DataSafe HX Series Manual

Available exclusively from EnerSys®, the world leader in stored power solutions.
DATASAFE®HX TOP TERMINATED BATTERIES
DataSafe®HX Top Terminated Batteries ®
HX
6 and 12 Volt
Battery Installation, Operation
and Maintenance Instructions

Publication No: US-HX-IOM-004 - September 2012
www.enersys.com
Important
Please read this manual immediately upon receipt of battery before unpacking and installing. Failure to comply with these instructions will render any warranties null
and void. The term battery within this literature pertains to (1) 12 Volt battery consisting of (6) individual cells or (1) 6 Volt battery consisting of (3) individual cells.
Care for Your Safety
Handling
DataSafe®HX batteries are supplied in a fully
charged state and must be unpacked carefully
to avoid very high short-circuit currents between
terminals of opposite polarity. Use care when
handling and moving batteries. Appropriate lifting
equipment must be used.
Keep flames away
In case of accidental overcharge, a flammable gas
can escape from the safety vent.
Discharge any possible static electricity from
clothes by touching an earth connected part.
Tools
Use tools with insulated handles.
Do not place or drop metal objects on the battery.
Remove rings, wristwatches and any other articles
of clothing with metal parts that may come into
contact with the battery terminals.
Dispose at registered
waste handling
facility
Receiving the Shipment
Carefully examine the battery shipment upon arrival for any signs of transit
damage and that it agrees with the materials list or packing slip. Be very careful
not to inadvertently discard any accessories contained in the packing material.
Batteries contain sulfuric acid in glass fiber separators.
Use rubber gloves when handling broken or damaged containers in case of
acid leakage.
Storage
Store D ataSafe®HX batteries in a dry, clean and preferably cool location.
Since the batteries are supplied charged, storage time is limited. In order to
easily charge the batteries after prolonged storage, it is advised not to store it
more than:
 6 months at ambient temperature no warmer than 77°F (25°C)
 4 months at 86°F (30°C)
 2 months at 104°F (40°C)
Give the battery a freshening charge before the end of the recommended
storage interval.
A refreshing charge shall be performed at 2.26 Volts per cell (VPC) at 77°F
(25°C) for 96 hours or until the charge current does not vary for a 3 hour period.
The necessity of a charge can also be determined by measuring the open
circuit voltage of a stored battery.
Charging is advised if the voltage drops below 2.07 VPC.
Maximum total storage prior to installation is 2 years from date of shipment
from the factory to the customer. Freshening charges are required before the
end of the storage time period or more frequently, as noted above.
Failure to observe these conditions may result in greatly reduced capacity and
service life.
FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S
WARRANTY.
Installation
Install in clean, dry area. DataSafe HX batteries release minimal amounts
of gas during normal operation (gas recombination efficiency ≥97%). The
batteries can be installed near the main equipment. Batteries must be
installed in accordance with federal, state and local law regulations and the
manufacturer’s instructions.
 Temperature
Avoid placing batteries in areas of high temperature or in direct sunlight. The
batteries will give their best performance and service life when operating at a
temperature between 68°F (20°C) and 77°F (25°C), however they are capable
of operating in a temperature range of -22°F (-30°C) to 122°F (50°C). Please
reference the charging float voltage section for more information regarding float
voltage adjustments for temperature variations. Reasonable precautions should
be taken to prevent continuous operation below -22°F (-30°C) or above 122°F
(50°C).
 Ventilation
Under normal conditions gas release is very low and natural ventilation is
sufficient for cooling purposes and inadvertent overcharge, enabling
DataSafe HX batteries to be used safely in offices and with main equipment.
However, care must be taken to ensure adequate ventilation when placed in
cabinets. Batteries must not be placed in sealed cabinets.
 Stowing
For proper installation, EnerSys®battery racks and cabinets are recommended.
For rack installations, reference Assembly Instructions for DataSafe HX and HX
Front Terminal UBC Battery Racks (US-HXRACK-IM).
For cabinet installations, reference DataSafe HX Battery Cabinet Systems
Range Summary (US-HXCAB-RS).
If provided, intercell connector covers should be installed after completing the
intercell connections.
Attention: Unless otherwise noted, battery racks and cabinets should not be
transported with rigid intercell connectors in place.
