Power Storage Solutions 12MQ100 - 620 Original operating instructions

Value Regulated Sealed Lead-acid Battery
Power Storage Solutions
Battery
Installation & Operation Guide
(Reserve Power Batteries)
AGM VRLA
12MQ100 - 620

CONTENTS
1. Introduction …………………………………………………………………………….3
2. Safety Precaution and Protection Equipment...…………………………………..3
3. Battery Storage ……………………………..………………………………………..4
4. Battery System Installation Considerations…………………………………..…..4
5. Installation of Batteries ………………………………………………………...…..5
6. Operation of Battery …………………………………………………...….…...…...10
7. Battery Maintenance ………………………………………………….…....……...…12
8. Exchange of Batteries …………...…..……………………………….….......………17
9. Maintenance Records and Forms ……………………………………....…………..18

Power Storage Solutions sealed lead acid battery is shipped
charged, handle the battery according to the following
instructions before use:
1. Introduction
Power Storage Solutions private label batteries technology is based on years of research and
development. Our products are manufactured under the guidelines of ISO9001 quality system. Each
battery undergoes a series of strict manufacturing and quality control processes before shipment.
We are committed to provide our customers batteries that provide reliable DC power and are
solutions to their critical power problems.
2. Safety precaution and protection equipment
 When working any battery system, be sure you have the necessary tools and safety equipment,
including but not limited to:
a) Insulated tools
b) Rubber apron and gloves
c) Face protection/face shield
d) Safety goggles
e) Fire extinguisher
f) Emergency eye wash and shower, if available
g) Acid spill cleanup kit
 Pay attention to the electrical warning symbols to avoid serious injury or death caused by
electrical shock or burns.
 Remove all rings and jewelry while working on batteries.
 Multi-cell battery systems can attain high voltage and/or currents. Do NOT touch un-insulated
batteries, connectors or terminals. To prevent serious electrical burns and shock, use EXTREME
CAUTION when working with DC Battery system
 Always wear safety protection clothes and protect all exposed skin and eye surfaces
 Use non-conductive or insulated tools when working with ANY battery system.
 All tools should be adequately insulated with the use of suitable no-conducting
material to minimize the possibility of shorting across connections.
 Never lay tools or other conductive objects on the battery.
 Avoid shorting of batteries and connections to prevent explosions, arc flash and personal injury.
 Dispose of batteries or battery components via licensed EPA approved recycling facilities.
pg.3

3. Battery Storage
 High temperature or poor ventilation during storage and delivery will result high self-discharge rate.
Therefore, it is important to maintaining good ventilation and keeping away from fire, flame, water and
heat supply etc.
 When storing the battery (not charging), disconnect from charger and load.
 Store the batteries in a dry, clean and preferably cool location.
 The batteries are supplied charged, however during storage it is advisable not to store batteries for
more than the time specified below without a supplementary recharge:
a) Six months at 20° C / 68o F
b) Three months at 30° C / 86o F
c) Six weeks at 40° C / 104o F
d) Do not store over 40° C / 104o F
 A supplementary charge is required to maintain the batteries stored for some period over advised time
limit from above. For detailed charging procedures, please refer to section 6.1 Supplementary Charge.
Failure to observe charging conditions may result in greatly reduced capacity and service life and limit
warranty of batteries.
4. Battery System Installation Considerations:
 No fire, flame or heat supply should be near the battery;
 Avoid installation near heat supply or in direct sunlight;
 Avoid operating in humid / damp locations;
 Do not operate in sealed enclosed or without ventilation.
 Temperature Range UL94-V0 Flame Retardant Jars
Charging -4°F ~ +131°F (-20°C ~ +55°C)
Discharging +32°F ~ 122°F (0°C ~ +50°C)
Storage -4°F ~ +131°F (-20°C ~ +55°C)
 Parallel Connections Recommended within 4 groups.
 Heat Dispersing Maintain 0.4 to .79” (10 to 20mm) inter-bloc distance between batteries.
 Multilayer Installation Temperature of each layer should be controlled within 3°C.
 Ventilation Ensure batteries are stored and used in ventilated conditions.
 Optimum Ambient Temp. 72°F to 78°F (23°C to 26°C)
 Float Charge (25°C) Limited current ≤0.30C10, voltage 2.23~2.30V/cell
 Cyclic Charge (25°C) Limited current ≤0.30C10, voltage 2.30~2.40V/cell
 Mixing Batteries Do not mix new and old batteries, batteries of different capacity or manufacturers.
If required, please consult with Power Storage Solutions technical support.
pg.4

