NorthStar NSB12-310 Instructions for use

Form: SES-541-01711
Issued: 12-08-16
ECO-101191

Table of Contents
AGM Thin Plate Lead Carbon Technology
Page Secon Title
3 - Quick Start Guide
4 1 Introducon
4 2 Charge
5 3 Discharge
6 4 Useful Life
6 5 Technical Specicaons
7 6 Baery Safety
7 7 Determining Baery Manufacturing Date
8 8 Handling
8 9 Storage
9 10 Commissioning/Installaon
12 11 Maintenance
13 12 Warranty Informaon
13 13 Contact Informaon
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

NorthStar UPS Quick Start Guide
Unpacking the Baeries
When received, the baeries should be inspected.
Make sure the baeries were not damaged during
transport, and that all the proper accessories were
included in the delivery. If problems arise, please
iniate a claim immediately.
Note: * indicates where further informaon can be
found in the NSB UPS Applicaon Manual. Warnings
and nocaons can be found on the label (shown
below) which appears on each product. Be aware and
adhere to all warnings which appear on the product.
15
BATTERY MUST
BE RECYCLED
Pb
Pb
Manufactured by:
NorthStar Battery Company
417 575 8000
MADE IN USA
DANGER
NON-SPILLABLE / NON-SERVICEABLE
Ensure reference materials are reviewed and made available to all operators
including application manual, installation guide, and MSDS.
Contains: Lead, Sulfuric Acid (Electrolyte), Lead Compounds, Arsenic
Harmful if swallowed, inhaled, or in contact with skin.
Acid causes severe skin burns and eye damage.
May damage fertility or the unborn child if ingested or inhaled.
May cause harm to breast-fed children.
May cause cancer if ingested or inhaled.
Causes skin irritation, serious eye damage.
Contact with internal components may cause irritation or severe burns.
Causes damage to central nervous system, blood and kidneys through prolonged
or repeated exposure if ingested or inhaled.
Irritating to eyes, respiratory system, and skin.
May form explosive air/gas mixture during charging.
Obtain special instructions before use.
Do not handle until all safety precautions have been read and understood.
Wash thoroughly after handling.
Do not eat drink or smoke when using this product.
Avoid contact during pregnancy/while nursing.
Wear protective gloves/protective clothing, eye protection/face protection.
Use only outdoors or in a well-ventilated area.
Avoid contact with internal acid.
Do not breathe dust/fume/gas/mist/vapors/spray.
IF SWALLOWED OR CONSUMED: rinse mouth. Do NOT induce vomiting. Call a
poison center/doctor if you feel unwell.
clothing and wash it before reuse. Rinse skin with water/shower.
IF INHALED: Remove person to fresh air and keep comfortable for breathing.
Immediately call a POISON CENTER or doctor/physician.
IF IN EYES: Rinse cautiously with water for several minutes. Remove contact lenses,
if present and easy to do. Continue rinsing.
If exposed/concerned, or if you feel unwell seek medical attention/advice.
Store locked up, in a well-ventilated area, in accordance with local and
national regulation.
Dispose of contents/container in accordance with local and national regulation
Keep out of reach of children.
PROPOSITION 65 WARNING: Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other
chemicals known to the State of California to cause cancer. Wash hands after handling.
WARNING: ºC or incinerate. Not recommended for inverted use.Follow product charging instructions.
ISO
9001
14001
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Installaon
1. Before proceeding with the installaon of the
baery, review or determine the arrangement of the
baeries for the applicaon.
2. Checking the voltage spread is vital before
connecng the monoblocks in series. Refer to secon
10.2 for more informaon.
3. If installing mulple parallel strings, the cabling to
each string should be the same size and approximate
length resulng in the same resistance per string.
*(Baery Connecon to Load/Charger 10.12)
4. The cable size selected should consider allowable
voltage drop of ≤ 0.5V
*(Baery Connecon to Load/Charger 10.12)
5. Carefully install baeries into posion as
determined. The baery should be oriented so that
the negave (-) post of one baery is adjacent to the
posive (+) post of the next adjacent baery.
6. Make sure the baeries are all evenly spaced
approximately 10mm (3/8 inch) apart.
7. Check that all contact surfaces are clean, and then
install the bloc or cell connectors and the terminal
screws using the torque value printed on the baery
label. *(Commissioning/Installaon 10.9)
8. The insulaon covers should be put back aer all
connecons have been completed.
*( Commissioning/Installaon 10.10)
Charging
8. It is highly recommended to give the baeries a
refreshing charge prior to commissioning. A refreshing
charge shall be performed with at least 2.35 V/cell at
25°C (77°F) for at least 24 hours. Failure to observe
these condions may result in greatly reduced capacity
and service life. *(Charge 10.14)
9. The opmum level for oat charging the NSB UPS
baeries is 2.27 volts/cell at 25°C (77°F). *(Charge 2.2)
a. Example: 40 baery string = 544.8V
b. Example: 32 baery string = 435.8V
10. If the ambient temperature increases above
25°C (77°F), a thermal compensaon of -2 mV/cell/°C
is recommended. Conversely, if the temperature
decreases below 25°C (77°F), the voltage should be
increased by 2 mV/cell/°C. *(Charge 2.2)
11. Verify the baery string voltage matches the
recer output voltage. *(Maintenance 11.3)
12. If a voltage dierence is idened due to a voltage
drop in the cables, then the recer must be adjusted
unl the baery string voltage is within baery
specicaon.
www.northstarbaery.com
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