 Torque
The maximum torque load of intercell connector bolts (M6) is 6.8 to 10 N•m
(60 to 88 in-lbs). A loose connector can cause problems in charger adjustment,
erratic battery performance, possible damage to the battery and/or personal
injury.
No smoking, no naked flames,
no sparks Electrolyte is corrosive
Clean all acid splash in eyes or on
skin with plenty of clean water.
Then seek medical help. Acid on
clothing is to be washed with water.
Danger
Risk of explosion or fire. Avoid any
short circuit. Metallic parts under
voltage on the battery, do not place
tools or items on top of the battery.
Other safety precautions that need to be taken
Battery must be
recycled
Protect eyes
from electrolyte
Read
instructions
Do not charge in
sealed container

®
HX
Publication No: US-HX-IOM-004 - September 2012
www.enersys.com
Cells in Parallel Strings
When utilizing a constant voltage charger, ensure that the connections from the
charger at the end of each string have the same electrical resistance.
To reduce the risk of current imbalance, the number of parallel strings in any
system should be limited to five.
Charging
 Float Voltage
The float/charge voltage is 2.265 VPC at 77°F (25°C).
When the average ambient temperature deviates more than ± 9°F (5°C) from the
reference, it is necessary to adjust the float voltage as follows:
2.33 to 2.36 VPC at 32°F (0°C)
2.30 to 2.33 VPC at 50°F (10°C)
2.27 to 2.30 VPC at 68°F (20°C)
2.25 to 2.28 VPC at 77°F (25°C) (reference)
2.23 to 2.26 VPC at 86°F (30°C)
2.22 to 2.25 VPC at 95°F (35°C)
Due to the phenomena of gas recombination, a difference of ± 2% (earlier
in float life ± 5% is common) for an individual cell voltage can be observed.
However, the total voltage of the battery shall be within the limits stated above.
 Fast Recharge
Occasionally (4 or 5 times a year) the battery may be recharged at 2.40 VPC
with a current limited to the values listed in the Table 1. This charging should not
be allowed to continue for more than 16 hours.
 Ripple Current
Unacceptable levels of ripple current from the charger or the load can cause
permanent damage and a reduction in service life. It is recommended to limit the
continuous ripple current to the values of the Table 1 (in amperes).
 Charging Current
The recommended charging method for DataSafe HX batteries is current
limited, constant voltage charging. Refer to Table 1 for the current limits for each
battery model.
 State of Charge
The battery state of charge can be determined approximately by measuring the
open circuit voltage after the battery has been at rest for a minimum of 24 hours
at 77°F (25°C).
Discharging
 End of Discharge Voltage
The end of discharge voltage must be limited to 1.60 VPC.
A protecting system shall have to be installed to prevent deep discharge.
 Discharged Cells
DataSafe®HX batteries must not be left in a discharged condition after
supplying the load, but must be immediately returned to float recharge mode.
Failure to observe these conditions may result in greatly reduced service life and
unreliability.
 Accidental Deep Discharge
When the battery is completely discharged, the sulfuric acid is completely
absorbed and the remaining electrolyte consists only of water.
At this point, the sulfation of the plates is at its maximum, considerably
increasing the cell’s internal resistance.
Important notice: This type of deep discharge will provoke a premature
deterioration of the battery and a noticeable effect on life expectancy.
 The Effect of Temperature on Capacity
Correction factor of the capacity, according to temperature.
Maintenance and Records
DataSafe HX batteries are maintenance free, sealed, lead acid batteries and
need no water addition. These batteries are equipped with self-resealing,
flame-arresting safety vents.
The containers and lids shall be kept dry and free from dust. Cleaning must be
done only with a damp cotton cloth. Check monthly that total voltage at battery
terminals, while on float, is (N x 2.24 to 2.27 V) for a temperature of 77°F (25°C),
(where N is the number of cells in the battery).
Every 12 months, read and record the following:
 Individual cell or battery voltages (in volts)
 Cell-to-cell connection resistance (in ohms)
 Terminal connection resistance (in ohms)
 Ambient temperature in the immediate battery environment
Keep a logbook to record values, power outages, discharge tests, etc.
An autonomy check can be carried out once or twice a year.
The above record taking is the absolute minimum to protect the warranty. This
data will be required for any warranty claim made on the battery.
