Polarity of assembled units/cells and inter-row, inter-tier
connections
Cell/unit polarities have been marked by a raised mark in the covers to
provide proper interconnection between cells. When connecting
cells/units be sure that all terminals, including inter-tier, have been
connected positive (+) to negative (-) from one cell/unit to another
throughout the battery.
4.3 Connecting and torquing battery terminal posts
Liberty Series 1000 batteries are available in various sizes and volt-
ages as described in Table 2 and with corresponding Ampere-hour
ratings at the 8 hour rate of discharge: 80 Ah, 100 Ah, 125 Ah, 200
Ah, 300 Ah, and 600 Ah. The units are connected positive to negative
from one unit to another unit in a series arrangement. This is accom-
plished by fastening the tin plated connector (used on larger size
units) or lugs found on cables (for smaller size units) from the positive
terminal of a unit to the negative terminal of the next unit. The lug or
connector is secured with the appropriate terminal hardware
described in Table 2 and tightened to the torque value specified in
Table 2.
Connect cells/units with the stainless steel hex head bolts and
washers in accordance with the connecting instructions for the
system. Torque all connections to the proper torque value shown in
Table 2.
It is recommended that the top tier of connectors be installed first on
multi-tier racks, then the second and so on, working from the top
down. This may avoid short circuiting connected groups of units in
lower tiers.
LS 12-100 Inter-Tier Connection
LS 12-100 Inter-Rack Connection

14
CAUTION
Use extreme care when installing connectors; maintain a firm
grasp on each connector as it is being installed, to prevent it
from dropping and potentially causing a short circuit.
Note: Over-torquing can damage the post seal causing electrolyte
leakage.
4.4 Checking connection integrity
• Check once again that all units are connected positive terminals to
negative terminals. Measure the battery voltage with a digital
voltmeter. The voltage should be approximately 2.15 Volts (open
circuit) times the number of cells per unit times the number of units
connected in series. Example: 2.15 Volts x 2 cells/unit (model LS 4-
300) x 6 units = 25.8 Volts, representative of the nominal open
circuit voltage of a 24-Volt system.
• Recheck the torque of connections to make certain that there are no
loose connections that could cause a poor connection thereby
creating an arc or spark or a hot connection that on discharge could
melt the lead components.
• Follow the charger manufacturer’s instructions and make the con-
nections to the battery with the charger de-energized.
CAUTION
It is the sole responsibility of the user to check connections.
All connections should be checked at regular intervals to
ensure that connections are clean and tight. Never operate a
battery with loose or corroded connections. When checking
connections, disconnect the battery from the load and the
charging equipment, and follow all precautionary measures
outlined above and the general safety references.
Typical internal cell resistance values are provided in Table 2
according to cell type. In addition a listing of short circuit current in
amperes is provided to further inform the user of the potential energy
available from the batteries.
4.5 Paralleling Batteries
When strings of batteries of equal voltage are connected in parallel,
the total capacity is equal to the sum of the capacities of the individual
strings. C&D Technologies recommends parallel strings when the
required capacity exceeds available Ampere-hour sizes or when
physical arrangement favors this choice. The use of parallel strings
permits maintenance on one string while the other(s) remain function-
al at a somewhat lower reserve time. Limit the number of paralled
battery strings to six.
When paralleling is necessary to obtain required capacity, the cable
size and external cable length should be optimized to match the cable

15
resistance for each battery. A wide variation in circuit resistance can
result in unbalanced discharging and charging of cells. As a
consequence this can produce unequal float voltages of the
connected cells and individual strings can sustain a loss of
performance and capacity, resulting in higher loads on the other
parallel strings with lower cable (circuit) resistance.

16
PART 2
CHARGING AND OPERATION OF BATTERY
SECTION 1 - CHARGING
1.1 General Information and Precautions
To safely charge the Liberty Series 1000 batteries and avoid
damaging the battery and/or connected equipment, observe the
following:
• Use only direct current for charging. AC ripple current from charger
must not exceed 5 percent of the 8-hour (Ampere-hour) rating of the
battery.
• Be sure charger is turned off before making electrical connections
between the battery and system.
• Connect battery positive terminal to charger positive terminal and
battery negative terminal to charger negative terminal. Grounding
battery may be either to positive or negative terminal of the battery.
This will depend upon the system design.
•Be certain that all connections are tight and secured before turning
on the charger.
•Perform a voltage test to assure proper connection (Section 4.4).
CAUTION
If the proper polarities are not observed when charging the
battery, the battery or groups of reverse-connected cells will be
irreparably damaged.
1.2 Initial charge
All cells/units are shipped fully charged but will lose some charge in
transit or storage before installation. Provide an initial charge by the
date stamped on the shipping container when stored in a clean, dry
and cool (between 32°F-77°F [0°C-25°C]) location.
CAUTION
Valve-regulated batteries must receive a boost charge (see Part
1, Section 2) if installation will not occur by the date on the
carton or if open circuit voltage drops to 2.10 Volts per cell.
Multiply the open circuit voltage by the number of cells in a unit
to obtain unit voltage. Use initial/equalize charge voltages as
shown in Table 2 of Part 1 or Table 3 of Part 2 for boosting cells
at the Initial/Equalize Voltage.

