EnerSys PowerSafe DDmP Setup guide

Battery Safety, Installation, Storage,
Operating and Maintenance Manual
Visit us at www.enersys.com
Publication No.: AMER-EN-IOM-PS-DDMPLP-0423
DDmP
VRLA Battery System
DDmP 125-33 LP

AMER-EN-IOM-PS-DDmPLP-0223
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Contact EnerSys® Energy Systems Technical Support at 1-800-538-3627 if you require
clarification on any information contained in this manual.
This manual provides instructions regarding safety, installation, storage, operation, and
maintenance for EnerSys® valve-regulated lead acid batteries, as well as certain installation
considerations. Failure to observe the precautions as presented may result in injury or loss
of life.
© 2023 by EnerSys
®
. All rights reserved.
This document is proprietary to EnerSys. This document cannot be copied or reproduced in
whole or in part, without the express written permission of EnerSys.
Please check our website for literature updates.
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GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in any of three ways:
Danger
Warning
Caution
The danger symbol is a lightning bolt mark enclosed
in a triangle. The danger symbol is used to indicate
imminently hazardous situations, locations and
conditions which, if not avoided, could result in death,
serious injury and/or severe property damage.
The warning symbol is an exclamation mark in a
triangle. The warning symbol is used to indicate
potentially hazardous situations and conditions, which
if not avoided COULD result in serious injury or death.
Severe property damage COULD also occur.
The caution symbol is an exclamation mark enclosed
in a triangle. The caution symbol is used to indicate
potentially hazardous situations and conditions, which
if not avoided may result in injury. Equipment damage
may also occur.
Other warning symbols may appear along with the Danger and Caution symbol and are used
to specify special hazards. These warnings describe particular areas where special care
and/or procedures are required in order to prevent serious injury and possible death:
Electrical
warnings
Explosion
warnings
The electrical warning symbol is a lightning bolt mark
enclosed in a triangle. The electrical warning symbol is
used to indicate high voltage locations and conditions,
which may cause serious injury or death if the proper
precautions are not observed.
The explosion warning symbol is an explosion mark
enclosed in a triangle. The explosion warning symbol
is used to indicate locations and conditions where
molten, exploding parts may cause serious injury or
death if the proper precautions are not observed.

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IMPORTANT SAFETY INSTRUCTIONS
DANGER
Abattery can present arisk of electrical shock and high short circuit current.
The following safety precautions should be observed when working with batteries.
1. Verify that all power has been disconnected from battery prior to servicing.
2. Remove watches, rings, or other metal objects.
3. Use tools with insulated handles to prevent inadvertent shorts.
4. Wear steel toe safety shoes.
5. Do not lay tools or metal parts on top of batteries.
6. Determine if the battery is inadvertently grounded. If inadvertently grounded,
remove source of ground. Contact with any part of a grounded battery can result
in electrical shock. The likelihood of such shock will be reduced if such grounds
are removed during installation and maintenance.
7. Verify circuit polarities before making connections.
8. Disconnect charging source and load before connecting or disconnecting
terminals.
9. Valve-regulated lead-acid (VRLA) batteries contain an explosive mixture of
hydrogen gas. Do not smoke, cause a flame or spark in the immediate area of the
batteries. This includes static electricity from the body.
10. Use proper lifting means when moving batteries and wear all appropriate safety
clothing and equipment.
11. Do not dispose of lead acid batteries except through channels in accordance with
local, state, and federal regulations.