1 Introducon
UPS baeries from NorthStar Baery (NSB) Compa-
ny provide excellent high-rate discharge and recharge
performance for mission crical applicaons. Ab-
sorbed-Glass-Microbre (AGM) technology is ulized,
which means the electrolyte is fully absorbed in a very
ne glass mat. This allows for very ecient recombina-
on of any gas generated during the charging process.
The release of gas from NSB baeries is very low, hence
natural venlaon is sucient for both cooling and the
dissipaon of any gas formed during inadvertent over-
charge. Hence, NSB UPS baeries can be used safely in
oces and with mains equipment.
NSB UPS baeries excel at providing both short duraon
high amperage pulses, low rate long duraon deep dis-
charges and high cyclic capabilies.
2 Charge
In order to maximize the life of the UPS baeries, it is
recommended that the baery be fully recharged fol-
lowing an outage.
2.1 Determining State of Charge (SOC)
The SOC of a baery can be determined by measuring
the open-circuit-voltage (OCV) of the baery. If the bat-
tery has been recently recharged, a rest period of at
least 3 hours is required before taking measurements.
The relaonship between OCV and SOC for the NSB UPS
baeries is displayed in the following graph:
A fully charged NSB UPS baery will measure
approximately 13.0 V.
2.2 Thermal Compensaon
The opmum level for oat charging the NSB UPS
baeries is 2.27 volts/cell at +25°C (+77°F). If the baery
temperature increases above this level, a thermal
compensaon of -2 mV/cell/°C is recommended.
Conversely, if the temperature decreases below 25°C,
the voltage should be increased by 2 mV/cell/°C. The
graph below shows values for an individual cell.
2.3 Fast Charging
If the charging system is properly sized, a fast charging
regime will serve to minimize the me needed to
recharge NSB UPS baeries. This can be benecial, for
maximizing the cycle life of the product.
In a fast charging regime, the charging system is assumed
to be adequately sized to provide the power needed (see
Secon 2.4). Fast charging is conveniently achieved by
using a higher charging voltage. This method maintains
the charge current at a high level during the second half
of the charging process. As a result, a discharged baery
bank will be returned to a fully charged state in a shorter
me.
The increased voltage seng is known as boost voltage.
In a fast charging regime the boost voltage shall be
2.41 Volts/Cell provided that the temperature is a
nominal +25°C (+77°F). The following graph shows the
recommended charging prole following a 100% DOD
cycle:
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

