Deka Unigy II User manual

Installation and Operation Manual
SECTION I
Safety Precautions
Protective Equipment ..........2
Procedures ..........................2
SECTION II
Receiving & Storage
Receiving Inspection............2
Unpacking............................2
Storage ................................3
SECTION III
Installation
Electric Code for
Maintenance Access............3
Floor Anchoring &
Module Arrangements..........3
Module Installations ............3
SECTION IV
Electrical Connection
Connector Assembly............4
Terminal Assembly ..............4
Final Assembly
Check Procedure ..............4-5
TABLE OF CONTENTS
®
FLUSH EYES
IMMEDIATELY
WITH WATER.
GET
MEDICAL
HELP
FAST.
SULFURIC ACID
CAN CAUSE
BLINDNESS OR
SEVERE BURNS.
NO
•SPARKS
•FLAMES
•SMOKING
SHIELD
EYES.
EXPLOSIVE GASES
CAN CAUSE BLIND-
NESS OR INJURY.
HIGH
VOLTAGE...
RISK OF SHOCK.
DO NOT TOUCH
UNINSULATED
TERMINALS OR
CONNECTORS.
KEEP VENT CAPS TIGHTLY IN PLACE. 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.
DANGER
Required by
California
Proposition 65
BATTERIES
AND RELATED PARTS
CONTAIN LEAD
California Proposition 65 Workplace Warning Sign 1/99
Must be posted in workplace near batteries.
WASH HANDS
AFTER HANDLING !
WARNING: Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known to the
State of California to cause cancer and reproductive harm.
WARNING: Battery posts, terminals and related accessories
contain lead and lead compounds, chemicals known to the
state of California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
SECTION IV (cont.)
Electrical Connection (cont.)
Parallel Strings ....................5
Module Front Shield
Assembly ............................6
Terminal Plate Shield
Assembly ............................6
Module Top Shield
Assembly ............................6
SECTION V
System Operations
Float Voltages ......................6
Operating Temperatures ....6
Equalizing ............................6
SECTION VI
Record Keeping
Voltages, Temperatures
& Micro-ohm Readings ....6-7
SECTION VII
Maintenance
Annual Inspection ................7
Battery Cleaning..................7
Capacity Testing ..................7
SECTION VIII
Cell Removal
Procedure ............................7
FIGURES............................8-12
APPENDIX A
Relay Rack
Assembly ......................13-14
APPENDIX B
Material Safety
Data Sheet ....................15-16
APPENDIX C
Battery Maintenance
Report..................................17
APPENDIX D
Technical
Information ....................18-20

SAFETY PRECAUTIONS
Although all valve-regulated batteries have the elec-
trolyte immobilized within the cell, the electrical hazard
associated with batteries still exists. Work performed
on these batteries should be done with the tools
and the protective equipment listed below. Valve-
regulated battery installations should be supervised by
personnel familiar with batteries and battery safety
precautions.
Protective Equipment
To assure safe battery handling, installation and main-
tenance, the following protective equipment should be
used.
1. Safety glasses or face shield
2. Acid-resistant gloves
3. Protective aprons
4. Proper lifting devices
5. Tools with insulated handles
Procedures
(Always wear safety glasses or face shield when
working on or near batteries. Refer to Fig. 1-1 on
pg. 2.)
The following safety procedures should be followed
during installation:
1.These batteries are sealed and contain no free
electrolyte. Under normal operating conditions, they
do not present any acid danger. However, if the
battery jar or cover is damaged, acid could be
present. Sulfuric acid is harmful to the skin and
eyes. Flush affected area with water immedi-
ately and consult a physician if splashed in the
eyes.
2. Prohibit smoking and open flames, and avoid
arcing in the immediate vicinity of the battery.
3. Do not wear metallic objects, such as jewelry,
while working on batteries.
4. Keep the top of the battery dry and clear of tools
and other foreign objects.
5. Provide adequate ventilation and follow recom-
mended charging voltages.
6. Refer to Material Safety Data Sheet for proper extin-
guishing mehod (See Appendix B, Sect. 4, pg 15.).
7. Never remove or tamper with the pressure relief
valves.Warranty void if vent valve is removed.
8. Inspect all flooring and lifting equipment for func-
tional adequacy. Specifically review floor-loading
capacity.
9. Adequately secure battery modules to the floor.
10. Connect support structures to ground system in
accordance with applicable codes.
RECEIVING & STORAGE
Receiving Inspection
Upon receipt of the battery and at the time of unload-
ing, each package should be visually inspected for
damage. If damage is evident, a more detailed inspec-
tion of the entire shipment should be conducted and
noted on the bill of lading. Record receipt date and
inspection data, and notify the carrier of any damage.
Unpacking
1. Always wear eye protection.
2. Check for visible defects.
3. Check the contents of the package against the
packing list. Report any missing parts or shipping
damage to your East Penn agent or East Penn Mfg.
Co. immediately. (See Fig. 2-1 and 2-2 on pg. 3.)
4. Never lift the batteries by the terminal posts. Always
lift batteries by the module mounting holes with the
lifting straps provided. (See Fig. 3-2, pg. 8.)
5.When lifting batteries, the proper equipment is
needed such as a forklift or a portable crane.
Always check the lifting capacities of the equipment
being used and never lift more than one module at
a time by the module mounting holes.
®
2
DANGER
SHIELD
EYES.
EXPLOSIVE
GASES CAN CAUSE
BLINDNESS OR INJURY.
HIGH VOLTAGE...
RISK OF SHOCK.
DO NOT TOUCH
UNINSULATED
TERMINALS OR
CONNECTORS.
VENTILATE WELL WHEN IN AN ENCLOSED
SPACE AND WHEN CHARGING.
SEE INSTALLATION, MAINTENANCE AND OPERATION
INSTRUCTIONS FOR IMPORTANT SAFETY PRECAUTIONS.
NO
•SPARKS
•FLAMES
•SMOKING
SULFURIC
ACID
CAN
CAUSE
BLINDNESS OR
SEVERE BURNS.
FLUSH EYES
IMMEDIATELY
WITH WATER.
GET
MEDICAL
HELP
FAST.
DO NOT REMOVE VENT VALVE.
WARRANTY VOID IF VENT VALVE IS REMOVED.
Fig. 1-1

