EnerSys DataSafe HX General instructions

Publication No: US-HX-IOM-002 - March 2004
Installation, Operation
and Maintenance
Instructions
www.enersysinc.com

2Publication No: US-HX-IOM-002 - March 2004
www.enersysinc.com
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
Handling
DataSafe HX 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 care when
handling and moving batteries. Appropriate lifting
equipment must be used.
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.
Dispose at registered
waste handling
facility
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.
STORAGE
Store DataSafe 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 2.26 V/cell at 77°F (25°C) for
96 hours or until the charge current does not vary for a 3 hour period.
The necessity of a charge can also be determined by measuring the open
circuit voltage of a stored battery.
Charge is advised if the voltage drops below 2.07 V/cell.
Maximum total storage prior to installation is 2 years from date of shipment
from 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.
INSTALLATION
Install in clean, dry area. DataSafe HX product releases minimal amounts of
gas during normal operation (gas recombination efficiency ≥95%). It can be
installed near the main equipment. Batteries must be installed in
accordance with local, state and federal regulations and manufacturers
instructions.
Temperature
Avoid placing the battery in areas of high temperature or in direct sunlight.
The battery will give the best performance and service life when working at
a temperature between 68°F (20°C) and 77°F (25°C). The usual operating
temperature is between -14°F (-10°C) and 113°F (+45°C). Limits are
comprised between -86°F (-30°C) and 113°F (+45°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.
Security
All installation and ventilation must comply with the current local, state and
federal regulations.
Mounting
EnerSys battery racks or cabinets are recommended for proper installation.
Assemble the rack according to instructions. Place the battery blocs 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 bloc or cell connectors and the terminal screws.
Tighten the screws securely. Follow the polarity to avoid short circuiting of
cell groups. Finally connect the battery terminals. It is important that the
battery is mounted firmly.
No smoking, no naked flames,
no sparks 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.
Danger
Risk of explosion or fire. Avoid any
short circuit. Metallic parts under
voltage on the battery, do not place
tools or items on top of the battery.
Other safety precautions that need to be taken
Battery must be
recycled
Protect eyes
from electrolyte
Read
instructions
Do not charge in
sealed container

3
Publication No: US-HX-IOM-002 - March 2004
www.enersysinc.com
Torque
The maximum torque load of intercell connector bolts is 6.8 to 10 Nm
(60 to 88 lb. in) for M6 screw. A loose connector can cause problems in
charger adjustment, erratic battery performance, possible damage to the
battery and/or personal injury. Finally, install the connector covers (optional).
CELLS IN PARALLEL STRINGS
When using constant voltage chargers, ensure that the connections
between the charger and the end of each string within the battery have the
same electrical resistance. Parallel strings must be limited to five strings.
CHARGING
Float Voltage
The float/charge voltage is 2.26 V per cell at 77°F (25°C).
When the average ambient temperature deviates more than ± 9°F (5°C)
from the reference, it is necessary to adjust the float voltage as follows :
2.37 to 2.38 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)
2.24 to 2.27 Vpc at 77°F, (25°C) (reference T°C)
2.23 to 2.26 Vpc at 86°F, (30°C)
2.21 to 2.24 Vpc at 95°F, (35°C)
Due to the phenomena of gas recombination a difference of ± 2% (earlier in
float life ± 5% is common) for an individual cell voltage can be observed.
However the total voltage of the battery shall be within the limits stated
above.
Charging Current
The charging current is self limiting.
Fast Recharge
Occasionally (4 or 5 times a year) the battery may be recharged at 2.40 V per
cell with a current limited to the values listed in the Table 2. Fast charging
should be stopped after approx. 10 or 15 hour.
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 2 (in amperes).
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).
DISCHARGING
End of Discharge Voltage
The end of discharge voltage must be limited to 1.60 V per cell.
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.
The effect of temperature
- on capacity
Correction factor of the capacity, according to temperature.
MAINTENANCE/CHECKS
DataSafe HX are maintenance free, sealed, lead acid batteries and need no
water addition.
The containers and lids shall be kept dry and free from dust. Cleaning must
be done only with a damp cotton cloth. Check monthly that total voltage at
battery terminals is (N x 2.24 to 2.27 V) for a temperature of 77°F (25°C).
(N being the number of cells in the battery).
Every 12 months, read and record the following:
Individual cell or unit voltages (volts)
Cell-to-cell connection resistance (ohms)
Terminal connection resistance (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.
RECOMMENDED CURRENT LIMIT VALUES WHEN
RECHARGING WITH CONSTANT VOLTAGE
RECHARGING METHOD
41°F, ( 5 °C) 0.84
50°F, (10°C) 0.88
59°F, (15°C) 0.93
68°F, (20°C) 0.97
77°F, (25°C) 1.00
86°F, (30°C) 1.03
95°F, (35°C) 1.05
104°, (40°C) 1.07
Time of discharge 1 min to 60 mins
HX205 4.0 2.0
HX300 7.0 3.5
HX330 7.0 3.5
HX400 8.5 4.25
HX500 10.0 5.0
Type Maximum charging Max recommended rms
current (A) value of the alternating
component (A)
Table 1
Table 2
State of charge Voltage
100% 2.13 to 2.14 V/Cell
80% 2.09 to 2.11 V/Cell
60% 2.06 to 2.08 V/Cell
40% 2.02 to 2.04 V/Cell
20% 1.97 to 2.00 V/Cell

Publication No: US-HX-IOM-002 - March 2004 - Subject to revisions without prior notice
www.enersysinc.com
Distributed by:
Printed in USA
Type Length Width CC RC A B C 1 2 3 4 5 6
HX205 8.9 5.5 5.6 9.1 2.1 1.9 9.0 866880 HRD2328 866881 HRD2328 866885 HRD2329
HX300 10.1 6.9 6.9 10.3 2.7 2.2 11.2 866881 HRD2328 866883 HRD2327 866886 HRD2330
HX330 11.9 6.9 6.9 12.1 2.7 2.5 11.2 866882 HRD2327 866883 HRD2327 866886 HRD2330
HX400 13.3 6.8 6.8 13.5 2.6 3.0 11.1 866884 HRD2327 866883 HRD2327 866886 HRD2330
HX500 13.3 6.8 6.8 13.5 2.6 3.0 11.1 866884 HRD2327 866883 HRD2327 866886 HRD2330
All measurements are in inches
INTER-UNIT CONNECTOR LAYOUT
TYPICAL LAYOUTS ON STEEL STANDS
SINGLE ROW STAND DOUBLE ROW STAND
Note! End terminal position will depend upon
number of units in row, ie. whether “ODD” or
“EVEN” number
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