Deka Unigy ii User manual

NB Module

Installation and Operation Manual

California

Proposition 65

Warning:

Batteries, battery posts, terminals and related accessories

contain lead and lead compounds, and other chemicals known

to the state of California to cause cancer and birth defects or

other reproductive harm. Wash hands after handling.

Safety Precaution

Protective Equipment..........................................3

Procedures ........................................................3

Receiving & Storage

Receiving Inspection ..........................................3

Unpacking ..........................................................3

System Shipment................................................3

Storage ..............................................................4

In tallation

General ..............................................................5

Grounding ..........................................................5

Electric Code for Maintenance Access ..............5

Floor Anchoring & Module Arrangement ............5

Hardware Torque Values ....................................5

Sy tem In tallation

Module Installation..............................................5

Cell Installation ..................................................8

Electrical Connection

Top Termination ................................................10

Side Termination ..............................................11

TABLE OF CONTENTS

Connector Assem ly ........................................13

Final Assem ly..................................................13

Safety Shield Assem ly ....................................14

Sy tem Operation

Charge Voltage ................................................15

Temperature Compensation ............................15

Cell Voltage ......................................................15

Rectifier Ripple Voltage ....................................15

Record Keeping ................................................15

Maintenance

Annual Inspection ............................................16

Battery Cleaning ..............................................16

Capacity Testing ..............................................16

Cell Removal Procedure ..................................16

Cell Weight & Volume ......................................17

Battery Maintenance Report ............................18

Appendix A ....................................................19

Appendix B ....................................................20

SAFETY PRECAUTIONS

Although all valve-regulated batteries have the electrolyte

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.

WARNING: Risk of fire, explosion or burns. o not

disassemble, heat above 40°C, or incinerate.

Protective Equipment

Although VRLA batteries can vent or leak small amounts of

electrolyte, electrical safety is the principle but not the only

concern for safe handling. Per IEEE 1188 recommendations,

the following minimum set of equipment for safe handling of

the battery and protection of personnel shall be available:

1. Safety glasses with side shields, or goggles, or face

shields as appropriate. (Consult application specific

requirements)

2. Electrically insulated gloves, appropriate for the installation.

3. Protective aprons and safety shoes.

4. Portable or stationary water facilities in the battery

vicinity for rinsing eyes and skin in case of contact

with acid electrolyte.

5. Class C fire extinguisher.

6. Acid neutralizing agent.

7. Adequately insulated tools.

8. Lifting devices of adequate capacity, when required.

Procedures

The following safety procedures should be followed during

installation: (Always wear safety glasses or face shield

when working on or near batteries.)

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

immediately and consult a physician if splashed in the

eyes. Consult MS S for additional precautions and first

aid measures.

2. Prohibit smoking and open flames, and avoid arcing in

the immediate vicinity of the battery.

3. o not wear metallic objects, such as jewelry, while work-

ing on batteries. o not store un-insulated tools in pockets

or tool belt while working in vicinity of battery.

4. Keep the top of the battery dry and clear of tools and other

foreign objects.

5. Provide adequate ventilation (per IEEE standard 1187 and/or

local codes) and follow recommended charging voltages.

6. Extinguishing media: Class ABC extinguisher.

Note: CO2may be used but not directly on the cells due

to thermal shock and potential cracking of cases.

7. Never remove or tamper with the pressure relief valves

unless for cell replacement. Warranty void if vent valve is

removed.

8. Inspect all flooring and lifting equipment

for functional adequacy.

9. Adequately secure battery modules, racks, or cabinets to

the floor.

10. Connect support structures to ground system

in accordance with applicable codes.

11. The below IEEE Standards contain additional information.

Other standards may be relevant to your specific application.

IEEE 1187 – Recommended Practice for Installation

esign of VRLA Batteries

IEEE 1188 – Recommended Practice for Maintenance,

Testing, of VRLA Batteries

IEEE 1189 – Selection of VRLA Batteries for

Stationary Applications

RECEIVING & STORAGE

Receivin Inspection

Upon receipt, and at the time of actual unloading, each

package should be visually inspected for any possible damage

or electrolyte leakage. If either is evident, a more detailed

inspection of the entire shipment should be conducted and

noted on the bill of lading. Record receipt date, inspection date

and notify carrier of any damage.