Storage
1. Cells should be stored indoors in a clean, level, dry,
cool location. Recommended storage temperatures
are 0˚F to 90˚F (–18˚C to 32˚C). Store in a horizon-
tal position only.
2. Stored lead-acid batteries self discharge and must
be given a boost charge six months from the date
of manufacture to prevent permanent performance
degradation. Batteries should not be stored for more
than 180 days without applying a boost charge of
2.30 VPC ± 1% for a maximum of 24 hours. Record
dates and conditions for all charges during storage.
INSTALLATION
Electric Code for Maintenance Access
Refer to ANSI/NFPA-70 National Electric Code for
access and working space requirements around the
battery. A minimum of 36" aisle space is recom-
mended in front of the battery for service and inspec-
tion.
Floor Anchoring & Module Arrangements
See East Penn Mfg. Co.’s schematic diagram illustra-
tion. One is supplied with each shipment. If it cannot
be located, contact East Penn Mfg. Co. for a copy.
Refer to your delivery number, located on the packing
slip.This will aid in obtaining the proper drawing.
Module Installations
Assemble modules per the following details.
NOTE: Batteries are typically packaged in the reverse
order for easy installation: Floor channels are on top,
followed by the bottom most module. (See Fig. 3-1, pg.8.)
CAUTION: Never lift more than one module at a
time with the lifting slings. (See Fig. 3-2, pg. 8.)
1. Unbolt the floor mounting channels from the top of
the battery. Secure mounting channels to the floor.
2. Using the two slings provided, remove the top module
and bolt onto the floor mounting channels. (See Fig.
3-3, pg. 8 on using the proper lifting equipment.)
3. Remove the next module and bolt onto the first
module. Repeat this procedure until the battery is
installed to the specified configuration. (See Fig. 3-4
and 3-5, pg. 4.)
Each battery is shipped with its own schematic. Make
sure the polarization on the batteries matches the
drawings.
3
Fig. 2-1
Fig. 2-2

ELECTRICAL CONNECTION
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” grease at the factory.
2.The intercell connector contact surfaces should be
cleaned by rubbing gently with a non-metallic brush
or pad. Apply a thin film of no-ox ID “A” grease
which has been supplied.
3. Install all intercell connectors loosely to allow for
final alignment of batteries, then torque to 100 ± 5
inch-pounds (11.3 ± .5 Nm). (Refer to Fig. 4-1 on
pg. 4.)
4.When more than one intercell connector per battery
terminal is required, place the connectors on each
side of the terminal. (See Fig. 4-2, pg. 9.)
Terminal Assembly
1. Attach the terminal mounting bracket to the module
frame. (Side terminal–see Fig. 4-3, pg. 9, top termi-
nal–see Fig. 4-4 and 4-5, pg. 10.)
2. Attach the terminal plates to the battery posts and
then to the mounting bracket.
3. For cable connection assembly, see Fig. 4-6, pg. 11.
Final Assembly Check Procedure
1. For future identification of all cells, number individ-
ual cells in sequence, beginning with number one
at the positive end of the first battery.
2. After torquing the electrical connections on assem-
bled modules, read the voltages of the battery to
assure that the individual cells are connected
correctly. (See Fig. 4-7 on pg 4.) The total voltage
should be approximately equal to the number of
cells times the measured voltage of one cell. If the
measurement is less, recheck the connections for
proper polarity.
®
4
Fig. 3-4
Fig. 3-5
Fig. 4-1
Fig. 4-7

3. Measure and record the intercell connection resis-
tance using a milliohmmeter.This helps determine
the adequacy of initial installation and can be used
as a reference for future maintenance requirements.
Refer to the recording forms in Appendix C of this
manual. Review the records of each connection and
detail resistance measurements. Clean, remake, and
remeasure any connection that has a resistance
measurement greater than 10% of the average of
all the same type connections (intercell, intermodule).
4. Battery performance is based on the output at the
battery terminals.Therefore, the shortest electrical
connection between the battery system and the
operating equipment results in maximum total
system performance.
Select cable size based on current carrying
capability and voltage drop.
Cable size should not provide a greater voltage drop
between the battery system and operating equipment
than specified. Excess voltage drop will reduce the
desired support of the battery system.
Parallel Strings
When paralleling valve-regulated batteries, the capacity,
arrangement, and external circuit length should be
identical for each battery.Wide variation in the battery
circuit resistance can result in unbalanced charging
(i.e., excessive charging currents in some batteries
and undercharging in others). As a result, cell failures
in one battery string and subsequent loss of perfor-
mance capabilities of that string will result in higher
loads in the other parallel string(s), which may exceed
the ratings of the battery connections. This can
damage the battery system and dramatically shorten
battery life.
5
Fig. 4-9
Fig. 4-10
Fig. 4-12
Fig. 4-14