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for PowerSafe® DDmP125-33 LP Lead-Acid
Battery Systems that should be followed during the installation and maintenance of the
battery system.
Only a qualified EnerSys® service representative or others who are qualified in batteries and the
required precautions should perform servicing of the batteries. Keep unauthorized personnel
away from batteries.
CAUTION
CAUTION
CAUTION
WARNING
WARNING
WARNING
WARNING
WARNING
Misuse of this equipment could result in human injury and
equipment damage. In no event will EnerSys®be responsible
or liable for either indirect or consequential damage or injury
that may result from the use of this equipment.
Do not dispose of the batteries in a fire.
Do not open or mutilate the batteries. Released electrolyte is
harmful to the eyes and skin and may also be toxic.
This unit contains sealed lead acid batteries. Lack of
preventative maintenance could result in batteries exploding
and emitting gasses and/or flame. An authorized, trained
technician must perform annual preventative maintenance.
Failure to replace a battery before it reaches end of life may
cause the case to crack, possibly releasing electrolyte from
inside the battery and resulting in secondary faults such as
odor, corrosion, smoke, and fire.
Installation and servicing of batteries should be performed by
personnel knowledgeable about batteries and the required
precautions. Keep unauthorized personnel away from the
batteries.
Proper maintenance to the battery system of this unit must
be done by a qualified service technician. This is essential to
the safety and reliability of your system.
Risk of fire, explosion, or burns. Do not disassemble, heat
above 60°C (140°F) or incinerate.

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TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS...........................................................................................................i
1. GENERAL INFORMATION ................................................................................................................ 1
1.1. Introduction.................................................................................................................................... 1
1.2. Precautions ................................................................................................................................... 2
1.3. Service .......................................................................................................................................... 2
2. SAFETY .................................................................................................................................................... 3
2.1. General ......................................................................................................................................... 3
2.2. Safety Equipment and Clothing .................................................................................................... 3
2.3. Safety Precautions ........................................................................................................................ 4
2.3.1. Electrolyte Burns.................................................................................................................. 4
2.3.2. Explosive Gases .................................................................................................................. 5
2.3.3. Electrical Shocks and Burns................................................................................................ 5
3. INSPECTING THE BATTERY SHIPMENT .............................................................................................. 7
3.1. General ......................................................................................................................................... 7
3.2. Visible External Damage............................................................................................................... 7
3.3. Concealed Damage ...................................................................................................................... 8
4. BATTERY STORAGE BEFORE INSTALLATION ................................................................................... 9
4.1. General ......................................................................................................................................... 9
4.2. Storage Location........................................................................................................................... 9
4.3. Advance Preparation................................................................................................................... 10
5. INSTALLATION CONSIDERATIONS ..................................................................................................... 11
5.1. General ....................................................................................................................................... 11
5.2. Considerations for Connecting the Battery System to Operating Equipment ........................... 12
5.3. Considerations for Parallel Installation........................................................................................ 13
6. UNPACKING AND HANDLING FOR INSTALLATION ......................................................................... 14
6.1. General ....................................................................................................................................... 14
6.2. Accessories................................................................................................................................. 14
6.3. Recommended Installation Equipment and Supplies................................................................. 15
7. SYSTEM LAYOUT.................................................................................................................................. 16

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8. MODULE ASSEMBLY AND INSTALLATION ....................................................................................... 17
8.1 Individual Module Placement.................................................................................................... 17
8.2 Stacked Module Placement ......................................................................................................................... 17
8.3 Top Bracket…………………………………………………………………………………………………. 18
9. BATTERY CELL INSTALLATION.......................................................................................................... 18
9.1 Module Retainers...................................................................................................................... 20
10. ELECTRICAL BONDING INSTRUCTIONS............................................................................................ 21
11. TERMINAL PLATES .............................................................................................................................. 21
12. CONNECTIONS .......................................................................................................................................22
12.1.Inter-Cell Connectors .................................................................................................................22
12.2.Terminal Connections.................................................................................................................23
13. INITIAL SYSTEM READINGS .............................................................................................................. 24
14. TERMINAL PLATE COVERS AND SAFETY SHIELDS.......................................................................25
14.1. Terminal Plate Covers ................................................................................................................25
14.2.Safety Shields ............................................................................................................................25
15. INITIAL and/or FRESHENING CHARGE ............................................................................................ 25
16. OPERATION.......................................................................................................................................... 27
16.1.General ………………........ ....................................................................................................... 27
16.1.1. Determining the State-of-Charge ................................... 27
16.2.Float Operation ......................................................................................................................... 28
16.2.1. Float Charge Method ...................................................... 29
16.3.Equalizing Charge..................................................................................................................... 30
16.3.1. Equalizing Charge Method.............................................. 31
17. BATTERY TAPS.....................................................................................................................................32
18. PILOT CELL ...........................................................................................................................................32
19. MAINTENANCE......................................................................................................................................32
19.1.Battery Cleaning ........................................................................................................................32
19.2. Test Procedures .........................................................................................................................34
19.3.Battery Maintenance Reports ....................................................................................................34
20. CELL READING.....................................................................................................................................37
21. TEMPORARY NON-USE (EXTENDED OUTAGE) ...............................................................................38
21.1.Installed/Out-of-Service-System ................................................................................................38
21.2.Return to Service .......................................................................................................................38

