EnerSys PowerSafe Data Safe Troubleshooting guide

Safety, Storage, Installation,
Operation & Maintenance Manual
Flooded Lead-Acid Batteries
C, D, E, F and G
Publication No. US-FL-IOM-002 January 2007

This manual provides instructions regarding safety, storage, installation, operation and
maintenance. Failure to observe the precautions as presented may result in injury or loss of life.
This document is proprietary to EnerSys. This document cannot be copied or reproduced in
whole or in part, nor can its contents be revealed in any manner or to any person except to meet
the purpose for which it was delivered, without the express written permission of EnerSys.

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GENERAL SAFETY INSTRUCTIONS
Warnings in this manual appear in any of three ways:
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, WILL result in death,
serious injury and/or severe property damage.
Danger
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.
Warning
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.
Caution
Other warning symbols may appear along with the Danger, Warning, 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:
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.
Electrical
warnings
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.
Explosion
warnings

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IMPORTANT SAFETY INSTRUCTIONS
DANGER
A battery can present a risk of electrical shock and high short circuit current.
The following precautions should be observed when working with batteries:
1. Verify that the Charging Power Supply to the battery is off and that all power is
disconnected from the power source.
2. Remove watches, rings or other metal objects.
3. Use tools with insulated handles to prevent inadvertent shorts.
4. Wear rubber gloves and boots.
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. Vented lead-acid (VLA) batteries can 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 and other items that may come in contact with the battery.
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 Flooded Lead-Acid Battery Systems that should
be followed during the installation and maintenance of the battery system.
Only a qualified EnerSys service representative who is knowledgeable in batteries and the
required precautions should perform servicing of the batteries. Keep unauthorized personnel
away from batteries.
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.
Caution
Caution Do not dispose of the batteries in a fire. The batteries may
explode.
Caution Do not mutilate the batteries. Released electrolyte is harmful to
the eyes and skin and may also be toxic.
This unit contains flooded 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.
Warning
Failure to replace a battery before it becomes exhausted may
cause the case to crack, possibly releasing electrolyte from inside
the battery and resulting in secondary faults such as odor, smoke
and fire.
Warning
Installation and servicing of batteries should be performed by
personnel knowledgeable about batteries and the required
precautions. Keep unauthorized personnel away from the
batteries.
Warning
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 power supply system.
Warning

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TABLE OF CONTENTS
GENERAL SAFETY INSTRUCTIONS..........................................................................................i
1.0 GENERAL INFORMATION ........................................................................................1
1.1 Introduction .................................................................................................................1
1.2 Precautions.................................................................................................................1
1.3 Service........................................................................................................................1
2.0 SAFETY......................................................................................................................2
2.1 General .......................................................................................................................2
2.2 Safety Equipment and Clothing...................................................................................2
2.3 Safety Precautions......................................................................................................3
2.3.1 Sulfuric Acid Burns..........................................................................................3
2.3.2 Explosive Gases..............................................................................................4
2.3.3 Electrical Shocks and Burns............................................................................4
3.0 INSPECTING BATTERY SHIPMENT.........................................................................6
3.1 General .......................................................................................................................6
3.2 Visible External Damage.............................................................................................6
3.3 Concealed Damage ....................................................................................................7
4.0 BATTERY STORAGE BEFORE INSTALLATION.....................................................8
4.1 General .......................................................................................................................8
4.2 Storage Interval...........................................................................................................8
4.3 Advance Preparation...................................................................................................8
5.0 INSTALLATION CONSIDERATIONS ........................................................................9
5.1 General .......................................................................................................................9
5.2 Considerations for Connecting the Battery System to Operating Equipment............11
5.3 Considerations for Parallel Installation......................................................................11
6.0 UNPACKING AND HANDLING FOR INSTALLATION............................................12
6.1 General .....................................................................................................................12
6.2 Recommended Installation Equipment and Supplies................................................12
6.3 Cell/Jar Handling.......................................................................................................13
6.3.1 Small Cell Handling (C).................................................................................13
6.3.2 Medium Cell Handling (E and F)...................................................................13
6.3.3 Large Cell Handling (D and G)......................................................................15
7.0 SYSTEM INSTALLATION........................................................................................18
7.1 System Layout ..........................................................................................................18
7.2 Installation Considerations........................................................................................19
7.2.1 Installation Precautions.................................................................................19
7.2.2 Arrangement..................................................................................................19
7.2.3 Spacing .........................................................................................................19
7.3 Battery Installation.....................................................................................................20
7.4 Preparing and Installing Connections .......................................................................23
7.4.1 Terminal Posts ..............................................................................................23
7.4.2 Intercell Connectors ......................................................................................23
7.4.3 Terminal Plates .............................................................................................26

