EnerSys PowerSafe RL Series User manual

1 Publication No: EN-GAZ-Standard-IOM 001 Dec 2012
INSTALLATION, OPERATING
MAINTENANCE INSTRUCTIONS
type RL …, RM …, RN …, RH …
Battery voltage: Capacity (5 h):
Type of cell: Nu ber of cells:
Asse bled and co issioned by: Date:
Warning!
The gases e itted during charging are explosive. The electrolyte (potassiu hydroxide, KOH) is highly
corrosive. Exposed etal parts of the battery always conduct a voltage and are electrically active parts.
Precautions in accordance with DIN EN 50272, Part 2 have to be observed.
Observe the instructions for use and
place the visibly close to the
battery! Work only on batteries after
receiving instruction fro qualified
personnel!
Warning: Risk of fire, explosion, or
burns! Avoid any short circuit!
Metallic parts under voltage on the
battery, do not place tools or ite s
on top of the battery!
Electrolyte is highly corrosive!
When working on batteries wear
safety glasses and protective
clothing. All etallic personal
objects, such as rings, watches,
bracelets etc. shall be re oved
before starting work on the battery!
Only use insulated tools! Co ply
strictly with the accident prevention
regulations and your national Health
and Safety standards as well as DIN
EN 50272, Part 1.
Cells are heavy!
Make sure they are safely
installed!
Only use suitable transport
equip ent!
Electrolyte is har ful to skin and
eyes. Therefore, after an accidental
contact with the electrolyte flood the
eyes i ediately with large
quantities of clean water for an
extended period of ti e of at least
15 inutes. In all cases, consult a
doctor i ediately!
Clothing conta inated with
electrolyte should be washed in
water i ediately!
No s oking! Do not allow naked
fla es, e bers or sparks near the
battery due to the risk of explosion
or fire!
Th Installation, Op ration and Handling Instructions must b strictly obs rv d. Non-complianc
with th Maint nanc and Handling Instructions, r placing with unoriginal spar s, usag oth r
than sp cifi d, us of additiv s to th l ctrolyt and unauthoriz d tamp ring will invalidat any
ntitl m nt to warranty.
Cd pocket plate battery
Us d batt ri s with this symbol ar r usabl products and hav to b
put into a r cycling syst m. Us d batt ri s must b dispos d of as
sp cial wast in accordanc with all standards.
with
all th r gulations.
WARNING!
N v r us sulphuric acid or acidic
wat r.
Acid will damag th batt ry!

2 Publication No: EN-GAZ-Standard-IOM 001 Dec 2012
1. R c iving th batt ry
The cells are not to be stored in
packaging, therefore, unpack the battery
i ediately after arrival. Do not overturn
the package. The battery cells are
equipped with a blue plastic transport plug.
The battery can be delivered:
- Fill d and charg d/ the battery
is ready for installation. Replace
the transport plug with the vent
cap included in our accessories
just before use;
- Fill d and discharg d/ Replace
the transport plug with the vent
cap included in our accessories
just before use; or
- Unfill d and discharg d/ do not
re ove the transport plug until
ready to fill the battery.
Th batt ry must not b charg d with
th transport plug in th c lls as this
can damag th batt ry.
2. Storag
The roo s provided for storing the
batteries ust be clean, dry, cool (+10 °C
to 30 °C - in co pliance with IEC 60623)
and well ventilated. The cells are not to be
stored in closed packaging and ust not
be exposed to direct sunlight or UV-
radiation.
If th c lls ar d liv r d in plywood
box s, op n th box s b for storag
and r mov th packing mat rial on th
top of th c lls. If th c lls ar d liv r d
on pall ts r mov th packing mat rial
on th top of th c lls.
2.1 Uncharg d and unfill d c lls
Provided the correct storage conditions
are et then the cells and batteries can be
stored for long periods without da age if
they are deeply discharged, drained and
well sealed. It is very i portant that the
cells are sealed with the plastic transport
plug tightly in place. It is necessary to
check after receipt and at least every year.
Leaky plugs allow the carbon dioxide fro
the at osphere to infiltrate the cell, which
will result in carbonation of the plates. This
ay influence the capacity of the battery.
2.2 Charg d and fill d c lls/
discharg d and fill d c lls
Filled cells can be stored for up to 12
onths fro the ti e of delivery. Storage
of filled cells at a te perature above
+30 °C results in loss of capacity of
approxi ately 5% per 10% year. It is very
i portant that the cells are sealed with the
plastic transport plugs tightly in place. In
case of loss of electrolyte during
transportation, refill the cell with distilled
water to the “MAX” ark before storage.
3. Installation
EN 50272-2:2001 “Accu ulators and
battery installations, stationary battery
installations” is binding for the setting up
and operation of battery installations. For
non stationary installations specific
standards are valid.
3.1 Location
Install the battery in a dry and clean roo .