The table above shows the me needed to recharge
following a 100% DOD cycle, depending on the
maximum charge current available. If the DOD is less
than 100%, the total recharge me will be less. To
prevent overcharge, the duraon from T1 to T2 (i.e.
the me at 2.41 Volts/Cell) should always be limited to
4 hours, and then the recer voltage returned to the
recommended oat voltage.
If the baery temperature increases above +25°C (+77°F),
it is recommended that a thermal compensaon of -2
mV/cell/°C be applied to the boost voltage. Conversely,
if the temperature decreases below 25°C, the boost
voltage should be increased by 2 mV/cell/°C. The graph
below shows values for an individual cell:
2.4 Recharge Power
Depending on the charging system, recharge mes can
vary greatly following an outage. If the recharge power
is relavely low, it will take longer to fully recharge
a baery. It is recommended to provide a regular
overcharge factor of between 103% and 106% SOC aer
a discharge.
The following chart shows the me required to fully
recharge an NSB UPS baery from a complete 100%
DOD discharge, as a funcon of recer voltage and
available current.
2.5 Ripple Current
Unacceptable levels or ripple current from the charger
or the load can have a major impact on baery internal
heat generaon, cause permanent damage, and reduce
service life. It is recommended to limit the connous
ripple current to a maximum of 5 amperes per 100 Ah
rated baery capacity.
3 Discharge
3.1 Storage and Self Discharge
During storage, lead-acid baeries will gradually self-
discharge. It is recommended that baery OCV be
maintained above 12.1V at all mes in order to avoid
irreversible capacity loss. The rate of self-discharge
increases with increasing temperature. For example, a
baery at 25°C will drop from 90% to 60% in 15 months,
whereas the same unit at 40 °C will take just 6 months. As
a result, maintenance charging needs to be performed
more frequently at higher temperatures.
3.2 End of Discharge Voltage (EODV)
In the event of a deep discharge, a recommended
minimum end-of-discharge voltage (EODV) should be
used to avoid over discharge. A value of 1.80 Volts/cell
is common, but this value should be adjusted based on
the discharge rate. The following table provides a guide
for EODVs at various discharge rates.
Discharge Rate (hours) EODV (Volts/Cell)
20 1.85
10 1.80
5 1.75
1 1.70
.25 (15 min.) 1.67
EODV can be controlled using a Low Voltage Disconnect
(LVD) as part of the load circuit.
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

3.3 Cold Temperature Performance
Colder temperatures can prolong baery life because
corrosion processes within the posive plates of the
baery slow down as the temperature decreases.
Unfortunately, lower temperatures also lower the
capacity of lead-acid baeries. As baery temperature
drops below the recommended operang temperature
of +25° C (+77°F), the baery capacity decreases.
4 Useful Life
4.1 Shelf Life
NSB UPS baeries may be stored for up to 2 years
provided that the OCV is never allowed to fall below 12.1
V. Failure to provide the required maintenance charging
(see Secon 3.1) may lead to irreversible capacity loss.
4.2 Design Life vs. Temperature
Lead-acid baeries operang under oat condions
are connually being charged. As a result, the lead
grids within the posive plates undergo slow corrosion,
which is a normal aging mechanism under oat duty.
Typical UPS applicaons require short duraon high
discharge current (5 to 15 minute rates) to support
the load. It should be noted that the presence of grid
corrosion increases internal resistance which, in turn,
decreases the available power. This behaviour is more
obvious for higher-rate UPS duty, than during the lower-
rate telecom applicaons.
The rate of grid corrosion increases with increasing
temperature and, as a result, the temperature of baeries
has a large aect on their oat life. For each increase of
10°C, oat life will decrease by a half. For example, if the
temperature rises from the recommended operang
temperature of +25°C, to +45°C, the expected life of the
UPS baery will decrease from 15 years to less than 2
years (see chart below).
As seen in the above graph, the baeries design life will
vary signicantly due to dierences in discharge rates
and environmental temperatures.
Under oat duty, a baery is considered to have reached
its end of life (EOL) when it can no longer deliver 80%
of its original rated capacity. For example, a 100 Ah
baery has reached EOL when its discharge capacity
has dropped below 80 Ah. The relaonship between
capacity loss during oat duty and baery temperature
is shown in the following chart:
5 Technical Specicaons
For detailed technical specicaons, please refer to the
product data sheets provided at www.northstarbaery.com
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