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1. GENERAL INFORMATION
1.1. Introduction
EnerSys® modular valve-regulated lead acid (VRLA) batteries have unique features that make
them easy to install and maintain. These batteries are composed of absorbed glass mat (AGM)
separators with flat plates and electrolyte.
The AGM retains the electrolyte between the plates to ensure long float service.
PowerSafe® batteries utilize calcium alloy grids (NO cadmium) which float at a lower current than
antimony (Sb) grids. Lower float currents, in conjunction with superior and uniform thermal
management, reduce the chances of thermal runaway. (Temperature compensation chargers
are also recommended.)
PowerSafe® VRLA batteries typically do not require a separate battery room or “Hood” exhaust
system like traditional Vented Lead Acid (VLA) Batteries. However, they do require adequate
ventilation and should not be placed in “airtight” locations.
Systems are available in a 3Wx8H configuration only. The design allows for assembly at remote
location.
An assembly drawing is included with the product shipment. The system Bill of Materials is shown
on this drawing.
Before installation: Verify items received versus Bill of Lading. Verify parts against system Bill of
Materials.

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1.2. Precautions
BEFORE UNPACKING, STORING, HANDLING, INSTALLING, OPERATING OR
PERFORMING MAINTENANCE ON THE ENERSYS®VRLA BATTERY SYSTEM:
READ
THE FOLLOWING
INFORMATION THOROUGHLY!
It is important to read, understand and strictly follow the instructions in this manual.
If the following precautions are not fully understood, or if local conditions are not covered,
contact your nearest EnerSys® sales/service representative for clarification or call the corporate
office number listed on the back of this manual and ask for EnerSys®Energy Systems Service.
Also, refer to all applicable federal, state, and local regulations and industry standards.
YOU SHOULD BE TRAINED IN HANDLING, INSTALLING, OPERATING AND MAINTAINING
BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM
1.3. Service
Should you require installation supervision, service, parts, accessories, or maintenance;
EnerSys® has a nationwide service organization to assist with your new battery purchase.
Please call your nearest EnerSys®sales/service representative for more information or call the
corporate office number listed on the back of this manual and ask for EnerSys®Energy
Systems Service.

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2. SAFETY
2.1. General
PowerSafe® VRLA lead acid batteries are reduced-maintenance batteries that operate on
recombinant principles and do not require water addition throughout their service life.
Under NORMAL operating conditions and use (i.e. properly charged and maintained), their
design features include:
•minimized hydrogen gas release
•the virtual elimination of acid misting
•essentially the elimination of electrolyte leakage
Under ABNORMAL operating conditions (i.e., not properly charged and maintained) or as a
result of damage, abuse and/or misuse, the potentially hazardous conditions of hydrogen
gassing, acid misting and leakage may occur.
YOU NEED TO BE TRAINED IN HANDLING, INSTALLING, OPERATING AND
MAINTAINING BATTERIES BEFORE YOU WORK ON ANY BATTERY SYSTEM.
You MUST understand the risk of working with batteries and BE PREPARED and
EQUIPPED to take the necessary safety precautions. If not, contact EnerSys® Energy
Systems Service.
2.2. Safety Equipment and Clothing
When working with any battery system, be sure you have the necessary tools and safety
equipment, including but not limited to:
• insulated tools • rubber apron • face shields
• rubber gloves • safety goggles & shoes • emergency eye wash
• fire extinguisher • acid spill cleanup kit • and shower, if available
ALWAYS:
•remove all jewelry (i.e., rings, watches, chains, etc.)
•keep sparks, flames and smoking materials away from the battery
NEVER lay tools or other metallic objects on the battery modules.
Using the correct tools and wearing proper safety equipment will help prevent injury should an
accident occur.

