EnerSys Varta RL User manual

Publication No: EN-VARTA-NB-IS-001 - September 2006
Instruction Sheet
For VARTA RL, RM, RN, RH, TP, TSP
The electrolyte is
harmful to skin and
eyes, therefore, after
contact wash
immediately with plenty of clean
water. If eyes are affected flush with
water and consult a doctor
immediately. Clothing contaminated
by electrolyte should be washed in
water immediately!
Risk of explosion and
fire - avoid short
circuits!
Warning! Metal parts of the battery
are always fraught with voltage, so
never place objects or tools on the
battery!
When working on
batteries wear safety
goggles and protective
clothing. Remove all
rings, watches and other items with
metal parts before working on the
battery! Only use insulated tools!
Strictly observe the accident
prevention regulation as well as DIN
VDE 0510, VDE 0105, Part 1.No smoking! Do not
allow open fire, ember
or sparks near the
battery due to the risk
of explosion or fire!
Electrolyte is highly
corrosive!
Cells are heavy!
Make sure they are
safely installed!
Only use suitable transport
equipment!
Observe the instructions
for use and position
them visibly near the
battery! Only qualified
personnel should work on batteries!
Warning!
The gases emitted during charging are explosive. The electrolyte (potash lye) is
highly corrosive. Exposed metal parts of the battery always conduct a voltage
and are electrically active parts. Precautions in accordance with DIN VDE 0510,
Part 2 have to be observed.
The Maintenance and Handling Instructions must be strictly observed.
Non-compliance with the Maintenance and Handling Instructions, replacing with
unoriginal spares, usage other than specified, use of additives to the electrolyte
and unauthorised tampering will invalidate any entitlement to warranty.
Do not place electrically conductive objects such as tools, etc. on the battery!
Risk of short circuit and fire!
No rings or metal bracelets should be worn during the assembly 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 from batteries are explosive. Do not allow open
fire or ember in the vicinity of the battery! Risk of explosion!
Caution - caustic potash solution is corrosive!
Caustic potash solution is used as electrolyte. Caustic potash solution is a highly
corrosive liquid which can cause severe damage to health if it comes into contact
with the eyes or the skin (risk of blinding). If even small quantities are swallowed
there is a possibility of internal injuries.
When working with electrolyte and on cells / batteries rubber gloves, safety
goggles with side guards and protective clothing must always be worn!
Contact with the eyes: Flush out immediately with copious amounts of water for
10 - 15 minutes. If necessary consult an eye clinic.
Contact with the skin: Remove splashed clothing immediately and wash the
affected skin areas with copious amounts of water. For any discomforts consult
a doctor.
Swallowing: Rinse out the mouth immediately with copious amounts of water
and keep drinking large amounts of water. Do not provoke vomiting. Call an
emergency doctor immediately.
In the event of injuries: Rinse thoroughly for a long period under running water.
Consult a doctor immediately.
WARNING !
Never use sulphuric acid or acidic water. Acid will damage the battery!
Old batteries with this symbol are reusable products
and have to be put into a recycling system. Old batteries
must be disposed of as special waste in accordance
with all standards and all regulations.
Ni-Cd
Cd
Index:
1. Receiving the battery 2
2. Storage 2
2.1 Uncharged and unfilled cells
2.2 Charged and filled cells/ discharged and filled cells
3. Installation 2
3.1 Location
3.2 Ventilation
3.3 Setting up
3.4 Electrolyte
3.5 Commissioning
3.5.1 Commissioning with constant current
3.5.2 Commissioning with constant voltage
4. Charging in operation 3
4.1 Continuous battery power supply
(with occasional battery discharge)
4.1.1 Two level charge
4.1.2 Single level charge
4.2 Buffer operation
5. Periodic Maintenance 3
5.1 Equalising charge
5.2 Electrolyte check and topping up
5.3 Replacing of electrolyte
5.4 Electrolyte temperature
6. Additional warning notes 4

2Publication No: EN-VARTA-NB-IS-001 - September 2006
www.enersys.com
1. Receiving the battery
The cells are not to be stored in packaging, therefore, unpack the
battery immediately after arrival. Do not overturn the package. The
battery cells are equipped with a blue plastic transport plug.