State of charge Voltage
100% 2.12 to 2.14 VPC
80% 2.09 to 2.11 VPC
60% 2.05 to 2.08 VPC
40% 2.01 to 2.04 VPC
20% 1.97 to 2.00 VPC
Table 2
Time of discharge 1 min to 60 mins
41°F (5°C) 0.84
50°F (10°C) 0.88
59°F (15°C) 0.93
68°F (20°C) 0.97
77°F (25°C) 1.00
86°F (30°C) 1.03
95°F (35°C) 1.05
104°F (40°C) 1.07
Table 3
DataSafe®HX
Battery Model Maximum charging current (A) Max recommended rms value of the alternating component (A)
12HX205 11.0 2.0
12HX300 18.0 3.5
12HX330 21.0 3.5
12HX400 24.0 4.2
12HX505 30.0 5.0
12HX540 31.0 5.0
6HX800 50.0 8.5
Table 1

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Reading, PA 19605
USA
Tel: [phone]
[phone]
EnerSys EMEA
EH Europe GmbH
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Zürich, Switzerland
Tel: [phone]
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Gateway East Building #11-03
Singapore 189721
Tel: [phone]
www.enersys.com
Publication No. US-HX-IOM-004-September 2012
Subject to revisions without prior notice. E.&O.E.
© 2012 EnerSys. All rights reserved.
Trademarks and logos are the property of EnerSys
and its affiliates, unless otherwise noted.
®
HX
Note: End terminal position will depend upon number of units in row, ie. whether “ODD” or “EVEN” number.
H
LONG
L
WSHORT
CC
Single row
configuration
(12HX models)
ROW
RC
Double row
configuration
(12HX models)
ROW
LONG
Double row
configuration
(6HX800 only)
Intercell Connector Layout
Batteries come standard with a stainless steel hardware package; p/n 867500 (one package per battery).
The hardware package includes (2) each M6x1 x 16mm long bolts, flat washers and lock washers.
Longer bolts are available but must be specified at the time of order placement.
DataSafe®HX
Battery Model Number of Cells L W H CC RC Short Long Row Weight
In mm In mm In mm In mm In mm In mm In mm In mm Lbs kg
12HX205 6 8.9 226 5.5 140 8.1 206 5.6 142 9.1 231 2.2 56 9.0 229 1.9 48 43 20
12HX300 6 10.2 259 6.9 175 8.2 208 6.9 175 10.3 262 2.7 69 11.2 284 2.2 56 60 27
12HX330 6 11.8 300 6.8 173 8.4 213 6.9 175 12.1 307 2.7 69 11.2 284 2.5 64 71 32
12HX400 6 13.3 338 6.8 173 8.3 211 6.9 175 13.4 340 2.7 69 11.2 284 3.0 76 80 36
12HX505 6 13.3 338 6.8 173 10.7 272 6.9 175 13.4 340 2.7 69 11.2 284 3.0 76 103 47
12HX540 6 13.3 338 6.8 173 10.7 272 6.9 175 13.4 340 2.7 69 11.2 284 3.0 76 106 48
6HX800 3 13.4 340 6.8 173 8.3 211 6.9 175 13.2 335 - - 9.0 229 13.4 340 80 36
L-Terminal
for multiple
cables
* For run times under 15 minutes or end voltages less than 1.67, consult technical support for assistance.
Connectors and L-Terminals are RoHS compliant.
Optional Extras
DataSafe
®
HX Battery
Model
SHORT LONG ROW
L-TERMINAL
Connector* Cover
Black Cover Clear Connector* Cover Black Cover Clear Connector* Cover Black Cover Clear
12HX205 866881TP HRD2328 827564 866885TP HRD2329 827567 866880TP HRD2328 827564 882044TP
12HX300 866883TP HRD2327 827565 866886TP HRD2330 827568 866881TP HRD2328 827564 882044TP
12HX330 866883TP HRD2327 827565 866886TP HRD2330 827568 866882TP HRD2327 827565 882043TP
12HX400 866883TP HRD2327 827565 866886TP HRD2330 827568 866884TP HRD2327 827566 882043TP
12HX505 866883TP HRD2327 827565 866886TP HRD2330 827568 866884TP HRD2327 827566 882042TP
12HX540 866883TP HRD2327 827565 866886TP HRD2330 827568 866884TP HRD2327 827566 882042TP
6HX800 - - - 866887TP HRD2329 827567 821940TP - 827569 882042TP
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