5. Installation of batteries
5.1 Unpack and Check
Check the packaging for signs of shipping damage.
Unpack and check the appearance of battery for signs of damage or unidentified fluid.
Check parts list ensuring all accessories are included.
Read through the operation guide before handling the battery.
Handle the battery with caution:
Avoid any impact or force on the battery terminals!
Avoid any impact to the battery!
Do not tamper with battery seals!
Do not place the battery upside down!
Do not short circuit the battery!
5.2 Inspection Before Installation
If no shipping damage after checking, install the batteries in the designated position;
When installing batteries in a cabinet or on a rack, start at bottom & finish with placement at the top.
DO NOT install batteries near any potential heat source such as heat exhaust of other
equipment; Batteries may release flammable gas during charge or discharge operation. Batteries
must kept away from any possible source of flames or sparks.
Before connecting inter-cell connectors, lightly clean post terminals with non-metallic brush to
remove any sulfate or dirt from the terminal. Brush gently and do NOT damage the tin plating on
terminal, connector, or lugs.
Avoid any conductive materials shorting positive and negative terminals.
All installation tools must be insulated to prevent accidental arc flash.
Do NOT lubricate rack rails or bottom of battery jar as some lubricating compounds may cause
deterioration of the plastic battery container.
Do NOT clean battery jars with detergent, petroleum-based solvents or solutions with any
ammonia to clean the battery containers, these materials may cause permanent damage to the
battery container. Physical damage such as these are not covered under warranty.
pg.5

5.3 Pre Installation Rack/Enclosure Location Check
Floor loading: Since batteries are heavy, check the floor loading is not exceeded. Check rack /
enclosure complies with any load spreading, and seismic zone requirements of the installed area.
To assemble a battery rack/enclosure, please see rack installation instructions.
5.4 Battery Installation and connection
Use insulated tools only;
Connect battery modules together to the required system voltage, then connect battery string with
charger or load; When multi-strings of batteries are to be parallel connected, connect batteries in series
first and then complete the parallel connection. Parallel cables to the charger / load should be as close
in size and length to each of the parallel strings to prevent uneven voltage drops that can imbalance
the parallel battery strings.
To ensure good ventilation, the batteries per row should kept around 0.4” to .79” (10 - 20mm) inter-bloc
spacing;
An estimated open air rating on the proper cable sizing between batteries:
1) AWG# 6 for loads up to 90 Amps.
2) AWG# 2 for loads up to 150 Amps.
3) AWG# 1/0 for loads up to 250 Amps.
4) AWG# 4/0 for loads up to 400 Amps.
5) Refer to NEC for voltage drops for long cables.
1. Before connection, lightly clean the battery terminals to remove sulfate and dirt.
2. Before connecting inter-cell connectors apply a light coating of No-Ox grease to the surface of
the terminal and inter-cell connectors or cable lugs;
3. After batteries are installed, test the voltage of the battery string. Make sure there are no
battery modules that have been incorrectly installed in reverse polarity. If all modules installed
correctly, link battery to load.
4. Use correct torque on all terminals, ensuring every connecting nut and screw is secure; see
torque settings as table 1 below.
～
～
～
pg.6

Torque Conversion Table
Unit Inch Pounds Foot Pounds kgf-cm N-m
1 Inch Pounds 1 12 1.152 0.113
1 Foot Pounds 0.0833 1 13.825 1.3558
1 kgf-cm 0.868 0.0723 1 0.098
1 N-m 8.851 0.7376 10.2 1
5.5 Battery Rack Assembly
To assemble a battery rack, see rack and/or cabinet enclosure installation instructions.
5.6 Batteries mounting on racks
Rack mounted Power Storage Solutions batteries follow the procedures below: If batteries are
small they can easily be lifted into place.
If batteries are large special caution should be used.
Step
1.
Carry batteries close to the rack, and then tear the box along its four corners.
pg.7

Step 2.
Remove all poly-foams out from the bottom of the battery.
Lift with two people if weight requires.
Place on battery rack or in battery
cabinet.
5.7 Example Images after Installation
5.7.1
12V Battery Vertical 2-Tier/ 1-Row/Non-seismic Rack (8 batteries shown)
pg.8