Unpackin

1. Always wear eye protection.

2. Check all batteries for visible defects such as cracked

containers, loose terminal posts, or other unrepairable

problems. Batteries with these defects must be replaced.

3. Check the contents of the packages against the packaging

list. Report any missing parts or shipping damage to your

East Penn agent or East Penn Mfg. Co. immediately.

4. Never lift batteries by the terminal posts.

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 and/or cell at a time.

System Shipment

Battery System will be received with cells and modules on

separate pallets. Amount of pallets dependent on number of

cells and module type.

RECEIVING & STORAGE CONT.

Module Shipment

All battery accessories (connectors, terminal plates, hardware)

will be included with a module pallet. The pallet will be indicat-

ed with an “Accessory” sticker. The “Accessory” module pallet

will include a base and a top plate. 3 x 2 modules will be

shipped two high with base plate and top plate on top of the

module assembly. 2 x 2 modules will be shipped 3 high with

base plate & top plate on either side of the module assembly.

Cell Shipment

Each cell will be in an individual sleeve. There will be a

maximum of 6 cells per pallet.

Stora e

1. Cells should be stored indoors in a clean, level, dry, cool

location. Recommended storage temperature is 0°F to 90°F

(–18°C to 32°C).

2. Stored lead-acid cells self discharge and must be

given a boost charge to prevent permanent performance

degradation.

0°F to 77°F (-18°C to 25°C) storage:

Batteries should be recharged six months from date

of manufacture.

>77°F (25°C) storage:

Use the chart below for recharge intervals. Voltage read-

ings should be taken on a monthly basis. Cells that reach

2.10V per cell or less should be recharged regardless of

scheduled interval. Record dates and conditions for all

charges during storage.

3. If a boost charge is required; the recommended charge is

24 hours at a constant voltage equal to 2.40V per cell.

4. o not store beyond 12 months.

5. Store in horizontal position only.

3 x 2 Module Assembly

2 x 2 Module Assembly

INSTALLATION

General

Caution should be taken when installing batteries to insure no

damage occurs. The battery cabinet, tray, rack, etc. shall be

inspected for sharp edges that could cause damage to the

battery casing. Batteries shall not be dropped, slid, or placed on

rough or uneven surfaces such as tray lips or grated flooring.

Mishandling of batteries could result in equipment damage or

human injury. East Penn will not be liable for damage or injury

as a result of mishandling or misuse of the product.

Groundin

When grounding the battery system, proper techniques should

be applied per electrical standards, such as NEC and/or local

codes. All module structural bolting connections are provided

with grounding washers. Two sets of 0.201 diameter x .750"

center holes are provided on the back side of the top plate to

accept a # 6 x .750 center compression grounding lug. The

holes must be tapped for a 1/4-20UNC thread and paint must

be removed for a proper grounding pad location. *

*Note: Battery y tem and/or individual module grounding, if

required, i the in taller’ re pon ibility.

E ectric 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 recommended in front of the battery for service and

inspection. Additional spacing may be required to meet

earthquake seismic requirements.

Modu e Arrangement See East Penn Mfg. Co.’s system layout

diagram. 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 diagram.

Hardware Torque Requirements

SYSTEM INSTALLATIONS

All part hould be verified again t packaging li t.

Report any mi ing part .

Module Installation

Assemble system per the following details.

1. Remove floor-mounting base support from module pallet.

2. Position base(s), consult included system layout diagram

for required configuration. Bases are required to be

level prior to installing modules.

3. Multiple stack systems should have a minimum of 4.00"

between bases. The additional spacing is for proper

installation of modules.

4. Anchor holes can be marked and drilled with bases in

place. All anchor holes in base (16 per base) are required

to be used to meet NEBS Zone 4 seismic requirements.

Anchors required to be installed prior to modules being

installed onto base. Reference Appendix A for base plate

anchor hole layout.

Consult local building codes for anchor bolt

requirements. Anchor bolts not included.

