First National Battery RAYLITE M-SOLAR User manual

RAYLITE M-SOLAR
BATTERIES
INSTALLATION AND
MAINTENANCE INSTRUCTIONS

SAFETY WARNINGS
NO CHILDREN. Children must be kept away from batteries at all times.
EXPLOSION HAZARD, NO SMOKING, NO
NAKED FLAMES. Batteries generate highly explosive gasses during charge.
No smoking, sparks or any form of naked flame is to be allowed near the battery at
any time. Assume that there is explosive gas present above the cells at all times.
Keep the battery tops clear from all conductive objects that may cause a spark. Use
an insulated torque wrench when assembling the battery. To avoid electrostatic
build-up use a damp cloth when cleaning cells. In order to prevent electrical tracking
between cells keep the cell tops clean and mop up any spillage.
ELECTRIC SHOCK. The battery remains live at all times, even if
isolated and discharged. The threshold voltage for fatal electric shock is lower with
Direct Current than with alternating Current.
CORROSIVE ACID. Battery electrolyte contains dilute sulphuric acid.
This is highly corrosive and can cause severe skin burns. If spilt or splashed onto
skin or clothing, neutralise with a solution of baking powder and water. If splashed
into the eyes wash for at least 15 minutes with copious amounts of water and consult
a doctor as soon as possible.
PROTECTIVE CLOTHING. Wear eye protection (goggles or face
mask) and rubber gloves when working on the battery. An acid resistant (rubber or
plastic) apron and thick rubber soled shoes are also recommended.

SIZING OF M-SOLAR INSTALLATIONS
It is recommended that the battery be sized to limit the daily depth of discharge to
20% of the 100-hour rate capacity. This caters for up to 5 days of cloudy weather
whilst giving optimum life expectancy.
The daily consumption can be calculated by taking each electrical item’s wattage
and estimating the maximum time in hours that it is likely to run each day. The
product of these two figures will give the Watt-hour consumption each day. Totaling
the result for each item will give the system consumption per day. Alternatively many
web sites give the expected consumption for household appliances.
The total daily Watt-hour consumption divided by the overall nominal battery voltage
will give the Ampere-hours required each day. Multiplying this by 5 will indicate the
size of battery required.
The solar array must be able to deliver sufficient power to supply the load and
recharge the battery on an average day of irradiation plus have reasonable excess to
cater for the recharge over a few days when the battery is more deeply discharged
due to consecutive days of poor weather.
PREPARING THE BATTERY FOR SERVICE
UNPACKING
Clean off any packing material from the cells and trays. Examine carefully to see if
there has been any damage in transit.
Check that all components have been supplied.
Cells may be supplied loose or pre-assembled in 4 volt (2 cell) or 6 volt (3cell)
trays. If in trays, inter-tray cables and two take-off cables will be supplied. If
loose cells, inter-cell cables and two take-off cables are supplied.
One electrolyte level indicator per cell.
One Installation and Maintenance Manual (this document).
One battery log book.
One hydrometer.
Important: Any damage or shortages must be reported to the carrier and First
National Battery must be notified.
PREPARING THE CELLS
•Open all vent filler plugs and examine the electrolyte levels in all cells.
•Check all specific gravities (25°C).
•Batteries can be put into service immediately, provided the specific gravities are
above 1.240 (25°C) and electrolyte levels are correct.
If the specific gravities are below 1.240 it is necessary to give the battery an
equalizing charge. This consists of charging at a constant current of 2.5% to 5% of

the C100 capacity until the voltages and specific gravities have remained constant
over 3 x 1 hourly readings.
If the battery is not required immediately for service, it should be stored under roof in
a cool, clean, dry and well-ventilated area. Where connection has not been made to
the cell terminals, remove the covers, wipe the terminals clean and apply a thin layer
of Vaseline to the outer surface. Replace the terminal covers. Equalize charge at
three monthly intervals or whenever the cell voltage drops below 2.05Vpc (Volts per
cell) or the specific gravity drops below 1.210. The electrolyte levels should be
adjusted as required by topping up with approved water.
WIRING STANDARDS
Comply with all local regulations concerning codes of practice that apply to
electrical/battery installations.
BATTERY ASSEMBLY
If the cells have been supplied loose assemble the battery in the container/s. If (for
whatsoever reason) cells are not in plastic moulded trays or steel tanks, it is
essential that cells be strapped together so as to support the internal plates of the
cells while in operation. This should be done as follows.
1 Wooden boards ≥18mm thick should be used as support when strapping the
cells.
2 Note: In all cases, the wooden boards must be fitted against the 158mm
width face of the cells / or 198mm in case of DIN cells. See Figure 3 below.
3 It is not necessary to place boards against the length of the cells.
4 It is not recommended to strap more than 2 rows of cells together as this can
potentially reduce the support on the ends of the rows as well as prevent
adequate air cooling to the cells.
5 Cell packing spacers must be placed between cells. A minimum of at least
one spacer should be used to separate four strapped cells.
6 Note: Fitting spacers between each cell will give the cells a better chance of
working cooler in operation, which is beneficial to the life of the cell.
7 Cells must be firmly strapped, reducing any bulging of the cells on the
supported ends.
8 Do not over tighten the strapping. The walls of the cell container must be
perpendicular and square and not bow inwardly or push inwardly due to over
tightening of the support boards.

9 Caution: strapping the cells will cause acid levels inside the cells to rise,
especially with taller cells. If the electrolyte levels rise above maximum, any
surplus acid should be removed.
10 It is important to support the cell adequately across the full height of the cell.
Depending on the cell height, 2 to 3 ratchet tie down should be used.
11 Failure to provide this support will nullify any warranty.
Where connectors have not yet been fitted remove the bolts, wipe the terminals
clean and apply a light coating of Vaseline to the outer surface of the terminal.
Connect the cells together using the inter-connectors provided ensuring that the cells
are connected negative to positive throughout. When numbering the cells always
begin at the positive end as cell number 1.
Connect the take-off cables one at a time, terminating both ends of the first cable
before connecting the second. When connecting the second take-off connect at the
battery first before connecting to the charger side. This minimises the chance of
creating a spark close to the battery.
Fit the float level indicators. Check that the indicators move freely and are at the ‘full’
level. If the levels are low do not top up until the battery has been fully charged.
COMMISSIONING
Switch on the solar array. Check that all regulator settings are correct (see Solar
System Set Points). Allow the battery to be fully charged before applying any loads.
When fully charged take and record temperature corrected individual specific gravity
and cell voltage plus pilot electrolyte temperature readings (see Temperature
Correction of Specific Gravities). These readings provide a base that can be referred
to when assessing the condition of individual cells during the battery life.