Avoid direct sunlight and heat in all cases.
The battery will give the opti al
perfor ance and axi u service life if
the a bient te perature lies between
+ 10 °C and + 30 °C.
3.2 V ntilation
During the last part of charging the battery,
gases (oxygen and hydrogen ixture) are
e itted. At nor al float charge the gas
evolution is very s all but so e ventilation
is necessary. Sp cial r gulations for
v ntilation might b r quir d in your
ar a for c rtain applications. If no
r gulations ar fix d DIN EN 50272,
Part 2:2001 should b m t.
3.3 S tting up
Always follow the asse bly drawings,
circuit diagra s and other separate
instructions. The transport plugs have to
be replaced by the vent caps included in
the accessories. If batteries are supplied
“filled and charged” , all the electrolyte
levels should be checked and, if
necessary, topped up as described in
point 3.4.
Cell connectors and/or flexible cables
should be checked to ensure they are
tightly seated. Ter inal nuts, screws and
connectors ust be tightly seated. If
necessary, tighten with a torque wrench.
Torqu loading for:
M10: 8 N
M16: 20 N
M20: 25 N
F mal thr ad:
M 8: 20 – 25 N
M10: 25 – 30 N
The connectors and ter inals should be
corrosion-protected by coating with a thin
layer of anti-corrosion grease.
3.4 El ctrolyt
The electrolyte for NiCd batteries consists
of diluted caustic potash solution (specific
gravity 1.20 kg/litre ± 0.01 kg/litre) with
a lithiu hydroxide co ponent, in
accordance with IEC 60993. The caustic
potash solution is prepared in accordance
with factory regulations. The specific
gravity of the electrolyte does not allow
any conclusion to be drawn on the
charging state of the battery. It changes
only slightly during charging and
discharging and is only ini ally related
to the te perature.
-
Batt ry d liv r d unfill d and
discharg d/ if the electrolyte is
supplied dry, it is to be ixed to
the enclosed ixing instruction.
Re ove the transport plugs fro
the cell just before filling. Fill the
cells up to 20 above the
lower level ark “MIN”. Steel
cased cells have to be filled up to
the top edge of the plates. When
using battery racks fill cells before
installing. Only use genuine
electrolyte.
- Batt ry d liv r d fill d and
charg d or discharg d/ check
electrolyte level. It should not be
less than 20 below the upper
level ark “MAX” (see 5.2).
3.5 Commissioning
A good co issioning is very i portant.
The following instructions are valid for
co issioning while 20 °C to 30 °C. For
different conditions please contact the
anufacturer. Charging at constant
current is preferable. If a site test is
requested it has to be carried out in
accordance with IEC 60623.
According to IEC 60623, 0.2 C5 A is also
expressed as 0.2 It A. The reference test
current It is expressed as:
It A Cn Ah
1 h
Exampl :
0.2 ItA eans:
20 A for a 100 Ah battery or
100 A for a 500 Ah battery
3.5.1 Commissioning with constant
curr nt
Batt ry d liv r d unfill d and
discharg d /after a period of 5 hours fro
filling the electrolyte, the battery should be
charged for 15 hours at the rated charging
current 0.2 It A. Approxi ately 4 hour after
the end of charging, the electrolyte level
should be adjusted to the upper electrolyte
level ark “MAX” by using only genuine
electrolyte. For cells with steel cases, the
electrolyte level should be adjusted to the
axi u level according to the
“Instruction for the control of electrolyte
level”. During th charg th l ctrolyt
l v l and t mp ratur should b
obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall b low
th “MIN” mark.
Batt ry d liv r d fill d and discharg d
/the battery should be charged for 15
hours at the rated charging current 0.2 It A.
Approxi ately 4 hours after the end of
charging, the electrolyte level should be
adjusted to the upper electrolyte level
ark “MAX” by using distilled or deionized
water in accordance with IEC 60993. For
cells with steel cases, the electrolyte level
should be adjusted to the axi u level
according to the “Instruction for the control
of electrolyte level”.

3 Publication No: EN-GAZ-Standard-IOM 001 Dec 2012
During th charg th l ctrolyt l v l
and t mp ratur should b obs rv d
(s point 5.4). Th l ctrolyt l v l
should n v r fall b low th “MIN” mark.
Batt ry d liv r d fill d and charg d
and stor d for mor than 12 months/
the battery should be charged for 15 hours
at the rated charging current 0.2 It A.
Approxi ately 4 hours after the end of
charging, the electrolyte level should be
adjusted to the upper electrolyte level
ark “MAX” by using distilled or deionized
water in accordance with IEC 60993. For
cells with steel cases, the electrolyte level
should be adjusted to the axi u level
according to the “Instruction for the control
of electrolyte level”. During th charg
th l ctrolyt l v l and t mp ratur
should b obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall b low
th “MIN” mark.