Bolt Size Torque/Retorque

1/2-13 100ft-lb 135.5 Nm

3/8-16 45ft-lb 61.0 Nm

1/4-20 125 in-lb 14.1 Nm

7. Base and module layout should be compared to system

layout diagram. All ½-13 x 1.75" hardware (2 per corner)

are to be installed on the inside of the module for module

to base connection. All hardware should be checked for

proper torque before proceeding. Star washers are to be

installed with teeth towards module to ensure proper

grounding. Consult “Hardware Torque Requirements”

(pg 5) for proper torque values.

SYSTEM INSTALLATIONS CONT.

5. Remove hardware holding modules together (4 bolt

assemblies) and holding modules to pallet (4 bolt

assemblies). Hardware removed from module to

module will be reused to attach modules to modules.

Hardware holding modules to pallet can be discarded.

6. Install modules onto bases using supplied lifting straps.

Consult below diagram for proper sling attachment and

lifting. Consult included system layout diagram for module

position.

CAUTION: Never lift more than one module at a time

with the supplied lifting slings.

Module to Pallet Disassemble

Module to Module Separation

10. The system layout diagram should be consulted to

determine module configuration. System design limits

modules to be stacked no higher than 4 modules (8 cells

high). Bolt assemblies (two per corner) are required on the

outside of the module to complete the module to module

connection. All ½-13 x 1.75" hardware should be checked

for proper torque before proceeding. Star washers are to

be installed with teeth towards module to ensure proper

grounding. Consult “Hardware Torque Requirements”

(pg 2) for proper torque values.

8. Bolt assemblies (two per corner) are required on the

outside of the module to complete the base to module

connection. All ½-13 x 1.75" hardware should be checked

for proper torque before proceeding. Star washers are to

be installed with teeth towards module to ensure proper

grounding. Consult “Hardware Torque Requirements”

(pg 5) for proper torque values.

9. Multiple battery systems — all stacks should have the

same tier completed before moving to the next tier.

Star washers are to be installed with teeth towards module to

ensure proper grounding.

Note: Top Plate hardware contain two different type of tar

wa her . Con ult below hardware diagram for proper

in tallation.

Retainer Bar Installation

1. Tier to Tier Retainer Bar Installation — Retainer bars

are to be installed per the below detail. All 3/8-16 x 1.25"

hardware should be checked for proper torque before

proceeding. Consult “Hardware Torque Requirements”

(pg 5) for proper torque values.

2. Top & Bottom Retainer Bar Installation — Retainer

bars are to be installed per the below detail. Top plate is to

be installed on the top module prior to installing top retain-

er bar. All 3/8-16 x 1.25" hardware should be checked for

proper torque before proceeding. Consult “Hardware

Torque Requirements” (pg 5) for proper torque values.

SYSTEM INSTALLATIONS CONT.

11. Cell / Sleeve Installation — Install cells into modules.

Cells are shipped separate from modules. Cell polarity

orientation responsibility of installer. Consult system

layout diagram for cell location and polarity.

Care should be taken when installing cells that lifting

device does not contact previously installed cells

possibly causing a short.

12. Top Plate Installation — The top plate is to be installed on

the top module after all cell / sleeve assemblies have been

installed. Bolt assemblies (two per corner) are required on

the outside of the module to complete the top plate to mod-

ule connection. All ½-13 x 1.75" hardware should be checked

for proper torque before proceeding. Consult “Hardware

Torque Requirements” (pg 5) for proper torque values.

Tier to Tier Retainer Bar

Top Retainer Bar

Safety Shield Bracket Installation

1. Safety Shield Brackets are to be installed at the outside

corners of each module (4 per module). Consult below

detail for locations. Use 3/8-16 x 1.25" hardware to install

brackets. Consult “Hardware Torque Requirements”

(pg 5) for proper torque values.

2. Module layout should be compared to system layout

diagram and all hardware should be checked for proper

torque before proceeding. Consult “Hardware Torque

Requirements” (pg 5) for proper torque values.

ELECTRICAL CONNECTION

Fo ow a safety requirements as detai ed in “Safety

Precautions” section prior to working on any e ectrica

connections.

