EnerSys Genesis TD Installation and operating instructions

2
Important
Please read this manual immediately on receipt of battery before unpacking and installing. Failure to comply with these instructions will render any warranties null and void.
Care for your safety
No smoking, no naked flames,
no sparks
Electrical hazard
Electrolyte is corrosive
Shield eyes
Danger
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
Read instructions
Warning: Risk of fire, explosion, or burns.
Do not disassemble, heat above 60ºC, or
incinerate. Avoid any short circuit. Metallic
parts under voltage on the battery, do not
place tools or items on top of the battery
Re-cycle scrap batteries.
Contains lead
Handling
Genesis® TD 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 lifting hooks compatible with the plastic
handles on the cell/monobloc.
Keep flames away
In case of accidental overcharge a flammable gas can
leak off 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, wristwatch and articles of clothing with
metal parts that may come into contact with the battery
terminals.
Unpacking
It is advisable to unpack all the cells or monoblocs and accessories before
commencing to erect and not to unpack and erect cell by cell.
All cells/units should be handled carefully, as the plastic container can be
damaged or broken if allowed to fall. Under no circumstances should they be lifted
by their terminal pillars.
All items should be carefully checked against the accompanying advice notes to
ascertain if any are missing and also inspected to see whether any are damaged
or broken. Should this happen the Sales Department should be consulted.
Transit insulation covers are fitted to one pole or a one rigid plastic insulating
cover is provided which totally protects the unit terminals. These are factory fitted
to all products of the range and there is no need to remove them until access to
the terminals is required.
Storage
Store the batteries in a dry, clean and preferably cool location.
As 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 batteries for
more than:
■ 6 months at 20°C
■ 3 months at 30°C
■ 1.5 month at 40°C
A refreshing charge shall be performed after this time at 2.27-2.30Vpc at 20°C for
48 to 96 hours. A current limit is not essential, but for optimum charge efficiency
the current output of the charger can be limited to 10% of the 3 hour capacity
rating. The necessity of a refreshing charge can also be determined by measuring
the open circuit voltage of a stored battery. Refreshing charge is advised if the
voltage drops below 2.10Vpc. Failure to observe these conditions may result in
greatly reduced capacity and service life.
Installation
Install batteries in a clean and dry area. Genesis® TD battery products release
minimal amounts of gas during normal operation (gas recombination efficiency
≥ 95%). Batteries must be installed in accordance with national standards (for
instance EN 50272-2), otherwise in accordance with the manufacturer’s
instructions.
■Temperature
Avoid placing the battery in a hot place or in front of a window. The battery will
give the best performance and service life when working at a temperature
between 20°C and 25°C. The usual operating temperature is between -15°C and
+45°C.
■Ventilation
Under normal conditions gas release is very low and natural ventilation is
sufficient for cooling purposes and inadvertent overcharge, enabling
Genesis® TD 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 close cabinets.
■Mounting
Enersys® battery racks or cabinets are recommended when installing the cells.
Assemble the rack according to instructions. Place the battery blocks or cells
on the rack and arrange the positive and the negative terminals for connection
according to the wiring diagram. Check that all contact surfaces are clean and
apply the block or cell connectors and the terminal screws. Tighten the screws
securely. Finally connect the battery terminals. It is important that the battery is
mounted firmly.
■Torque
Tighten the nuts or bolts to the recommended levels of fastening torque as
specified on the product label. A loose connector can cause problems in
charger adjustment, erratic battery performance, possible damage to the
battery and/or personal injury. Finally fix the connector covers.
Cell strings connected in parallel
Using constant voltage chargers and ensuring that the connections made
between the charger and the batteries have the same electrical resistance, no
special arrangements have to be made for batteries in parallel.
Although no special circuit arrangements are required, where the parallel
connection is made at the charger or distribution board, to avoid out of step
conditions, the bus bar run length and the area of cross section should be
designed so that the circuit resistance value for each of the strings is equal
within limits ± 5%.