The battery can be delivered:
Filled and charged / the battery is ready for installation. Replace
the transport plug with the vent cap included in our accessories
just before use
Filled and discharged / Replace the transport plug with the vent
cap included in our accessories just before use
Unfilled and discharged / do not remove the transport plug until
ready to fill the battery.
Before any electrical operation is carried out on the new battery it
has to be ensured that cells are filled with electrolyte and the
transport plugs are removed from the cells and replaced by vent
plugs.
2. Storage
The rooms provided for storing the batteries must be clean, dry,
cool (+10°C to 30°C - in compliance with IEC 60623) and well
ventilated. The cells are not to be stored in closed packaging and
must not be exposed to direct sunlight or UV-radiation.
If the cells are delivered in plywood boxes, open the boxes before
storage and remove the packing material on the top of the cells. If
the cells are delivered on pallets remove the packing material on
the top of the cells.
2.1 Uncharged and unfilled cells
Provided the correct storage conditions are met then the cells and
batteries can be stored for long periods without damage if they are
deeply discharged, drained and well sealed. It is very important that
the cells are sealed with the plastic transport plug tightly in place. It
is necessary to check the transport plug after receipt and at least
every year. Leaky plugs allow the carbon dioxide from the
atmosphere to infiltrate the cell, which will result in carbonation of
the plates. This may influence the capacity of the battery.
2.2 Charged and filled cells/ discharged and filled cells
Filled cells can be stored for up to 12 months from the time of
delivery.
Storage of filled cells at a temperature above +30°C results in loss of
capacity of approximately 5% per 10°C per year. It is very important
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 “MIN” mark before storage.
3. Installation
Battery installations have to be in accordance with EN 50272-2:2001.
For non stationary installations specific standards are valid.
3.1 Location
Install the battery in a dry and clean room. Avoid direct sunlight and
heat in all cases. The battery will give the optimal performance and
maximum service life if the ambient temperature lies between
+10°C and +30°C.
3.2 Ventilation
Before end of charge, battery can release a mixture of oxygen and
hydrogen which is directly proportional to the charge current. At
normal float charge the gas evolution is very small but some
ventilation is necessary.
Special regulations for ventilation might be required in your area
for certain applications.
3.3 Setting up
Always follow the assembly drawings, circuit diagrams and other
separate instructions. The transport plugs have to be removed by
the vent caps included in the accessories. If batteries are supplied
“filled and charged”, first of all the electrolyte level 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 fixed. Terminal nuts, screws and connectors must be
tightly fixed. If necessary tighten with a torque wrench.
Torque loading for:
M10: 8 Nm
M16: 20 Nm
M20: 25 Nm
Female thread:
M 8: 20 - 25 Nm
M10: 25 - 30 Nm
The connectors and terminals should be corrosion-protected by
coating with thin layer of anti-corrosion grease.
3.4 Electrolyte
The electrolyte for NiCd batteries is a diluted caustic potash solution
(specific gravity 1.20 kg/litre ±0.01 kg/litre) with a lithium hydroxide
component, in accordance with IEC 60993. The caustic potash
solution is prepared in accordance with factory regulations. The
specific gravity of the electrolyte does not indicate the charging state
of the battery. It changes only slightly during charging and
discharging and is only minimally related to the temperature.
Battery delivered unfilled and discharged / if the electrolyte is
supplied dry, it is to be mixed according to the enclosed mixing
instruction. Remove the transport plugs from the cell just before
filling. Fill the cells up to 20 mm above the lower level mark “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.
Battery delivered filled and charged or discharged / check
electrolyte level. It should not be less than 20 mm below the upper
level mark “MAX” (see 5.2).
3.5 Commissioning
A good commissioning is very important. The following instructions
are valid for commissioning between 20°C to 30°C. For different
conditions please contact the manufacturer. 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, 0.2C5A is also expressed as 0.2 lt A.