6 Baery Safety
For full informaon please read the Safety Data Sheet
(SDS). The SDS document is tled SDS-430-00607
and can be downloaded from the internet at www.
northstarbaery.com
When dealing with Valve Regulated Lead Acid (VRLA)
Baeries some addional safety informaon is required.
Please read and observe the installation and
operation instructions.
When working on batteries wear appropriate
Personal Protective Equipment (PPE). Refer
to battery MSDS for complete list.
Do not expose the battery to an open ame
or other ignition source. During operation
an explosive mixture of hydrogen gas may
accumulate.
Battery terminals are always energized and,
if short-circuited, cause electrical arcing.
Always use insulated tools.
Batteries are heavy objects. Use proper
handling equipment safety gear during
installation.
Inappropriate lead acid battery disposal
can result in environmental contamination.
Please dispose of batteries according to
local regulations.
Battery may be returned, shipping pre-paid,
to the manufacturer or any distributor for
recycling.
Batteries contain concentrated sulfuric acid
in water. Any uid found outside the batteries
should be regarded as acid.
Clean all acid splash in eyes or on skin with
plenty of clean water. Then seek medical
help. Acid on clothing is to be washed with
water
Risk of explosion or re. Avoid any short
circuit. Metallic parts under voltage on the
battery, do not place tools or items on top of
the battery.
Baeries are supplied in a fully charged state and must
be unpacked carefully to avoid very high short-circuit
currents terminals of opposite polarity. Use care when
handling and moving baeries. Appropriate liing
equipment must be used.
Pb
Pb
6.1 Keep away from open ames
In case of accidental overcharge, a ammable gas can
leak from the safety vent. Discharge any possible stac
electricity from clothes by touching an earth connected
part.
6.2 Tools
Use tools with insulated handles. Do not place or drop
metal objects on the baery. Remove rings, wrist
watches and arcles of clothing with metal parts that
may come into contact with the baery terminals.
7 Determining Baery Manufacturing Date
Locaon of Serial Numbers
The baery serial numbers are located in two places on
the baery case.
The rst is on the front of the baery. The manufacturing
date is also located on this label below the serial number.
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

The second is on the right hand side towards the rear of
the baery (see picture below).
Manufacturing codes are limited to 12 alphanumeric digits:
• The rst two digits specify the model of the monobloc.
• The remaining ten digits are a random, non-
sequenal serial number which is unique to this
parcular monobloc and will not be duplicated.
8 Handling
8.1 Receiving the shipment
Carefully examine the baery shipment upon arrival
for any signs of transit damage and that it agrees with
the materials list or packing slip. Be very careful not to
inadvertently discard any accessories contained in the
packing material. Baeries contain sulfuric acid in glass
ber separators. Use rubber gloves when handling
broken or damaged containers in case of acid leakage.
In addion to safety requirements (see secon 6) special
care should be taken when handling baeries. The
following are some DOs and DON’Ts.
8.2 Do
• Always use the handles on the baeries when liing
or carrying them.
• Always perform a visual inspecon of the baery
prior to handling. If any damage or electrolyte
leakage is detected during this inspecon do not
install the baery.
• Always use the baery packing from new baeries
for transporng old baeries for proper disposal.
Having baeries loose during transportaon can
lead to an accidental short circuit between
terminals, or to damage of the baeries and
electrolyte leakage.
8.3 Don’t
• Never drag a baery along the oor. Doing so
could cause damage to the baery case leading to
leakage of electrolyte and damage to equipment.
• Never install a baery that has been dropped.
A dropped baery could have internal damage
causing premature failure or unsafe operaon.
• Never drill, or in any other way aempt to breach
the baery case.
• Do not move the baeries using the baery
terminals. The terminals are not designed to
support the weight of the baery, and damage to
internal components could result.
9 Storage
9.1 Storage condions
Below is a list of equipment that is recommended to be
on hand in the area where baeries are stored.
• DC volt meter
• Baery chargers
• Mechanical liing device (such as a fork li etc.)
• Appropriate Personal Protecve Equipment (PPE),
which is listed in the baery SDS
The SDS document is tled SDS-430-00607 and can be
downloaded from the internet at www.northstarbaery.com
It is strongly recommended to store the baeries in a
clean, cool and dry environment.
The baeries should be stored in the original containers.
The packaging serves to protect the baeries from
harsh environmental condions and accidental damage.
If they must be removed, palleze them, and ulize as
much of the original packaging as possible.
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

