EnerSys DataSafe 12HX205-FR Manual

Battery Installation, Operation and
Maintenance Instructions
®
HX
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Handling
D ataSafe®HX batteries are supplied in a charged
condition and are capable of extremely high short
circuit currents. Take care to avoid short-circuiting
terminals of opposite polarity.
Important
Please read this manual immediately on receipt of the battery before unpacking and installing. Failure to comply with these instructions will render any warranties
null and void.
Care for your safety
2AM-HX-IOM AA December 2018
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.
No smoking,
no naked flames,
no sparks
Shield
eyes
Read
instructions
Electrical
hazard Danger
Recycle scrap
batteries.
Contains lead
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
Warning: Risk of fire, explosion, or burns. Do not
disassemble, heat above 60°C (140°F), or incinerate.
Avoid any short circuit. Metallic parts under voltage on the
battery, do not place tools or items on top of the battery
California Proposition 65 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. Wash hands after handling.
DANGER
Contains: Lead, Sulfuric Acid (Electrolyte), Lead Compounds.
Harmful if swallowed, inhaled, or in contact with skin. Acid causes severe skin burns
and eye damage. May damage fertility or the unborn child if ingested or inhaled.
May cause harm to breast-fed children. May cause cancer if ingested or inhaled.
Causes skin irritation, serious eye damage. Contact with internal components may
cause irritation or severe burns. Causes damage to central nervous system, blood
and kidneys through prolonged or repeated exposure if ingested or inhaled. Irritating
to eyes, respiratory system, and skin. May form explosive air/gas mixture during
charging. Extremely flammable gas (hydrogen). Explosive, fire, blast or projection
hazard.
Obtain special instructions before use. Do not handle until all safety precautions
have been read and understood. Wash thoroughly after handling. Do not eat, drink
or smoke when using this product. Avoid contact during pregnancy/while nursing.
Wear protective gloves/protective clothing, eye protection/face protection. Use
only outdoors or in a well-ventilated area. Avoid contact with internal acid. Do not
breathe dust/fume/gas/mist/vapors/spray. Keep away from heat/sparks/open flames/
hot surfaces. No smoking. IF SWALLOWED OR CONSUMED: rinse mouth. Do NOT
induce vomiting. Call a poison center/doctor if you feel unwell. IF ON CLOTHING
OR SKIN (or hair): Remove/Take off immediately all contaminated clothing and wash
it before reuse. Rinse skin with water/shower. IF INHALED: Remove person to
fresh air and keep comfortable for breathing. Immediately call a POISON CENTER
or doctor/physician. IF IN EYES: Rinse cautiously with water for several minutes.
Remove contact lenses, if present and easy to do. Continue rinsing. If exposed/
concerned, or if you feel unwell seek medical attention/advice. Store locked up,
in a well-ventilated area, in accordance with local and national regulation. Dispose
of contents/container in accordance with local and national regulation. Keep out of
reach of children.
1. 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.
2. 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 2.27 Volts per cell (Vpc) at 77°F (25°C)
for 96 hours or until the charge current does not vary for a three 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 two 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.
3. 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 optimum 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).
BCI Warning
Pb

AM-HX-IOM AA December 201 83
®
For cabinet installations, reference DataSafe®HX Battery Cabinet Systems
Range Summary (AM-DSCAB-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
Tighten the M6 connector bolts between 60 to 88 in-lbs (6.8 to 10 N•m). A
loose connector can cause problems in charger adjustment, erratic battery
performance, possible damage to the battery and/or personal injury.
4. 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 six.
5. Charging
 Commissioning Charge
Upon installation, perform a Commissioning Charge on the battery with a
constant voltage charger by either:
- Charging at 2.40 Vpc at 77°F (25°C) for 24 hours or
- Charging at 2.35 Vpc at 77°F (25°C) for 72 hours.
Follow the Maximum Charging Current values shown in Table 1. After
completion of the Commissioning Charge at either level, reduce the charger to
the appropriate Float Charge level for the battery temperature shown in the Float
Charge Section. A discharge test can be given after float charging for 24 hours.
 Float Voltage
The float/charge voltage is 2.27 Vpc at 77°F (25°C).
When the average ambient temperature deviates ± 9°F (5°C) or more 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)
 Equalize Charge
The battery can be charged at an elevated voltage of 2.40 Vpc (14.4 Volts
for the battery) for the purpose of an equalize charge or as part of a 2-step
recharge profile to reduce charge time. Charge time at 2.40V should not
exceed 16 hours and the current limits in Table 1 must be followed.
 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).
Table 1
 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). See Table 2.
Table 2
State of Charge Voltage per Cell Voltage per Battery
100% 2.12 to 2.14 12.72 to 12.84
80% 2.09 to 2.11 12.54 to 12.66
60% 2.05 to 2.08 12.30 to 12.48
40% 2.01 to 2.04 12.06 to 12.24
20% 1.97 to 2.00 11.82 to 12.00
6. Discharging
 End of Discharge Voltage
The end of discharge voltage must be limited to a minimum value of 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.
For temperature correction factors for use when load testing a battery,
please refer to the Temperature Correction factor tables published in
IEEE Standard 1188, latest version.
7. Maintenance and Records
DataSafe HX batteries are virtually 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 with a cotton cloth dampened with water only. Check monthly that
total voltage at battery terminals, while on float, is (N x 2.25 to 2.28 Vpc) 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 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.
Battery Model
Maximum
Charging Current
(Amps)
Maximum Allowable
Ripple Current
(Amps RMS)
12HX205-FR 11.0 2.1
12HX300-FR 18.0 3.5
12HX330-FR 21.0 4.1
12HX400-FR 24.0 4.7
12HX505-FR 30.0 5.9
12HX540-FR 31.0 6.1

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© 2018 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. Subject to revisions without prior notice. E.&O.E.
AM-HX-IOM AA December 2018
Note: End terminal position will depend upon number of units in row, ie. whether “ODD” or “EVEN” number.
Single row
configuration
(12HX models)
Double row
configuration
(12HX models)
Intercell Connector Layout
Batteries come standard with a stainless steel hardware package; p/n 867500 (one package per battery).
The hardware package includes two (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.
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
Battery Model Number
of Cells
Length Width Height 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-FR 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-FR 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-FR 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-FR 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-FR 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-FR 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
Battery Model
Short Long Row
L-TERMINAL
Connector* Cover
Black Cover Clear Connector* Cover
Black Cover Clear Connector* Cover
Black Cover Clear
12HX205-FR 866881TP HRD2328 827564 866885TP HRD2329 827567 866880TP HRD2328 827564 882044TP
12HX300-FR 866883TP HRD2327 827565 866886TP HRD2330 827568 866881TP HRD2328 827564 882044TP
12HX330-FR 866883TP HRD2327 827565 866886TP HRD2330 827568 866882TP HRD2327 827565 882043TP
12HX400-FR 866883TP HRD2327 827565 866886TP HRD2330 827568 866884TP HRD2327 827566 882043TP
12HX505-FR 866883TP HRD2327 827565 866886TP HRD2330 827568 866884TP HRD2327 827566 882042TP
12HX540-FR 866883TP HRD2327 827565 866886TP HRD2330 827568 866884TP HRD2327 827566 882042TP