The reference test current is expressed as:
lt A= Cn Ah
1 h
3.5.1 Commissioning with constant current
Battery delivered unfilled and discharged / after a period of 5 hours
from filling the electrolyte, the battery should be charged for
15 hours at the rated charging current 0.2 lt A. Approximately
4 hours after the end of charging the electrolyte level should be
adjusted to the upper electrolyte level marked “MAX” by using only
genuine electrolyte. For cells with steel cases the electrolyte level
should be adjusted to the maximum level according to the
“Instruction for the control of electrolyte level”. During the charge
the electrolyte level and temperature should be observed (see point
5.4). The electrolyte level should never fall below the “MIN” mark.

3
Publication No: EN-VARTA-NB-IS-001 - September 2006
www.enersys.com
Battery delivered filled and discharged / the battery should be
charged for 15 hours at the rated charging current 0.2 lt A.
Approximately 4 hours after the end of charging the electrolyte level
should be adjusted to the upper electrolyte level marked “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
maximum level according to the “Instruction for the control of
electrolyte level”. During the charge the electrolyte level and
temperature should be observed (see point 5.4). The electrolyte
level should never fall below the “MIN” mark.
Battery delivered filled and charged and stored for more than
12 months / the battery should be charged for 15 hours at the rated
charging current 0.2 lt A. Approximately 4 hours after the end of
charging the electrolyte level should be adjusted to the upper
electrolyte level marked “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 maximum level according
to the “Instruction for the control of electrolyte level”. During the
charge the electrolyte level and temperature should be observed
(see point 5.4). The electrolyte level should never fall below the
“MIN” mark.
Battery delivered filled and charged / a 5 hour charge at the rated
charging current 0.2 lt A must be carried out before setting the
battery into service. Approximately 4 hours after the end of charging
the electrolyte level should be adjusted to the upper electrolyte level
marked “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 maximum level according to the “Instruction for
the control of electrolyte level”. During the charge the electrolyte
level and temperature should be observed (see point 5.4). The
electrolyte level should never fall below the “MIN” mark.
3.5.2 Commissioning with constant voltage
If the charger´s maximum voltage setting is too low to supply
constant current charging, divide the battery into two parts that will
be charged individually.
Battery delivered unfilled and discharged / after a period of 5 hours
from filling the electrolyte, the battery should be charged for 30
hours at the rated charging voltage of 1.65 V/cell. The current limit
should be 0.2 lt A maximum. Approximately 4 hours after the end of
charging the electrolyte level should be adjusted to the upper
electrolyte level marked “MAX” by using only genuine electrolyte.
For cells with steel cases, the electrolyte level should be adjusted to
the maximum level according to the “Instruction for the control of
electrolyte level”. During the charge the electrolyte level and
temperature should be observed (see point 5.4). The electrolyte
level should never fall below the “MIN” mark.
Battery delivered filled and discharged / the battery should be
charged for 30 hours at the rated charging voltage of 1.65 V/cell. The
current limit should be 0.2 lt A maximum. Approximately 4 hours
after the end of charging the electrolyte level should be adjusted to
the upper electrolyte level marked “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 maximum level
according to the “Instruction for the control of electrolyte level”.
During the charge the electrolyte level and temperature should be
observed (see point 5.4). The electrolyte level should never fall
below the “MIN” mark.
Battery delivered filled and charged and stored for more than 12
months / the battery should be charged for 30 hours at the rated
charging voltage of 1.65 V/cell. The current limit should be 0.2 lt A
maximum. Approximately 4 hours after the end of charging the
electrolyte level should be adjusted to the upper electrolyte level
marked “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 maximum level according to the “Instruction for
the control of electrolyte level”. During the charge the electrolyte
level and temperature should be observed (see point 5.4). The
electrolyte level should never fall below the “MIN” mark.
Battery delivered filled and charged / a 10 hour charge at the rated
charging voltage of 1.65 V/cell must be carried out before putting the
battery into operation. The current limit should be 0.2 lt A maximum.
Approximately 4 hours after the end of charging the electrolyte level
should be adjusted to the upper electrolyte level marked “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
maximum level according to the “Instruction for the control of
electrolyte level”. During the charge the electrolyte level and
temperature should be observed (see point 5.4). The electrolyte
level should never fall below the “MIN” mark.