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2.3. Safety Precautions
2.3.1. Sulphuric Acid Burns
Because VRLA cells are sealed, they normally do not present an acid
danger. However, they do contain electrolyte which contains sulfuric acid
that can cause burns and other serious injuries.
Always wear safety goggles,protective clothing AND use the correct safety tools.
In case of SKIN CONTACT with sulphuric acid, IMMEDIATELY
1. REMOVE contaminated CLOTHING
2. FLUSH the area THOROUGHLY with WATER
3. Get MEDICAL ATTENTION, if required.
In case of EYE CONTACT with sulphuric acid, IMMEDIATELY
1. FLUSH THOROUGHLY for at least 15 minutes with large
amounts of WATER.
2. Get MEDICAL ATTENTION.
In case of sulphuric acid CONTACT WITH CLOTHING OR MATERIAL,
IMMEDIATELY
1. REMOVE contaminated CLOTHING
2. Apply a solution of sodium bicarbonate solution (1.0lb/1.0gal or
0.5 kg/5.0 liters of water) on the clothing or material.
3. Apply the solution until bubbling stops, then rinse with clean water.
NOTE:
In case of an electrolyte SPILL, bicarbonate of soda or an emergency
spill kit should be within the battery room.
CAUTION

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2.3.2. Explosive Gases
Batteries can generate gases which, when released, can explode
causing blindness and other serious personal injury.
Always wear safety goggles, protective clothing and use the correct
safety tools.
Eliminate any potential of sparks, flames, or arcing.
IN CASE OF FIRE: To extinguish a fire in a battery room containing lead-acid batteries, use a
CO2, foam, or dry-chemical extinguishing medium. Do NOT discharge the extinguisher directly
onto the battery. The resulting thermal shock may cause cracking of the battery case/cover.
SPECIAL PROCEDURES:
If batteries are on charge, shut off power. Use positive-pressure, self-contained breathing
apparatus. Wear acid resistant clothing. Water applied to electrolyte generates heat and
causes it to splatter.
TOXIC FUMES:
Burning plastic may cause toxic fumes. Leave area as soon as possible if toxic fumes
are present. Wear breathing apparatus if required to remain in the area.
2.3.3. Electrical Shocks and Burns
Multi-cell battery systems can attain high voltage and/or currents. Do NOT
touch uninsulated batteries, connectors, or terminals. To prevent serious
electrical burns and shock, use EXTREME CAUTION when working with
the system.
Always wear protective clothing and use nonconductive or insulated safety tools when
working with ANY battery system.
Remove all jewelry that could produce ashort circuit.
BEFORE working on the system:
Disconnect ALL loads and power sources to the battery. Use appropriate
lockout/tagout procedures.

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IF BATTERY SYSTEM IS GROUNDED (system is intentionally grounded by connecting a
battery terminal to ground):
1. An increased shock hazard exists between the terminal of
opposite polarity and ground (i.e., dirt and acid on top of battery
cell touching rack).
2. If an unintentional ground develops within the already grounded
system, a short circuit may occur and cause explosion or fire.
IF BATTERY SYSTEM IS UNGROUNDED (system is NOT grounded):
1. If an unintentional ground develops within the system, an
increased shock hazard exists between the terminal of opposite
polarity and ground.
2. If a second unintentional ground develops within the already
unintentionally grounded system, a short circuit may occur and
cause explosion or fire.
Therefore, should you be required to work on a grounded battery system, make absolutely
sure you use the correct safety precautions, equipment and clothing.
IMPORTANT:
If you have ANY questions concerning safety when working with the battery
system, contact your nearest EnerSys®sales/service representative to clarify any of
the noted safety precautions, or call the corporate office number listed on the back
of this manual and ask for EnerSys®Energy Systems Service.

