Lucent Technologies Unigy II User manual

Unigy®II Batteries
WP-93379
Product Manual
Select Code 157-622-030
Comcode 107728016
Issue 4
March 2000
© 2000 Lucent Technologies

Product Manual
Select Code 157-622-030
Comcode 107728016
Issue 4
March 2000
Lucent Technologies
Unigy®II Batteries
WP-93379
Notice:
Every effort was made to ensure that the information in this
document was complete and accurate at the time of printing.
However, information is subject to change.
© 2000 Lucent Technologies
All Rights Reserved
Printed in U.S.A.

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 Table of Contents - 1
Table of Contents
1 Introduction
Unigy® II Batteries 1 - 1
Customer Assistance Contacts 1 - 3
Customer Training 1 - 3
Customer Service 1 - 3
Technical Support 1 - 3
Product Repair and Return 1 - 3
Warranty Service 1 - 4
On-Line Power Systems Product Manuals 1 - 4
2 Product Description
Overview 2 -1
Construction 2 -2
Container and Cover 2 -2
Grids 2 -2
Posts 2 -2
Post Seals 2 -2
Separators 2 -2
Intercell Connectors 2 -2
Safety Vent 2 -3
Safety Shields 2 -3
Specifications 2 -3
3 Ordering Information
Battery Modules 3 -1
Sample Order 3 -4
4 Safety and Environmental
Safety Symbols 4 -1
Safety Precautions 4 -1
Poison 4 -1
Electrical Hazard 4 -3
Battery Gases 4 -4
First Aid 4 -6

Lucent Technologies Unigy®II Batteries
2 - Table of Contents Issue 4 March 2000
Lifting Information 4 -6
Transportation and Handling 4 -6
Environmental 4 -6
5 Battery Storage
State of New Battery 5 -1
Storage Conditions 5 -1
Storage Time 5 -1
6 Installation
Introduction 6 - 1
Installation Tools, Materials, and Test Equipment 6 - 1
Accessory Package 6 - 2
Product Manual 6 - 2
Unpacking and Handling 6 - 2
Safe Handling 6 - 2
Specific Unpacking Instructions 6 - 3
Battery String Location 6 - 4
Environmental Requirements 6 - 4
Mixing Batteries in a String 6 - 5
Battery Installation 6 - 6
Module Assembly 6 - 6
Relay Rack Assembly 6 - 8
Electrical Connections 6 - 10
Connector Assembly 6 - 10
Terminal Assembly 6 - 11
Final Assembly and Verification 6 - 13
Initial Charging 6 - 13
Placing a Battery String Into Service 6 - 14
Installation Records 6 - 15
Voltage Measurements 6 - 15
Attaching Module Shield Assemblies 6 - 16
7 Operation
Lead-acid Battery Gassing Rate 7 - 1
Service Life 7 - 2
Charging 7 - 3
Battery String Float Voltage 7 - 4
Charging Voltage Ripple 7 - 4
Battery and Ambient Temperatures 7 - 4
Capacity 7 - 5
Temperature Correction for Capacity 7 - 5
Discharge Capacity Test 7 - 7

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 Table of Contents - 3
Recharge After Discharge 7 - 7
Boost Charge 7 - 7
8 Maintenance
Maintenance Schedule 8 - 1
Maintenance Routines 8 - 2
Individual Cell Voltages 8 - 2
Measuring Battery Temperatures 8 - 3
String Current Measurement 8 - 3
Inspection and Cleaning 8 - 3
Retorquing Inter-battery Connections 8 - 3
Flame Arrestor Vent Feature 8 - 3
Cell Replacement 8 - 4
9 Discharge and Power Data
10 Installation and Maintenance Record
11 Material Safety Data Sheet
12 Product Warranty