3
Temperature Float voltage range per cell
Duty Minim um end volt age
Discharge
0°C 5°C 10°C 15°C 20°C 2 5°C 3 0°C 35°C 4 0°C
Tim e
5 mins t o 0.80 0.86 0.91 0.9 611.0 4 1.0 6 1.0 9 1.1
59 mins
1h to 24h 0.86 0.90 0.94 0.9 711.0 3 1.0 5 1.0 6 1.07
Temperature Float Volt age Recharging Volt age
Charging
■Commissioning charge
Before use, the batteries should be charged at a constant charging voltage
(with a charging current limited to 0.1C10) with one of the following method :
• Charge during 96 hours with the floating voltage between 2.27 and 2.30 Vpc in
ambient temperature range between 15 to 25°C.
• or charge with the 2.40Vpc boost charge voltage during minimum 24 to 48
hours maximum to reduce the commissioning charging period (the battery will
then be switched over to float charging, maintain the battery under floating
voltage for 24 hours before any discharge test, see hereafter).
« If the battery is to be subjected to a discharge test, in this case the test will
be performed imperatively after that the commissioning charge has been
carried out. Check that the battery is fully charged. »
■Float voltage
The recommended float charge voltage is 2.275 volts per cell at 25°C.
Following a commission charge and after 6 months continuous charge at the
recommended float voltage, individual cell voltages will stabilise within ±4.5%
of the mean applied voltage.
However, immediately following commissioning and for the initial 6 months of
continuous float charge, individual cell voltage values outside the above
tolerance may be observed without adverse effect. There is no relationship
between a cell’s float voltage and its discharge capacity. Cells are perfectly
capable of giving their discharge capacity even when outside the ±4.5% range.
After 6 months service, should any individual cell or monobloc show a
continuing reduction or increase in voltage outside the above limits over 3
successive monthly periods, Enersys® should be contacted for advice.
When the average ambient temperature deviates more than ±5ºC from the
reference temperature (20°C), it is necessary to adjust the float voltage as
follows:
0°C
10°C
20°C
25°C
30°C
35°C
40°C
2.33-2.36V
2.30-2.33V
2.27-2.30V
2.25-2.28V
2.24-2.27V
2.22-2.25V
2.21-2.24V
If the charger does not permit an adjustment of float voltage in relation to the
temperature, it is possible to set a float voltage value according to the
temperature ranges as indicated in the last table of this publication.
■Charging current
A discharged VRLA battery will accept a high recharge current, but for those
seeking a more economical charging system a current limit of 0.08 C10 : 0.1 C3
(A) is adequate.
■Fast recharge
Increasing the charge voltage to 2.45Vpc with a current limited to 0.1 C10 : 0.125
C3 (A) can reduce recharge times. Fast charge should be stopped after
approximately 10 to 15 hours. This charge regime, in order to achieve a normal
service life, must not be used more than once per month.
■Float charge ripple
Excessive ripple on the D.C. supply across a battery has the effect of reducing
life and performance.
It is therefore recommended that voltage regulation across the system,
including the load but without the battery connected, under steady state
conditions, shall be better than ±2% through 5% to 100% load.
Discharging
The Genesis® TD batteries must not be left in a discharged condition after
supplying the load, but must immediately return to float recharge mode.
Failure to observe these conditions may result in greatly reduced service life.
■Accidental deep discharging
For optimum operation the minimum voltage of the system should be related to
the duty as follows:
5min≤t≤1h
1h≤t≤5h
5h≤t≤8h
8h≤t≤20h
1.65V
1.70V
1.75V
1.80V
In order to protect the battery it is advisable to have system monitoring and low
voltage cut-out.
Deep discharge will produce a premature deteriation of the battery and a
noticeable reduction in the life expectancy of the battery.
■The effect of temperature
- on capacity
Correction factors of the capacity, according to the temperature, are as follows:
- on life
Operation of valve regulated batteries at temperatures higher than 20°C will
reduce life expectancy. Life is reduced by 50% for every 10°C rise in
temperature.
Maintenance/Checks
Genesis®TD are maintenance free, sealed, lead acid batteries and need no
water addition.
The containers and lids shall be kept dry and and free from dust. Cleaning must
be done only with a damp cotton cloth without man-made fibres.
WARNING - Do NOT use any type of oil, solvent, detergent, petroleum-based
solvent or ammonia solution to clean the battery containers or lids. These
materials will cause permanent damage to the battery container and lid and will
invalidate the warranty.
Check monthly that total voltage at battery terminals is (N x 2.28 V) for a
temperature at 20°C. (N being the number of cells in the battery). Make annual
readings of the voltages of cells making up the battery.
Keep a logbook to record values, power outages, discharge tests, etc.
An autonomy control can be done once a year.
Technical
■Data when charging with a constant voltage
If the charger does not permit an adjustment of the float voltage in relation with
the temperature, it is possible to set a float voltage value and a recharging
voltage value according to the temperature ranges as indicated in the table
below:
0°C to 10°C
10°C to 20°C
20°C to 30°C
30°C to 40°C
2.34Vpc
2.31Vpc
2.28Vpc
2.25Vpc
2.50Vpc
2.40Vpc
2.35Vpc
2.45Vpc

Publication No. AS-TD-IOM -003 -2014 -Subject to revisions without prior notice. E.& O.E.
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