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3. INSPECTING THE BATTERY SHIPMENT
3.1. General
Precautions have been taken to pack the battery units, racks and accessories for shipment to
ensure their safe arrival. However, upon receipt, you should inspect for evidence of damage
that may have occurred during transit.
3.2. Visible External Damage
IMMEDIATELY upon delivery (while the carrier representative is still on-site) inventory all
materials against the Bill of Lading and inspect for visible external damage.
Check material quantities received against the Bill of Lading, including the number of
battery pallets and the number of accessory boxes.
Note any:
Damage to packing material and/or product wetness or stains, indicating electrolyte leakage.
If damage is noted:
1. Make a descriptive notation on the delivery receipt before signing.
2. Request an inspection by the carrier.
3. File a damage report.
WARNING
During inspections, take precautions against electrical shock.
You are handling LIVE batteries.

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3.3. Concealed Damage
Within 15 days of receipt, unpack the cells/batteries and check for concealed
damage. Remember, you are handling a LIVE battery. Take precaution against
a shock hazard. Follow all safety precautions as noted in Section 2.0.
Note any:
•damage to packing material and/or product.
•wetness or stains, indicating electrolyte leakage.
If damage is noted:
1. Request an inspection by the carrier.
2. File a concealed-damage claim.
Check the received materials against the detailed packing list to verify receipt of all materials
in the quantities specified.
For export, the cells may be packed in wooden boxes which must be opened completely and
carefully, and the cells then handled as described hereafter. See Section 6 for unpacking and
handling.
DELAY IN NOTIFYING THE CARRIER MAY RESULT IN LOSS OF YOUR RIGHT TO
REIMBURSEMENT FOR DAMAGES. Refer to the Bill of Lading, if, when performing the parts
inventory, you are unsure about the appearance of a part.
If you have any questions concerning potential damages, contact your nearest EnerSys®
sales/service representative, or call the corporate office number listed on the back of this
manual and ask for EnerSys Energy Systems Service.
CAUTION

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4. BATTERY STORAGE BEFORE INSTALLATION
4.1. General
Batteries should be unpacked, installed, and charged as soon as possible after receipt. However,
if this is impractical, follow the instructions below for storing the battery before installation.
4.2. Storage Location
1. Store batteries indoors in a clean, dry and cool location. Storage at higher
temperatures will result in accelerated rates of self-discharge and
possible deterioration of battery performance and life.
2. Do NOT stack pallets. DAMAGE MAY OCCUR AND WARRANTIES MAY
BE VOIDED.
3. Recharge the PowerSafe®DDmP125-33 LP Series batteries before their Open Circuit Voltage
(OCV) reaches 2.11 Vdc.
4. If no voltmeter is available, the maximum storage time from shipment to initial charge is
six months for batteries stored at ambient temperatures no warmer than 77˚F (25˚C). For
storage temperatures greater than 77˚F (25˚C), the battery must be recharged one (1)
month sooner for every 5˚F (3˚C) increase above 77˚F (25˚C). See Table 4.1.
TABLE 4.1
STORAGE TEMPERATURE STORAGE TIME
32˚F (0˚C) to 50˚F (10˚C) 9 months
51˚F (11˚C) to 77˚F (25˚C) 6 months
78˚F (26˚C) to 92˚F (33˚C) 3 months
If storage time exceeds the storage time recommended in Table 4.1, give the battery a
freshening charge before the end of the recommended storage interval. See Section 16 for
charging information.
PowerSafe®DDmP125-33 LP Series batteries must be charged in the horizontal position.
Charging in the vertical position may void product warranty.
5. Repeat the freshening charge (Reference Section 16) for each additional storage interval until
the battery is installed. Storage at higher temperatures will result in accelerated rates of
self-discharge and possible deterioration of battery performance and life. Storage times
exceeding the above may result in plate sulfation, which may adversely affect electrical
performance and expected life.
6. Maximum total storage time prior to installation is two (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 in Table 4.1.
7. FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S WARRANTY.
CAUTION