Batt ry d liv r d fill d and charg d/ a 5
hour charge at the rated charging current
0.2 It A ust be carried out before putting
the battery into operation. Approxi ately 4
hours after the end of charging, the
electrolyte level should be adjusted to the
upper electrolyte level ark “MAX” by
using distilled or deionized water in
accordance with IEC 60993. For cells with
steel cases, the electrolyte level should be
adjusted to the axi u level according
to the “Instruction for the control of
electrolyte level”. During th charg th
l ctrolyt l v l and t mp ratur
should b obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall b low
th “MIN” mark.
3.5.2 Commissioning with constant
voltag
If the charger´s axi u voltage setting
is too low to supply constant current
charging, divide the battery into two parts
that will be charged individually.
Batt ry d liv r d unfill d and
discharg d / after a period of 5 hours
fro filling the electrolyte, the battery
should be charged for 30 hours at the
rated charging voltage of 1.65 V/cell. The
current li it should be 0.2 It A axi u .
Approxi ately 4 hours after the end of
charging, the electrolyte level should be
adjusted to the upper electrolyte level
ark “MAX” by using only genuine
electrolyte. For cells with steel cases, the
electrolyte level should be adjusted to the
axi u level according to the
“Instruction for the control of electrolyte
level”. During th charg th l ctrolyt
l v l and t mp ratur should b
obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall b low
th “MIN” mark.
Batt ry d liv r d fill d and discharg d
/
the battery should be charged for 30
hours at the rated charging voltage of 1.65
V/cell. The current li it should be 0.2 It A
axi u . Approxi ately 4 hours after the
end of charging, the electrolyte level
should be adjusted to the upper
electrolyte level ark “MAX” by using
distilled or deionized water in accordance
with IEC 60993. For cells with steel cases,
the electrolyte level should be adjusted to
the axi u level according to the
“Instruction for the control of electrolyte
level. During th charg th l ctrolyt
l v l and t mp ratur should b
obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall
b low th “MIN” mark.
Batt ry d liv r d fill d and charg d
and stor d for mor than 12 months/
the battery should be charged for 30 hours
at the rated charging voltage of 1.65
V/cell. The current li it should be 0.2 It A
axi u . Approxi ately 4 hours after the
end of charging, the electrolyte level
should be adjusted to the upper electrolyte
level ark “MAX” by using distilled or
deionized water in accordance with IEC
60993. For cells with steel cases, the
electrolyte level should be adjusted to the
axi u level according to the
“Instruction for the control of electrolyte
level”. During th charg th l ctrolyt
l v l and t mp ratur should b
obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall b low
th “MIN” mark.
Batt ry d liv r d fill d and charg d/ a
10 hour charge at the rated charging
voltage of 1.65 V/cell ust be carried out
before putting the battery into operation.
The current li it should be 0.2 It A
axi u . Approxi ately 4 hours after the
end of charging, the electrolyte level
should be adjusted to the upper electrolyte
level ark “MAX” by using distilled or
deionized water in accordance with IEC
60993. For cells with steel cases, the
electrolyte level should be adjusted to the
axi u level according to the
“Instruction for the control of electrolyte
level”. During th charg th l ctrolyt
l v l and t mp ratur should b
obs rv d (s point 5.4). Th
l ctrolyt l v l should n v r fall b low
th “MIN” mark.
4. Charging in Op ration
4.1 Continous batt ry pow r supply
(with occasional battery discharge)
Reco ended charging voltage for
a bient te peratures + 20 °C to + 25 °C.
Do not re ove the vent caps during float-,
boost charge and buffer operation. The
current li it should be 0.3 It A axi u in
general.
4.
1.2 Two l v l charg
Floating: 1.40 – 1.42 V/cell
Boost charge: 1.55 – 1.70 V/cell
A high voltage will increase the speed and
efficiency of recharging the battery.
4.1.3 Singl l v l charg
1.45 – 1.50 V/cell
4.2 Buff r op ration
Where the load exceeds the charger
rating.
1.45 – 1.55 V/cell
5. P riodic Maint nanc
The battery ust be kept clean using only
water. Do not use a wire brush or solvents
of any kind. Vent caps can be rinsed in
clean water if necessary but ust be dried
before using the again.
Check regularly (approxi ately every 6
onths) that all connectors, nuts and
screws are tightly fastened. Defective vent
caps and seals should be replaced. All
etal parts of the battery should be
corrosion-protected by coating with a thin
layer of anti-corrosion grease. Do not
coat any plastic part of th batt ry, for
xampl c ll cas s!
Check the charging voltage. If a battery is
parallel connected it is i portant that the
reco ended charging voltage re ains
unchanged. The charging current in the
strings should also be checked to ensure it
is equal. These checks have to be carried
out once a year. High water consu ption
of the battery is usually caused by
i proper voltage setting of the charger.