Since the baeries are supplied charged, storage me is
limited. During storage, lead-acid baeries will gradually
self-discharge. The rate of self-discharge increases
with increasing temperature. As a result, maintenance
charging needs to be performed more frequently at
higher temperatures. In order to easily charge the
baeries aer prolonged storage, it is advised not to
store it more than:
• 24 months at ambient temperature no warmer than
77°F (25°C)
• 20 months at 86°F (30°C)
• 11 months at 104°F (40°C)
Give the baery a freshening charge before the end
of the recommended storage interval. For details, see
secon 5.7.
FAILURE TO CHARGE AS NOTED VOIDS THE BATTERY’S
WARRANTY
9.2 Shelf Life
NorthStar batteries have a two year shelf life at
+25° C (+77°F).
10 Commissioning/Installaon
10.1 Unpacking the Baeries
When received the baeries should be inspected. Make
sure the baeries were not damaged during transport,
and that all the proper accessories were included in
the delivery. If problems arise, please iniate a claim
immediately.
10.2 Checking the Voltage Spread
Before connecng the monoblocs in series, the voltage
variaon must be checked. If the voltage varies more than
0.15 V between the highest and the lowest monobloc
voltage, the monoblocs should be charged individually
before being connected in series. Refer to the recharge
table(s) in this manual for the parcular monobloc type
used.
10.3 Installaon
Install in clean, dry area. NorthStar baeries release
negligible amounts of gas during normal operaon,
because they have a high gas recombinaon eciency.
They can be installed near the mains equipment. Baeries
must be installed in accordance with federal, state and
local law regulaons and manufacturers instrucons.
10.4 Temperature
Avoid placing the baery in areas of high temperature
or in direct sunlight. The baery will give the best
performance and service life when working at a
temperature between 68°F (20°C) and 77°F (25°C). The
usual operang temperature is between -4°F (-20°C)
and 113°F (+45°C). Operang limits have been tested
between -40°F (-40°C) and +158°F (+70°C).
10.5 Venlaon
Under normal condions gas release is very low and
natural venlaon is sucient for cooling purposes and
inadvertent overcharge, enabling NorthStar baeries to
be used safely in open spaces in oces and with mains
equipment. However, care must be taken to ensure
adequate venlaon when the baeries are placed in
cabinets. If cabinets are used they must be venlated.
10.6 Security
All installaon and venlaon must comply with the
current federal, state and local regulaons.
10.7 Pung the Baeries in Place
NorthStar baery racks or cabinets are recommended
for proper installaon. Assemble the rack according to
instrucons. Place the baery blocs or cells on the rack
and arrange the posive and the negave terminals
for connecon. Make sure the baeries are all evenly
spaced approximately 10mm (3/8 inch) apart, aligned
and resng on a at surface. It is strongly recommended
that the surface the baeries rest on is acid resistant,
and electrically insulated. It is important that the baery
is mounted rmly.
10.8 Baery Terminal Preparaon
To minimize contact resistance, it is important that the
terminals of the baery be cleaned of any oxidaon.
Lightly brush the terminal contact surface areas with a
brass bristle brush, or the equivalent, and then apply a
light coat of anoxidant grease such as a conducve NO-
OX-ID to the surfaces to protect the terminal from future
oxidaon or corrosion. Wipe clean prior to installing
hardware.
Form: SES-541-01711
Issued: 12-08-16
ECO-101191

10.9 Torque
The maximum torque load of intercell connector bolts
is provided on the front baery label based on the size
of the baery. A loose connector can cause problems
in charger adjustment, errac baery performance, and
possible damage to the baery and/or personal injury.
Finally, install the connector covers (oponal).
10.10 Connecng the Baeries
Please be aware of the risk of short circuits when
connecng baeries in series strings. A short-circuit can
result in the arcing of very high currents. Circuit breakers
or other means of disconnecon should be in an open or
o posion.
A torque wrench, set to proper torque values according
to the baery label, must be used for making the
terminal connecons. When heavy cables are used they
need to be supported with cable es in order to limit
stress on the baery terminals.
Check that all contact surfaces are clean, and then install
the bloc or cell connectors and the terminal screws.
Tighten the screws securely. Follow the polarity to avoid
short circuing of cell groups. Finally connect the baery
terminals. The insulaon covers should be put back aer
all connecons have been completed.
See the following gures:
Insulaon Cover
10.11 Front Terminal Adapter
NSB UPS baeries may be ordered with oponal front
terminal adapters if front terminal access is required in
the installaon.
19” Baery w/ Front Terminal Adapter
23” Baery w/ Front Terminal Adapter
10.12 Baery Connecon to Load/Charger
Select the proper size and type cable and busbar per
the NEC or other applicable code which can handle the
charge and discharge current related to the baery.
The cable size selected should also consider the cable
resistance per foot and the voltage drop allowed
between the baery output terminals and the load.
A cable voltage drop of no more than 0.5V is recommended.
10.13 Parallel Baery Strings
The following guidelines should be followed when
operang parallel strings of baeries:
• Baeries should all be of the same model number
• Each string should be connected to an individual
disconnect or circuit breaker
• Cabling to each string should be of the same size
and approximate length resulng in the same
resistance per string.
Form: SES-541-01711
Issued: 12-08-16
ECO-101191