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4.3. Advanced Preparation
If storage times are likely to be exceeded, it may be beneficial to plan ahead and have an
adequate charger available with an appropriate AC supply voltage. The positioning of the
cells to accept temporary inter-cell connectors is another consideration for advanced
planning.
Make every effort to get the battery connected to the charger before expiration of the
storage period, thereby avoiding the additional labor cost of freshening charges.
WARNING
Failure to charge as noted voids the battery’s warranty.

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BEFORE INSTALLATION READ THIS SECTION THOROUGHLY
5. INSTALLATION CONSIDERATIONS
5.1. General
If you have any questions concerning the installation considerations, contact your EnerSys®
sales/service representative for clarification or call the corporate office number listed on the
back of this manual and ask for EnerSys Energy Systems Service.
When planning the system space requirements, consider the following:
•space
•environment
•temperature
•distance from operating equipment
•ventilation
•battery system configuration
•floor loading
•floor anchoring
Table 5.1 will assist you to ensure that all requirements for installation location are considered.
TABLE 5.1
CONSIDERATION RECOMMENDATION
Space Aisle space should be in accordance with the National Electric Code
(NEC) Article 110-16 or local codes.
Clearance from wall/equipment - 4" (10 cm) recommended minimum
Environment Clean, cool, and dry. The location should be selected to keep water,
sunlight, oil, and dirt away from all cells.
Temperature Ambient temperature between 72˚–78˚F (23˚–26˚C)
Elevated temperatures reduce operating life. Lower temperatures
reduce battery performance.
Minimize temperature variations between the cells. To avoid
temperature variation between the cells, do NOT locate the battery
near HVAC ducts or exhausts, heat sources (i.e., equipment that
generates heat) or direct sunlight.
Continued on next page
CAUTION

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CONSIDERATION RECOMMENDATION
Ventilation No separate battery room or “hood” exhaust is required. However,
VRLA batteries do require adequate ventilation and should not be
installed in “airtight” locations.
Grounding It is recommended that the modules or racks be grounded in
accordance with NEC and/or local codes.
Floor Reasonably level. Shimming up to 1/4" (6mm) maximum to level
battery front to rear and side to side. Capable of supporting the
weight of the battery as well as any auxiliary equipment.
Anchoring All installations are required to be floor anchored. Anchoring should
meet all local, state, federal codes and industry standards.
Floor anchoring and its design are the responsibility of the installer.
Ensure seismic requirements are considered.
Proximity to Electronic
Equipment
PowerSafe®VRLA batteries may be installed next to electronic
equipment unless the equipment generates heat.
Cell Identification/
Numbering
EnerSys® recommends battery one (1) be at the positive (+) output.
Then label the cells in ascending sequential order as the cells are
connected in series. The cells at the end or last cell should be the
highest numbered cell and be at the negative (-) output.
5.2. Considerations for Connecting the Battery System to Operating Equipment
The battery has been sized based on a specific load (amps or KW) for a specific run time,
temperature, and end voltage. Consult with the system/equipment supplier to determine these
parameters. Battery performance is based on these values which are measured
at the battery terminals.
It is important to ensure that the load cables:
•between the battery and its load are the shortest routing possible to the
terminal, allowing sufficient additional cable (about 6" [15 cm]) for
connect/disconnect.
•are the proper size to minimize the voltage drop between the battery output
terminals and the load.
•are connected to the terminal plate (NEVER connect the load cable(s) directly
to the battery terminal).