Some installations may require the terminal plates to be in

close proximity of each other. It is recommended that the

terminal plate assembly installations be completed prior

to installing the inter-cell connections. This practice will

reduce the risk of a possible electrical short from damag-

ing the entire battery system.

TERMINAL ASSEMBLY

Top Termination

Consult system layout diagram for termination locations.

1. Install terminal plate bracket to the top of the module.

Slide clip onto back of channel at hole locations.

Use 3/8-16 x 1.25" hardware. Install loosely for

future alignment.

Top Shield Bracket Installation

Center Shield Bracket Installation

Bottom Retainer Bar Bottom Shield Bracket Installation

5. Install terminal plate to battery posts using 1/4-20 x 1.00"

hardware.

6. Attach terminal plate to terminal plate bracket. Note posi-

tion of terminal plate. Terminal Plate Bracket may have to

be moved in order to be flush with the terminal plate.

7. All hardware should be checked for proper torque before

proceeding. Consult “Hardware Torque Requirements”

(pg 5) for proper torque values.

TERMINAL ASSEMBLY CONT.

2. Remove module bolts directly behind location of

terminal plate.

3. Replace flat washer with cap washer. Re-install 3/8-16 x

1.25" into module with safety shield bracket (if required).

Torque hardware before proceeding. Consult “Hardware

Torque Requirements” (pg 5) for proper torque values.

4. Install rubber caps over bolts.

Terminal Plate to be installed on battery posts as shown

8. Lug Hole Layout — Top terminal plate designed to use up

to 0.50" dia. bolt and a maximum 1.75" centers and 1.188"

min., 2 hole lug.

9. Lug Attachment — Maximum of six cable lugs can be

installed per terminal plate. Lug Hardware not included.

10. Safety Shield Installation — Top terminal safety shield

consists of three pieces. Assemble per the below illustra-

tion. Clear plastic shields are of different lengths. Longer

shield to be installed on the front side of the terminal plate.

The shields should be even at the bottom, making the front

shield longer at the top.

Side Termination

Consult system layout diagram for side termination location.

1. Remove safety shield bracket if required.

2. Install plastic Side Terminal Bracket and re-install safety

shield bracket using bolts from previous step. Use 3/8-16

x 1.50" bolt for the remaining bracket assembly. Bolts

should be installed loosely for future adjustments.

3. Install side terminal connector to battery posts using 1/4-

20 hardware plate to terminal plate bracket using 1/4-20

x 1.00" hardware. Bolts should be installed loosely for

future adjustments.

0.88

1.39

3.75

.56 DIA. HOLES FOR

1/2" BOLTS

Complete Assembly

TERMINAL ASSEMBLY CONT.

4. Connect side terminal plate to side terminal plate connec-

tors. Side terminal bracket and side terminal connectors

may have to be adjusted to insure plate and connectors are

flush. Use 1/4-20 x 1.25" hardware.

5. Connect side terminal plate to terminal plate bracket using

1/4-20 x 1.00" hardware. Bolts should be installed loosely

for future adjustments.

6. After all parts are installed and alignment is confirmed,

torque all bolts. Consult “Hardware Torque

Requirements” (pg 5) for proper torque values.

7. Install Side Terminal Shield to Side Terminal Plate using

¼-20 screws.

Tighten but do not torque hardware.

8. Side Terminal Plate is designed to use up to 0.50" dia. bolt

and a maximum 1.75" centers and 1.188" min., 2 hole lug.

Plate is capable of handling 4 runs of cable.

Lu Positionin Options:

Maximum of four cable lugs can be installed per terminal

plate. Lug Hardware not included.

Complete Assembly

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-I

“A” grease at the factory. Assure the contact surfaces are

free of dust or dirt prior to assembly. A clean non-abrasive

cloth should be used to remove ny dirt. Re-apply a light

coat of No-Ox-I “A” grease to all cleaned surfaces.

2. The battery system is supplied with a connector package

appropriate to the required load the batteries are connected

to. Review the below chart “Connector Packages” to ensure

the correct connector package has been supplied.

3. Installation and direction of the battery post hardware is

important to ensure proper electrical clearance between

battery posts of adjacent cells and within a cell. Consult the

below diagram for clarification.