Higher than normal storage temperature (77°F [25°C] nominal) will
accelerate internal self-discharge of a battery by a factor of two for
each 15°F (9°C) over nominal 77°F (25°C) storage temperature. This,
in turn, will reduce the allowable time before initial and subsequent
charging.
Therefore it is very important that boost charges be given at the
appropriate time to avoid major remedial action or damage to
product.
All batteries, including Liberty Series 1000, are capable of generating
potentially explosive gases when charged at higher than normal
voltages typical of initial or equalizing charge.The Liberty Series 1000
cells are equipped with a “flame arrestor and pressure relief valve”
assembly that seals the cells during normal charge and operation but
allows it to safely vent in case of overcharge. Removing the cover
and/or valve assembly can cause the release of potentially explosive
gases and such action will void the warranty.
CAUTION
Never expose a cell or battery to sparks or an open flame.
When working on a battery, discharge static electricity on the
body, tools, etc., by touching a grounded surface in the vicinity
of the battery rack.
1.3 Constant voltage charging
The recommended method of providing an initial/equalize charge is to
first determine the maximum allowable voltage that may be applied to
the connected equipment. Divide this by the number of cells in the
battery to obtain maximum average voltage per cell allowed by the
equipment. Adjust this number down to a recommended initial value
found in Table 3 and continue charging at this voltage for the time
specified. Next put the battery at the recommended float voltage for a
17
TABLE 3
CHARGE VOLTAGES FOR LIBERTY SERIES 1000 CELLS
CHARGE VOLTAGES AT 77°F (25°C)
Cell Type Open Minimum Float Voltage Initial Charge Typical Charging
Circuit Cell (Vpc) Voltage (Vpc) Time for Initial
(Vpc) Voltage (Vpc) Charge
All Liberty 2.15 2.20 2.26 +/- 0.01 2.33 +/- 0.02 12 - 16 Hours
Series 1000®
Note 1:
1 - Applies to average cell voltage. Battery voltage should be set at average cell voltage multiplied by the number of cells in unit or string. Individual cell voltages may
vary by +/- 0.05 Volts from the average.
2- Charging time will vary due to open circuit stand, temperature and charger voltage available.
3- If cell temperature is below 60°F (16°C), double the charge time for initial or equalize charge.
Note 2:
All lead-acid batteries lose a certain amount of charge when removed from a constant voltage source charger, set at a potential that is higher than the open circuit
potential of the battery. As the charge is lost, the electrochemical process produces lead sulfate in the positive and negative plates of every cell in the battery. If left
uncharged for a significant period of time, the lead sulfate will begin to form large crystals of lead sulfate. Because of their size, these crystals may be somewhat
difficult to reduce (break down) through normal charging procedures and may inhibit the complete electro/chemical process necessary to sustain a healthy lead-acid
battery. Frequently, higher-than-normal charging potentials or even more sophisticated remedial approaches may be necessary to recover the affected battery. In
cases of severe sulfation, replacement may be the only solution.

18
minimum of 72 hours before any load is placed on the system. The
battery is now considered fully charged and is ready for either initial
acceptance testing or regular service.
Use only direct current for charging. AC ripple current from charger
must not exceed 5 percent of the 8-hour (Ampere-hour) rating of the
battery.
1.4 Initial charge records
At the completion of the initial charge and after the cells have been on
float charge for approximately one week, record voltages of the indi-
vidual cells or units, the total battery voltage and ambient
temperature. Retain this information in your files for future reference.
This information establishes one baseline for future reference. Refer to
RS-1511 found in the appendix. Make a photocopy of the form and
use it whenever necessary to record readings taken on the battery.
IMPORTANT:Initial charge records are essential for review by C&D
Technologies sales/service agents in the event of a problem. Since
records can materially affect your warranty, be sure to maintain clear,
signed, and dated copies.
1.5 Warning labels
C&D Technologies, Inc., provided a warning label to assist in maintain-
ing standby batteries and to advise you of certain hazards.This label
may be found on the battery cover visible to anyone in the immedi-
ate vicinity of the battery. Make certain that all individuals who could
be operating near the battery read the warning that is intended to
inform the individuals of basic safety practices.
SECTION 2 - BATTERY OPERATION
2.1 Float charging
Standby batteries are continuously connected to control circuits, which
must be energized at all times. Connected to a load in parallel with a
continuously operating power supply, these batteries assure
instantaneous support of the load in the event of a power failure or
brownout. In addition to operating the connected load, the power
supply keeps the standby battery fully charged. This parallel
interconnection and operation is called float service. Maximum battery
life can be expected in full float service, in which the frequency and
depth of discharges are kept at a minimum.
Deep and/or frequent discharges, such as those in a UPS application,
can shorten service life, even with proper battery maintenance.
Maximum battery life can be expected only in full float service.
FLUSH EYES
IMMEDIATELY
WITH
WATER.
GET
MEDICAL
HELP FAST
DANGER
HIGH VOLTAGE…
RISK OF SHOCK. DO NOT
TOUCH UNINSULATED
TERMINALS OR
CONNECTORS
SHIELD
EYES
EXPLOSIVE
GASES CAN CAUSE
BLINDNESS OR INJURY
NO
•SPARKS
•FLAMES
• SMOKING
SULFURIC
ACID
CAN
CAUSE BLINDNESS
OR SEVERE BURNS
“DO NOT REMOVE VENT VALVES.” VENTILATE WELL WHEN IN AN ENCLOSED
SPACE AND WHEN CHARGING.
SEE INSTALLATION, MAINTENANCE AND OPERATION
INSTRUCTIONS FOR IMPORTANT SAFETY PRECAUTIONS. REPAIR SHOULD BE PERFORMED ONLY BY
A QUALIFIED SERVICE TECHNICIAN.
FIGURE 1.1 - BCI Battery Warning Label