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 List of Figures - 1
List of Figures
Figure 1-1: Unigy® II Battery 1 - 2
Figure 6-1: Unigy® II Battery Module with Lifting Straps 6 - 2
Figure 6-2: Unigy® II Battery Modules 6 - 7
Figure 6-3: Battery Module Assembly 6 - 7
Figure 6-4: Base Support Placement 6 - 8
Figure 6-5: Module Placement 6 - 9
Figure 6-6: Stabilizing Bracket Placement 6 - 9
Figure 6-7: Connector Assembly 6 - 10
Figure 6-8: Side Terminal Assembly 6 - 11
Figure 6-9: Top Terminal Assembly 6 - 12
Figure 6-10: Top Terminal Assembly 6 - 12
Figure 6-11: Cable Connection Assembly 6 - 13
Figure 6-12: Module Shield Assembly 6 - 17
Figure 6-13: Side Terminal Assembly 6 - 17
Figure 6-14: Top Terminal Assembly 6 - 18
Figure 7-1: Temperature Correction Chart 7 - 6
Figure 8-1: Hardware Removal 8 - 4
Figure 8-2: Valve Removal 8 - 5
Figure 8-3: Cell Removal and Replacement 8 - 5

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 List of Tables - 1
List of Tables
Table 2-A: Specifications for Unigy® II Batteries 2 -3
Table 3-A: Unigy® II Battery Modules
Ordering Information 3 -1
Table 6-A: Initial Charging 6 - 14
Table 7-A: Float Voltages 7 - 3
Table 8-A: Required Maintenance Routines 8 - 1
Table 12-A: New Product Warranty Periods and
Conditions 12 - 1

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 Introduction 1 - 1
1 Introduction
Unigy®II
Batteries This product manual (Select Code 157-622-030) provides information
on Lucent Technologies’ Unigy®II batteries. The Unigy®II battery is
a stationary, valve-regulated, rechargeable, lead-acid battery backed by
Bell Laboratories, an acknowledged leader in technology, research, and
design of power systems.
Lucent Technologies power products have proven their field reliability
by providing dependable standby reserve power for the
telecommunications industry for decades. All battery components and
the manufacturing processes meet Lucent Technologies' strict
specifications and quality standards.
Designed for applications where loads are large, temperatures are
controlled, and long backup time is desired, Unigy®II batteries are an
excellent choice for huts and controlled environment vaults (CEVs),
remote switching offices, small- to medium-sized central offices, and
customer premise applications.
Figure 1-1 is a cut-away view of a Unigy®II battery.

Lucent Technologies Unigy®II Batteries
1 - 2 Introduction Issue 4 March 2000
Figure 1-1: Unigy®II Battery
Polypropylene
Cover and Jar
(28% L.O.I. Optional)
Copper Posts
with Large
Contact Area
All Seals
100% Air and
Water Tested
Epox-Z™
Post Seal
Tested to 80°C
(176°F)
Hovosorb®II
Glass Mat
Separators
Collapsible
Bottom Bridge
Pure Lead
Positive Grid
Alloy (99.2%)
Tank-Formed Plates
(All cells shipped at
100% capacity.)
Tear Guard

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 Introduction 1 - 3
Customer
Assistance
Contacts
Customer Training Lucent Technologies offers customer training on many Power Systems
products. For information call 1-972-284-2163. This number is
answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6),
Monday through Friday.
Customer Service For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797). Services
provided through this contact include initiating the spare parts
procurement process for out of service emergencies, ordering Lucent
Technologies documents, and providing other product and service
information.
For other customers worldwide, call 001-972-840-0382. This number is
answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6),
Monday through Friday.
Technical Support Technical support for Lucent Technologies customers is available
around the world during the normal product warranty period and also
while specific contractual agreements extend this service.
For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-CAL-RTAC (1-800-225-7822) to contact a
product specialist to answer your technical questions and assist in
troubleshooting problems.
For other customers worldwide, contact your local field support center
or your sales representative to discuss your specific needs.
ProductRepairand
Return Repair and return service is provided for Lucent Technologies
customers around the world.
For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-255-1402 for information on returning of
products for repair.
For other customers worldwide, contact your sales representative to
discuss your particular circumstances.

Lucent Technologies Unigy®II Batteries
1 - 4 Introduction Issue 4 March 2000
Warranty Service For domestic warranty service, contact your Warranty Service Manager
(WSM). For international warranty service, contact your sales
representative.
On-Line Power
Systems Product
Manuals
For Lucent Technologies users logging in from inside the corporate
firewall, the address of the “Power Systems On-Line Product Manuals”
page is http://www.cic.lucent.com/lineage.html.
For customers logging in from outside the firewall, the address is
http://www.lucent8.com/lineage.html. The annual subscription fee for
access to this site is $25. To obtain a password, follow the instructions
on-line or call 1-888-Lucent8 (1-888-582-3688). When prompted for an
order number, enter or say “167-790-010.”