4. Battery post bolt hardware to be installed as shown.

5. NB battery systems are supplied with multiple connectors

to be used per battery post. A 2CU connector package will

require 2 connectors per connection (1 per side), see

example below. A 4CU package will require 4 connectors

per connection (2 per side) and an 6CU package will

require 6 connectors per connection (3 per side). Tighten

& torque all bolts after all connectors are installed.

Consult “Hardware Torque Requirements” (pg 5) for

proper torque values.

Final Assembly Check Procedure

1. For future identification of all cells, number individual

cells in electrical connection sequence, beginning with

number one (1) at the positive end of the battery. The

last cell of the battery is located at the negative output

terminal.

2. Read and record the voltages of the individual cells to

assure that they are connected properly. The total battery

voltage should be approximately equal to the number of

cells connected in series, multiplied by the measured

voltage of one cell If the measured is less, recheck the

connections for proper polarity. Verify that all cells and

battery connections have been properly torqued.

3. Measure and record the intercell connection resistance

using a micro-ohms meter. This helps determine the ade-

quacy of initial connection installation and can be used as

a reference for future maintenance requirements. Refer to

the recording forms in Appendix B of this manual.

Review the records of each connection and detail resist-

ance measurements. Clean, remake, and remeasure any

connection that has a resistance measurement greater

than 10% of the average of all the same type connections

(i.e. intercell, intermodule, etc.).

Connector Packages

Type Plates AMPS WPC

2CU 5-33 ≤1000 ≤1600

4CU 5-33 ≤2000 ≤3200

6CU 5-33 ≤3000 ≤4800

Bolt Package

2CU 1/4-20 x 1.50" JMP1407

4CU 1/4-20 x 1.75" JMP1435

6CU 1/4-20 x 2.00" JMP1409

2CU Package Detail

Tier to Tier

Cell to Cell

CONNECTOR ASSEMBLY CONT.

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.

Excessive voltage drop in cables will reduce the desired

reserve time and power from the battery system.

SAFETY SHIELD ASSEMBLY

1. All Safety Shield Brackets should already be installed at

this time. Refer to Cell Installation Section for bracket

installation.

2. Safety Shields are designed with a “keyhole” type

attachment.

3. One shield will cover one module or two tiers. Starting with

the bottom module, hang the first shield on the top brackets

through the large part of the keyhole. At the same time

aligning the cutout at the bottom of the shield with the

second set of brackets. After all shields are in place tighten,

but do not torque hardware.

Top Protection Shield Installation

For side terminal assembly, attach top protective cover to

highest front shield.

Bottom

Overlap

Top

For top terminal assembly, align protective cover in front of

top terminal plates. Mark area of protective shield that is

required to be removed in order to fit between the terminals.

Cut protective cover along marks.

Attach to front shield and verify fit. Additional trimming may be

required to ensure proper fit.

SYSTEM OPERATIONS

Char er Volta e

These batteries are designed for continuous float applications.

Float / Standby

2.25 vpc ± 0.01 @ 77°F (25°C)

When setting the float voltage on the charger, the system

should be set to float at the nominal cell float voltage times the

number of cells per string. The charger must be able to main-

tain the system voltage within ± 0.5% of the desired level at all

times. The desired float voltage varies with temperature

according to the table in the next column.

Temperature Compensation

Battery voltage should be adjusted for ambient temperature

variations.

2mV per °C (1.8°F) per cell

For temperatures above 77°F (25°C) subtract and for tempera-

tures below 77°F (25°C) add.

Consult Voltage Compensation Chart in Appendix B

for temperature compensation voltage maximum and

minimum limits.

The average battery operating temperature should not exceed

95°F (35°C) and should never exceed 105°F (40.5°C) for more

than an eight-hour period. Operating at temperatures greater

than 77°F (25°C) will reduce the operating life of the battery.

If operating temperatures are expected to be in excess of 95°F

(35°C), contact East Penn for recommendations.

ischarging at temperatures less than 77°F (25°C) will reduce

the capacity of the battery.

Battery Volta e

Although the charger must maintain the system voltage within

± 0.5%, individual cell voltages may vary by ± 0.05 volts of the

average battery float voltage.