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8.0 INITIAL and/or FRESHENING CHARGE.................................................................28
9.0 OPERATION.............................................................................................................30
9.1 Float Operation..........................................................................................................30
9.2 Hydrometer Readings - Specific Gravity ...................................................................31
9.3 Full-Charge Specific Gravity......................................................................................31
9.4 Equalizing Charge.....................................................................................................33
9.4.1 Equalizing Charge Method............................................................................33
9.5 Operating Temperature.............................................................................................34
10.0 BATTERY TAPS.......................................................................................................35
11.0 PILOT CELL .............................................................................................................35
12.0 MAINTENANCE........................................................................................................35
12.1 Battery Cleaning........................................................................................................35
12.1.1 Standard Cleaning.......................................................................................35
12.1.2 Corrosion Cleaning......................................................................................36
12.1.3 Heavy Corrosion Cleaning...........................................................................36
12.1.4 Cleaning Flame Arrestors............................................................................37
12.1.5 Replacing or Isolating a Cell........................................................................37
12.2 Maintenance Records ...............................................................................................37
12.3 Corrective Actions.....................................................................................................39
12.4 Adding Water.............................................................................................................39
12.5 Quality of Water.........................................................................................................40
Storage Battery Report - Battery in Float Service.......................................................................41
12.6 Filling and Charging Moist-Charged Cells.................................................................42
13.0 TEST PROCEDURES...............................................................................................44
13.1 Procedure for Battery Capacity Tests........................................................................44
APPENDIX - HYDROGEN EVOLUTION CALCULATION.........................................................46

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1.0 GENERAL INFORMATION
1.1 Introduction
EnerSys flooded lead-acid batteries set the benchmark for reliability and durability in flooded
lead-acid batteries and battery systems.
1.2 Precautions
BEFORE UNPACKING, STORING, HANDLING, INSTALLING, OPERATING OR
PERFORMING MAINTENANCE ON THE FLOODED LEAD-ACID STATIONARY 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 Reserve Power 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 Reserve Power
Service.

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2.0 SAFETY
2.1 General
All flooded, lead-acid batteries, may leak, release hydrogen gas or cause acid misting. Always
follow the generally accepted safety procedures for handling batteries. In addition, it is vitally
important that you observe the precautions recommended in this manual.
YOU SHOULD 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 Reserve
Power 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 protection / face shield
•rubber gloves •safety goggles •emergency eye wash and
shower, if available
•fire extinguisher •acid spill cleanup kit
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/cell.
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 Sulfuric Acid Burns
Batteries are safe when operated and handled properly. However, they do contain sulfuric acid,
which can cause burns and other serious injuries.
Always wear protective clothing AND use the correct safety tools.
In case of SKIN CONTACT with sulfuric 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 sulfuric acid, IMMEDIATELY
1. FLUSH THOROUGHLY for at least 15 minutes with
large amounts of WATER.
2. Get MEDICAL ATTENTION.
In case of sulfuric acid CONTACT WITH CLOTHING OR
MATERIAL, IMMEDIATELY
1. REMOVE CONTAMINATED CLOTHING
2. Apply a solution of sodium bicarbonate solution (1.0 lb/1.0
gal 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 a sulfuric acid SPILL, bicarbonate of soda or an emergency spill kit
should be within the battery room in accordance with OSHA regulation
1910.178g2.

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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 protective clothing and use the correct safety tools.
•Eliminate any potential of sparks, flames or arcing.
•Provide adequate ventilation. See Appendix.
IN CASE OF FIRE: To extinguish a fire in a battery room containing lead acid batteries, use
CO2, foam, or dry chemical extinguishing media. 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. Water applied to electrolyte generates heat and causes it to splatter. Wear acid-
resistant clothing.
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 tools when
working with ANY battery system.
•Remove all jewelry that could produce a short circuit.
BEFORE working on the system:
1. Disconnect ALL loads and power sources to the battery. Use appropriate lockout/tagout
procedures.
2. If working on an assembled battery system, sectionalize (interrupt the battery in sections)
into safe working voltage levels.
3. Check the battery system grounding. Grounding of the battery system is NOT
recommended. However, grounding of the rack is recommended.