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 Product Description 2 - 1
2 Product Description
Overview Unigy®II batteries are the solution for quality, valve-regulated
rechargeable stationary lead-acid batteries reserve requirements from
160Ah to 4200Ah at the 8-hour rate.
The Unigy®II batteries consist of free-standing modules stacked and
assembled in various configurations to meet varying site requirements.
Standard modules contain 1, 3, or 6 two-volt cells with each cell
containing from 5-33 positive and negative plates of 75 or 85Ah
capacity. The module space between cells for heat dissipation provides
consistent operation over the life of the battery.
The Unigy®II battery occupies a slightly larger footprint than others in
the market due to its innovative design for greater thermal and age
management over its life. This size impact is seen primarily in the
module design and the depth of the battery jars. The unique module
design ensures spacing between battery cells to aid in heat dissipation,
without which battery life and performance is reduced. When multiple
modules are assembled together, the sturdy module construction
provides the benefits of a solid battery stand that passes Zone 4 seismic
testing.
A primary feature of Lucent Technologies Unigy®II batteries is the
valve-regulated design and construction that prevents electrolyte
leakage and minimizes water loss and maintenance throughout the
design life. During normal operation, oxygen isgenerated at the positive
electrode and hydrogen is generated at the negative electrode. In
conventional (flooded) lead-acid cells, these electrochemical reactions
result in water loss from the electrolyte. The self-resealing pressure
release safety valves in Unigy®II batteries are designed to aid in the
electrochemical recombination of nearly all the oxygen within the
battery. In addition, the safety valves prevent the build-up of excessive
internal pressure.

Lucent Technologies Unigy®II Batteries
2 - 2 Product Description Issue 4 March 2000
The Unigy®II batteries comply with the requirement for sealed
battery/cell pressure release test of UL924, Standard for Emergency
Lighting and Power Equipment, and UL1989, Standard for Standby
Batteries.
Construction
Container and
Cover The standard cell case and cover material is impact resistant polypropylene. Also available are an optional case and cover that are
constructed of flame retardant, UL94 V-0/28% Low Oxygen Index
(L.O.I.) polypropylene.
Grids Primarily made of pure lead, the grids exhibit slow growth and provide
easy reclamation of spent batteries. The increased depth of the battery
jars accommodates the minimal grid expansion as it occurs. An
exclusive collapsible bridge under the plates provides room for the
plates to grow without harm to battery post and jar-to-cover seals. Tank
formation of plates ensures uniform voltages of all cells.
The positive grid is 99.2% pure lead, 0.8% tin; the negative grid is lead
calcium.
Posts The cell terminals are solid copper with lead plating, and are designed
for maximum conductivity. Cells with up to 15 plates have two posts,
cells with 17 to 27 plates have four posts, and cells with 29 to 33 plates
have six posts.
Post Seals The redesigned and recently automated epoxy post seal uses new
Epox-zmaterial, which has been tested to 176°F (80°C) to ensure seal
integrity. The epoxy around the post seals is color-coded for positive
and negative to aid proper installation.
Separators The separators are microporous glass mats.
Intercell
Connectors The intercell connectors are tin-plated solid copper.

Lucent Technologies Unigy®II Batteries
Issue 4 March 2000 Product Description 2 - 3
Safety Vent Each 2-volt cell contains a pressure-regulating vent located in the jar
cover. The low pressure, self-sealing vent is covered with a porous
plastic disk that acts as a flame arrestor. The flame arrestor prevents
sparks from entering the battery cell. In multi-cell configurations, the
vents and flame arrestors are hidden from view by the bus bar cover.
Safety Shields The flame-retardant, clear plexiglass shields protect the terminal posts
and terminal plate assembly from shorting.
Specifications
Table 2-A: Specifications for Unigy®II Batteries
Life 20 Years in Float Applications at 77°F (25°C)
Float Voltage 2.25 ± 1% Volts per Cell (Temperature Compensated)
Self-Discharge <2% Per Month at 77°F (25°C)
Voltage Stabilization Occurs within days after initial float charge
Cell Performance 100% of rated capacity at shipment
Recombination
Efficiency Greater than 99%