Equalizin

Upon installation of the battery, an optional boost charge of

2.40 vpc ± 0.01 vpc for of 24 hours (not to exceed 24 hours)

can be applied. (Note: Verify that the higher battery voltage

will not adversely affect the other connected equipment.) If

this is done, be sure to reset the charging equipment to the

proper float voltage.

Cell Volta e

Although the charger must maintain the system voltage with-

in ± 0.5%, individual cell voltages may vary by ± 0.05 volts

of the average cell float voltage.

Rectifier Ripple Volta e

FRE UENCY

Ripple that has a frequency greater than 667Hz (duration

less than 1.5ms) is acceptable, unless it is causing addi-

tional battery heating. Ripple that has a frequency less

than 667Hz (duration greater than1.5ms), must meet the

following voltage specification to be acceptable.

VOLTAGE

Ripple voltage shall be less than 0.5% peak to peak of the

manufacturer’s recommended string voltage. Failure to

comply can void the warranty.

RECORD KEEPING

Volta es, Temperatures & Ohmic

Readin s

Record keeping is an important part of stationary battery

maintenance and warranty coverage. This information will

help in establishing a life history of the battery and inform

the user if and when corrective action needs to be taken.

(Refer to Appendix A, Battery Maintenance Report)

While it is acceptable to operate at temperatures less than

77°F (25°C), it will require longer charging time to become

fully recharged. Also, the capacity will be less at operating

temperatures below 77°F (25°C).

After installation and when the batteries have been on float

charge for one week, the following data should be recorded:

1. Battery terminal voltage.

2. Charger voltage.

3. Individual cell float voltages.

4. Ambient temperatures.

5. Terminal connections should be checked to verify that the

installer did torque all connections properly, consult

“Hardware Torque Requirements” (pg 2) for proper

torque values. Micro-ohm readings should be taken

across every connection. Refer to meter manufacturer’s

instructions for proper placement of probes. If any read-

ing differs by more than 20% from its initial installation

value, re-torque the connection, consult “Hardware

Torque Requirements” (pg 5) for proper torque values.

If reading remains high, clean contact surfaces

according to Step 1 under Connector Assembly.

6. Individual cell Ohmic readings. For 6-post cells, measure

from center positive to center negative posts. o not

measure diagonally from positive to negative posts. See

next page for specific location.

RECORD KEEPING CONT.

MAINTENANCE

Always wear eye protection when working on or near batteries.

Keep sparks and open flames away from batteries at all times.

Review Safety Precautions on pg. 1.

Annual Inspection (1)

1. Conduct a visual inspection of each cell.

2. Record the battery string voltage.

3. Record the charger voltage.

4. Record the individual cell voltages. The accuracy of the

MM ( igital Multimeter) must be .05% (on dc scale) or

better. The MM must be calibrated to NIST traceable

standards. Because float readings are affected by dis-

charge and recharges, these readings must be taken when

batteries have been on continuous, uninterrupted float for

at least one month. Cells should be within ± 0.05 volts of

the average cell float voltage.

5. Record the ambient temperatures.

6. Record individual cell Ohmic readings.

7. Record all intercell, interunit and terminal connection

resistances. Micro-ohm readings should be taken during

this inspection. If any reading differs by more than 20%

from initial readings taken, retorque the connection.

Recheck the micro-ohm reading. If the reading remains

high, clean the contact surface according to installation

portion of this manual.

(1) Other Maintenance Inspection interva s fo ow

IEEE 1188

Battery Cleanin

Batteries, cabinets, racks, and modules should be cleaned with

clear water or a mixture of baking soda and water.

Never use solvents to clean the battery.

Capacity Testin

Per IEEE 1188 “Capacity testing is used to trend battery aging.

The result of a capacity test is a calculation of the capacity of

the battery. The calculated capacity is also used to determine if

the battery requires replacement.”

o not discharge the batteries beyond the specified final volt-

age. When discharging at higher rates, extra connectors may

need to be added to prevent excessive voltage drop and / or

excessive temperature rise. Consult “Connector Packages”

chart (pg. 15) for current limits. When performing capacity

testing and recording data use IEEE 1188 instructions. Should

it be determined that any individual battery(ies) or cell(s) need

to be replaced, contact your nearest East Penn agent or East

Penn Service Center.