5.1 Equalizing charg
It is reco ended to carry out an
equalizing charge once a year to aintain
capacity and to stabilize the voltage levels
of the cells. The equalizing charge can be
carried out for 15 hours at 0.2 It A or with
the boost charging stage in confor ity with
the characteristic curve of the available
charging equip ent. The electrolyte level
ust be checked after an equalizing
charge.
In order to equalize the floating derating
effect, it is reco ended to charge the
battery once a year for 15 hours at the
rated charging current 0.2 It A. Then
discharge the battery down to 1.0 V/cell
and charge again for 8 hours at the rated
charging current 0.2 It A.

4 Publication No: EN-GAZ-Standard-IOM 001 Dec 2012
5.2 El ctrolyt ch ck an
d topping
up
Check the electrolyte level and never let
the level fall below the lower level ark
“MIN”. Use only distilled or deionized water
to top-up the cells in accordance with IEC
60993. Experience will tell the ti e interval
between topping-up. Refilling with
electrolyte is only per issible if spilled
electrolyte has to be replaced. If during
refilling or topping up electrolyte has been
splashed onto the cell cover or between
the cell cases, clean this off and then dry
the area.
NOTE: Once the battery has been
filled with the correct electrolyte
either at the factory or during the
battery commissioning, there is no
need to check the electrolyte
density periodically. Interpretation
of density measurements is difficult
and could lead to
misunderstandings.
5.3 R placing of l ctrolyt
In ost stationary applications the
electrolyte will retain its effectiveness for
the total lifeti e of the battery. However,
under special battery operating conditions,
if the electrolyte is found to be carbonated,
the battery perfor ance can be restored by
replacing the electrolyte. Only us
g nuin l ctrolyt !
It is reco ended to change the
electrolyte when reaching a carbonate
content of 75 g/litre. It is possible to test
the electrolyte in the anufacturer’s
laboratory. For this, a ini u quantity of
0.2 litres of electrolyte in a clean glass or
polyethylene container should be sent in,
paying strict attention to the valid
dangerous goods regulations. The sa ple
of electrolyte should be taken half an hour
after charging has ended and fro several
cells of the battery. Do not take the
sa ples i ediately after topping up. The
electrolyte sa ple and the cells should be
closed i ediately after the electrolyte has
been taken.
CAUTION – caustic potash solution is
highly corrosiv !
5.4 El ctrolyt t mp ratur
The te perature of the electrolyte should
never exceed 45 °C as higher
te peratures have a detri ental effect on
the function and duration of the cells. In the
course of charging, ai for an electrolyte
te perature of
≤ 35 °C. On exceeding
45 °C the charging should be te porarily
interrupted until the electrolyte te perature
falls down to 35 °C. The te perature
easure ents are to be ade on one of
the cells in the iddle of the battery. Low
a bient or electrolyte te peratures down
to –25 °C do not have any detri ental
effect on the battery. They just cause a
te porary reduction in capacity.
6. Additional Warning not s
NiCd batteries ust not be installed or
stored in the sa e roo as lead acid
batteries. In addition to this, the charging
gases fro lead acid batteries ust be
kept away fro Ni-Cd batteries by suitable
precautions such as ventilation or her etic
isolation of the roo s. Tools for lead acid
batteries ust not be used for NiCd
batteries.
Do not place electrically conductive objects
such as tools, etc. on the battery!
Risk of short circuit and fir !
No rings or etal bracelets should be worn
during the asse bly of the battery – Risk
of injury!
Open the doors of the battery cabinet
during charging so that the charging gases
can escape. The charging gases fro
batteries are explosive. Do not allow open
fire or e ber in the vicinity of the battery!
Risk of xplosion!
Caution – potassium hydroxid
(KOH) solution is highly corrosiv !
Potassiu hydroxide (KOH) solution is
used as electrolyte. Potassiu
hydroxide (KOH) solution is a highly
corrosive liquid which can cause severe
da age to health if it co es into contact
with the eyes or the skin (risk of blinding). If
even s all quantities are swallowed there
is a possibility of internal injuries.
Wh n working with l ctrolyt and on
c lls / batt ri s rubb r glov s, saf ty
goggl s with sid guards and prot ctiv
clothing must always b worn!
Contact with th y s: Flush out
i ediately with abundant a ounts of
water for 10 – 15 inutes. If necessary
consult an eye clinic.
Contact with th skin: Re ove splashed
clothing i ediately and wash the affected
skin areas with abundant a ounts of
water. For any disco forts consult a
doctor.
Swallowing: Rinse out the outh
i ediately with abundant a ounts of
water and keep drinking large a ounts of
water. Do not provoke vo iting. Call an
e ergency doctor i ediately.
In th v nt of injuri s: Rinse thoroughly
for a long period under running water.
Consult a doctor i ediately.