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IF BATTERY SYSTEM IS GROUNDED (system is intentionally grounded by connecting a
battery terminal to ground):
1. a shock hazard exists between all other terminals and
ground (i.e., dirt and acid on top of battery cell touching
rack).
2. if an unintentional ground developes within the already
grounded system, a short circuit may occur and cause
cause explosion or fire.
IF BATTERY SYSTEM IS UNGROUNDED (system is NOT grounded):
1. if an unintentional ground develops within the system, anincreased shock hazard exists between the terminals 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 question concerning safety when working with the battery system, contact your
local 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 Reserve
Power Service.

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3.0 INSPECTING BATTERY SHIPMENT
3.1 General
Precautions have been taken to pack the cells/battery units for shipment to ensure its safe
arrival. However, upon receipt, you should inspect for evidence of damage that may have
occurred during transit.
WARNING
During inspections, take precautions against electrical shock.
You are handling LIVE batteries.
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.
•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.

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3.3 Concealed Damage
Within 15 days of receipt (or as soon as practical), unpack the cells and check for
concealed damage. Remember, you are handling a LIVE battery. Take
precautions against a shock hazard. Follow all safety precautions as noted in
Section 2.0.
Examine the electrolyte level to ensure that none has been spilled. If electrolyte has been lost in
transit and the level is less than 1/2 inch (12 mm) below the top of the plates, add Battery Grade
sulfuric acid electrolyte of the nominal operating specific gravity indicated on the cell nameplate,
and bring to the low level line on open circuit.
If the electrolyte level is more than 1/2 inch (12 mm) below the top of the plates, request an
inspection by a representative of the carrier and file a claim for concealed damage.
NOTE: For export, cells are usually shipped assembled, moist charged with
separate electrolyte. Fill when ready to place in service, not before.
Refer to Section 12.6, “Filling and Charging Moist-Charged Cells”.
Check the received materials against the detailed packing list to verify receipt of all materials in
the quantities specified.
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 questions concerning potential damages, contact your local EnerSys sales/service
representative, or, call the corporate office number listed on the back of this manual and ask for
EnerSys Reserve Power Service.

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4.0 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.
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.
Do NOT stack pallets. DAMAGE MAY OCCUR AND THE WARRANTY WILL BE VOIDED.
4.2 Storage Interval
Do NOT store flooded batteries longer than the following intervals without giving periodic
freshening charges. Under higher temperature conditions, greater charging frequency may be
required. Use date of battery shipment to determine freshening charge requirements.
•Lead Antimony — every three months
•Lead Calcium — every six months
Storage times exceeding the above may result in plate sulfation, which may adversely affect
electrical performance and expected life.
Give the battery a freshening charge before the end of the recommended storage interval. See
Section 8 for charging information.
Repeat the freshening charge for each additional storage interval until the battery is installed.
Maximum total storage time before installation is two years from date of shipment from the
factory to the customer. Freshening charges are required a minimum of every three to six
months during the storage time period, as noted above.
4.3 Advance Preparation
If freshening time interval is likely to be exceeded in storage, make advance preparation to have
an adequate charger available and adjacent to an appropriate AC supply voltage. Positioning of
the cells to accept the temporary intercell connectors is another consideration of advance
planning. Keep cells on styrofoam pads until they are installed on the rack.
Make every effort to get the battery installed and connected to the charger before the expiration
of the storage period, thereby avoiding the additional labor cost of preliminary freshening
charges.
WARNING
FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S WARRANTY.

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BEFORE INSTALLATION
READ THIS SECTION THOROUGHLY.
5.0 INSTALLATION CONSIDERATIONS
5.1 General
If you have any questions concerning the installation considerations, contact your EnerSys
sales/ service representative. The diagrams shown are general representations and may not
depict all models and options.
When planning the system space requirements for the EnerSys flooded stationary batteries,
consider the following:
•space •ventilation
•environment •battery system configuration
•temperature •floor loading
•distance from operating equipment •floor anchoring
Use Table 5.1 to ensure that all requirements for installation location are considered.
TABLE 5.1
CONSIDERATION RECOMMENDATION
Space It is recommended that the aisle space provided in front of all racks be a
minimum of 36 inches (915 mm). The designer must verify the
requirements for aisle space in all applicable local codes or regulations.
A minimum of 9 inches (230 mm) is desirable above the tops of the cell
posts of the top row of cells to permit access for maintenance or cell
removal.
Each cell should be accessible for the addition of water and for taking
individual cell voltage and hydrometer readings.
Environment Clean, cool and dry. The location should be selected to keep water, oil, and
dirt away from all cells.
Temperature Ambient temperature between 72o- 78oF (23o - 26oC).
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.