CELL REMOVAL PROCEDURE

1. Before removing cell, review Safety Precautions on pg. 2

of this manual. Contact East Penn Mfg. Company, Inc. with

specific questions or concerns.

2. Remove one cell at a time.

3. Confirm the lifting device is rated to handle the weight of

one cell.

4. All tools used to remove the cell shall be insulated to

avoid metal contact with battery posts.

5. Remove bolts from the retainer bar from the cell to be

replaced.

6. Cells develop internal pressure. Relieving this pressure

from the cell will make it easier to remove the cell from the

sleeve assembly.

a. Pry off the vent shroud

b. Remove the flame arrestor

c. Loosen valve using a 17mm hex key approximately

½ turn to release the internal pressure. A cloth

should be used to cover the valve when releasing

pressure to avoid any chance of acid spray being

released”

d. Immediately tighten the valve and torque to

12-14 in-lb (1.4-1.6 Nm).

7 Thread Polypropylene rope through the battery posts as

illustrated below and knot.

8. Remove the two retaining bars holding in the

cell to be removed.

9. Pull cell from module onto lifting device. Care should

be taken so lifting device does not come in contact with

cell posts.

10. Replacement cell may have built up pressure while on

open circuit. Refer to step 5 for relieving the internal

cell pressure.

11. After cell has been installed into sleeve refer to “Retainer

Bar Installation” section (pg 8).

AVR125-33

Acid Volumes & Weights

Data subject to cha ge.

MSDS sheets can be obtained at

www.eastpennuni y.com.

Cell Electrolyte Pure

Size cc gal gm lb acid lb

AVR125-33 25,793 6.61 33,531 73.92 29.55

Cell Serial Cell Volts Cell Connector Ohmic Value Cell Serial Cell Volts Cell Connector Ohmic Value

No. Number Temp. (Float) Ohmic Value* 1 2 3 No. Number Temp. (Float) Ohmic Value* 1 2 3

1 31

2 32

3 33

4 34

5 35

6 36

7 37

8 38

9 39

10 40

11 41

12 42

13 43

14 44

15 45

16 46

17 47

18 48

19 49

20 50

21 51

22 52

23 53

24 54

25 55

26 56

27 57

28 58

29 59

30 60

*Consult Cell type/Battery Type Label – Found on Retaining Bar or Left Side of Each Module.

*CONSULT I&O MANUAL, “RECOR KEEPING”, FOR A ITIONAL INFORMATION INCLU ING PROPER LOCATION OF PROBES FOR MULTI-TERMINAL JARS.

Remarks and Recommendations: ____________________________________________________________________________________________________________________________________________________________________________________

_______________________________________________________________________________________________________________________________________________________________________________________________________________

Readings Taken By: ______________________________________________________________________________________________________________________ Notation: This form must be comp eted and submitted with any product warranty c aim.

(EPM Form : XXXX 08/08 Form available as a Excel Spreadsheet. Co sult your EPM Represe tative.) Readi gs should be take at I stallatio a d at least a ually thereafter.

Battery Maintenance Report

Company _______________________________________________________________ Service ate

Address_________________________________________________________________ Battery wg #

Battery Location & I. . Number ______________________________________________ Connector Pkg Ambient Air Temp.__________ºF

Total No. of Cells ____________________________ Charger Output Voltage _________ Float Currnet _________ Battery I. . # ______________________________________

Battery Type* _____________________________________ Total Battery Voltage _____________________(read at battery ter inals) Installer ______________________________

ate of Mfg.* _____________________________________ Panel Meter Voltage ______________________(display voltage) ate Installed ______________________________

Site Load Current ______________________________A ps Conductance/Impendance Meter _________________________________________________________( fg. & odel)

Rectifier Mfg. & Model__________________________________________________ AC Ripple Voltage _______________________(Note if voltage is expressed in RMS, Peak. or Peak To Peak)

Environment (i.e. Hut. Central Office. etc...) __________________________________________________________________________________________________________

(See Manual)