4. Charging in operation
4.1 Continuous battery power supply (with occasional battery
discharge)
Recommended charging voltage for ambient temperatures + 20°C
to + 25°C
Do not remove the vent caps during float, boost charge and buffer
operation. The current limit should be 0.3 lt A maximum in general.
4.1.1 Two level charge
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.
4.1.2 Single level charge: 1.45 - 1.50 V/cell
4.2 Buffer operation: Where the load exceeds the charger rating.
1.45 - 1.55 V/cell
5. Periodic Maintenance
The battery must 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 must be dried before using them again.
Check regularly (approximately every 6 months) that all connectors,
nuts and screws are tightly fastened. Defective vent caps and seals
should be replaced. All metal 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 the battery, for example cell
cases!
Check the charging voltage. If a battery is parallel connected it is
important that the recommended charging voltage remains
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 consumption of the battery is usually
caused by improper voltage setting of the charger.
5.1 Equalising charge
It is recommended to carry out an equalising charge once a year to
maintain capacity and to stabilise the voltage levels of the cells. The
equalising charge can be carried out for 15 hours at 0.2 lt A or with
the boost charging stage in conformity with the characteristic curve
of the available charging equipment. The electrolyte level must be
checked after an equalising charge.
In order to equalise the floating derating effect it is recommended to
charge the battery once a year for 15 hours at the rated charging
current 0.2 lt A. Then discharge the battery down to 1.0 V/cell and
charge again for 8 hours at the rated charging current 0.2 lt A.

www.enersys.com
EnerSys EMEA
Brussels, Belgium
Tel: [phone]
EnerSys Asia
Guangdong, China
Tel: [phone]
EnerSys Limited
Rake Lane,
Clifton Junction,
Swinton, Manchester
M27 8LR, UK
Tel: [phone]
Fax: [phone]
EnerSys
P.O. Box 14145
Reading, PA 19612-4145
USA
Tel: [phone]
[phone]
Fax: [phone]
Contact:
© 2006 EnerSys. All rights reserved.
Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. VARTA is a registered trademark of Varta Automotive Systems GmbH, used under license.
Publication No: EN-VARTA-NB-IS-001 - September 2006- Subject to revisions without prior notice. E.&O.E.
5.2 Electrolyte check and topping up
Check the electrolyte level and never let the level fall below the lower
level mark “MIN”. Use only distilled or deionized water to top-up the
cells in accordance with IEC 60993. Experience will tell the time
interval between topping-up. Refilling with electrolyte is only
permissible 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 Replacing of electrolyte
In most stationary applications the electrolyte will retain its
effectiveness for the total lifetime of the battery. However, under
special battery operating conditions, if the electrolyte is found to be
carbonated, the battery performance can be restored by replacing the
electrolyte. Only use genuine electrolyte!
It is recommended to change the electrolyte when reaching a
carbonate content of 75 g/litre. It is possible to test the electrolyte in
the manufacturer’s laboratory. For this a minimum 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 sample of electrolyte should be taken half an hour
after charging has ended and from several cells of the battery. Do not
take the samples immediately after topping up. The electrolyte sample
and the cells should be closed immediately after the electrolyte has
been taken.
CAUTION - caustic potash solution is corrosive!
5.4 Electrolyte temperature
The maximum recommended electrolyte temperature is 50°C.
For optimal product life and performance, the recommended average
temperature is ≤35°C. Continuous operation with electrolyte
temperature > 45°C can impact product life and performance.
Electrolyte temperature readings are to be made on one of the cells in
the middle of the battery
Low ambient or electrolyte temperatures down to -25 °C do not have
any detrimental effect on the battery. They just cause a temporary
reduction in capacity.
6. Additional warning notes
NiCd batteries must not be installed or stored in the same room as
lead acid batteries. In addition to this the charging gases from lead
acid batteries must be kept away from Ni-Cd batteries by suitable
precautions such as ventilation or hermetic isolation of the rooms.
Tools for lead acid batteries must not be used for NiCd batteries.
Layout details: inter unit connection
A) nut connection B) screw connection
1) cell container 2) cell connector
3) spring washer 4) nut
5) connector cover
1) cell container 2) cell connector
3) spring washer 4) screw
5) connector cover