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Table 5.1 (continued)
CONSIDERATION RECOMMENDATION
Ventilation Adequate ventilation must be provided, so as to prevent hydrogen gas
from exceeding a 2% concentration as shown in IEEE 484-1987.
Hydrogen accumulation must be limited to less than 2% of the total
volume of the battery area.
Ventilation must be adequate to ensure that pockets of trapped
hydrogen gas do not develop, particularly at the ceiling.
See Appendix for additional information
Grounding It is recommended that the racks be grounded in accordance with NEC
and/or local codes.
Codes Building codes and fire codes may require a spill containment system
for battery installations. Please consult local building codes. EnerSys
offers spill containment systems. Contact your EnerSys sales/ service
representative for more information.
Floor Reasonably level. Shim up to 1/4 inch (6 mm) maximum to level battery
rack or cabinet front to rear and side to side. Capable of supporting the
weight of the battery as well as any auxiliary equipment.
Anchoring Anchoring should meet all local, state, and federal codes and all
industry standards.
Floor anchoring and its design are the responsibility of the user.
Racks EnerSys flooded stationary batteries designed for racks or cabinets
must be installed on racks specifically designed for those batteries by
the manufacturer. Use of any other rack design is the responsibility of
the user.

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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 to a
specific end voltage. Consult with the system/equipment supplier to determine these
parameters, because battery performance is based on these values, as measured at the battery
terminals.
Therefore, 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 inches/15 cm) for connect/disconnect.
•are the proper size to minimize the voltage drop between the battery output terminals
and the load.
To select the proper cable size:
1. Determine the cable size necessary to carry the design load.
2. Calculate the voltage drop of the cable between the battery terminal plate and the
operating equipment.
3. Increase cable size to achieve the allowable voltage drop.
Cable selection should create no greater voltage drop than allowed between the battery system
and the operating equipment as determined by the equipment/system supplier. Excessive
voltage drop will reduce the desired support time of the battery system.
5.3 Considerations for Parallel Installation
If it is necessary to connect the battery system in parallel to obtain sufficient capacity, cable
connections to each of the parallel strings are important.
To obtain:
•proper load sharing on the discharge,
•satisfactory recharge, and
•the same float voltage for each string.
cables from the batteries to the load must be:
•as short as possible,
•of equal lengths to the load (do not exceed cable ampacity), and
•of sufficient ampacity.

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6.0 UNPACKING AND HANDLING FOR INSTALLATION
6.1 General
Batteries are shipped assembled, charged, and filled with the electrolyte near the low level lines
marked on the jar. If the electrolyte level is significantly above the low level line after the battery
has been on a long open circuit stand, care must be taken to avoid flooding during the
freshening charge. Electrolyte may be removed to the low level line to prevent overflowing.
All accessories for installation and use are supplied as optional prepackaged kits. Cells may be
packed in wooden boxes, which must be opened completely and carefully. The cells are then
handled as described in Section 6.3.
6.2 Recommended Installation Equipment and Supplies
Before working with the battery system, be sure that you have the proper protective clothing,
safety equipment and insulated tools as specified in Section 2.0. Additional equipment for the
installation of the battery system is listed in Table 6.1.
TABLE 6.1 CHECK IF
ON HAND
EQUIPMENT REQUIRED
Forklift or Portable Lift Crane
Chalk Line
Torpedo Level (Plastic)
Torque Wrench (10-200 in-lbs)
Torque Wrench (50-100 ft-lbs)
Drift Pins
Floor Anchors (User-supplied per battery system and attached stress analysis)
Floor Shims (User-supplied)
Insulated 3/8 inch Drive Ratchet Wrench with Minimum 3" Extension
With 3/8 inch thru 11/16 inch Sockets
Insulated Box Wrenches (3/8 inch to 11/16 inch)
Screwdrivers
Wipes, Paper or Cloth
Plastic Bristle Brush or Nonmetallic Cleaning Pad
Tape Measure (Nonmetallic)
Safety Equipment and Clothing
Small Paint Brush
Standard Allen Wrench Set
NO-OX-ID Grease
Be sure you have all the proper protective clothing and safety tools
and equipment on hand before starting the installation.