5.7.2
12V Batteries: Vertical 3-tier/ 2-row Rack (30 batteries shown)
pg.9

6 Operation of Battery
6.1 Refresh Charge
 During the delivery and storage, the battery will lose part of the capacity due to self discharge, so
please apply a supplemental charge before use;
 If storage occurs before installation / connection, supplement charge regularly; Supplementary
charge according table 2 below before use:
Table 2 the time interval of supplementary charge and storage temperature
Storage
temperature
Time interval of
supplementing
charge
Supplementing charge way
< 20°C Every 9 months
Three options to choose from:
a) Charging at a constant voltage of 2.23-2.30V/cell and initial
current to be less than 0.3C (A) for 2-3 days
b) Charging at a constant current of 0.3C(A) and a constant
voltage of 2.30-2.40V/cell for 10-16 hours
c) Charging at a constant of 0.1C(A) for 8-10 hours
20°C ~30°C Every 6 months
>30°C to 40°C Every 3 months
Note:
Current value C is rated capacity of battery.
Example: rated capacity of 2V300AH battery is 300AH, 0.1C (A) = 0.1X300 = 30A;
6.2 Discharge
 Ensure the maximum allowable discharge current does not exceed the rated value.
 Refer to the individual battery literature for discharge rates to different end VDC at 77⁰F (25⁰C).
6.3 Capacity Discharging Test
Use the test procedure as identified in IEEE standard 1188.
6.3.1 Before doing any type of discharge test
Make sure the battery is fully charged with an equalize charge, followed by a battery returning to
float for 7 additional days before the test for maximum results. Make sure all of the connections
are clean, tight, and do not have high resistance connections. The ambient temperature should
be 77°F (25°C) or corrected for temperature as per the IEEE K factor chart.
Terminal voltage, ambient temperature, and start time should all be checked and recorded before
commencing discharge.
Terminal voltage, discharge current, room temperature should be checked and recorded throughout
the discharge period.
Battery should be recharged soon after the discharge, using a voltage regulated charger.
pg.10

equalize charge to reduce recharge time.
6.4 Charge
6.4.1 Float Charge Parameters:
 Charge voltage: 2.23 ~2.30V/cell at 77°F (25°C)
 The maximum charge current: 0.30C10
 Temperature compensation coefficient: -3mV/cell (taking 77°F (25°C) as base point)
 Total variation range of charge voltage is ±0.02V/cell
Note:
1) All cell/jar voltages of a battery string have a little difference at the beginning of use,
after approximately six months voltage ranges should tighten up.
2) Effects from too high float voltage or too low float voltage are: Too high for a long time
(overcharge): life shortened. Too low for a long time (not charged enough): Cannot meet
load and/or makes battery voltages inconsistent. The battery string capacity will drop
accordingly and life is shortened.
6.4.2 Cycle Usage Charge Parameters:
 Charge voltage: 2.40 ~2.50V/cell at 77°F (25°C)
 The maximum charge current: 0.30C10
 Temperature compensation coefficient: -5mV/cell (taking 77°F (25°C) as base point)
 Total variation range of charge voltage: ±0.02V/cell
 Charge capacity is 110% ~ 130% of discharge capacity.
6.4.3 Equalization Charge Parameters:
 Charging voltage
 Maximal charging current
 Temperature equalization parameter
 Variation scope of charging voltage
: 2.35 ~ 2.40V/cell (25°C)
:
0.30C10
: -3mV/cell(25°C)
: ±0.02V/cell
Note:
Do not use equalization charging as the standard floating application. Adopt equalization charging
under recommended situations below:
1. Discharging capacity is below 80% of rated capacity.
2. Batteries have not been used for more than 3 months.
3. Float voltage of battery unit is less than 2.18V/cell
4. Batteries have been floating for 3 ~ 6 months and found low voltage batteries in the string.
5. Batteries have been floating for a year.
6. Batteries supplementary charged before used.
7. After performing a capacity test.
pg.11

6.4.4 Notes during charging
1. Charge current at the end of charge is over 0.05 C10A, which may result in permanent damage on
battery appearance and battery life; pay close attention to charging voltages.
2. The used charger should have digressive automatic constant voltage device, please contact us if
use other kind of charger.
3. If the ambient temperature is not 25°C, temperature compensation should be applied on the
voltage, use the formula U=U25°C - K×(T -25) T—ambient temperature; K—temp. compensation
coefficient
* Judgment on charge end point, if the battery charge can meet any one of the below listed
conditions, it can be regarded as the charge end point.
a) Charged value is not less than 1.2 times of the released value.
b) The current is less than 0.005C10A (C10 = rated capacity of the battery) during the final
period of charging.
c) The current is steady for 5 hours during the final period of charging.
7 Battery Maintenance
7.1 Cleanness
 Keep the battery surface clean and dry avoid static electric discharge conditions.
 Clean battery with damp cloth, avoiding contact with terminals. No solvents should be added. Use of
unapproved cleaning solvents may permanently damage the battery container and void battery warranty.
7.2 Inspection and maintenance
To maintain the optimal operation of the battery and associated equipment and prevent battery damage
during maintenance inspection, please periodically inspect the battery and record it listed parameters
pg.12

Items Contents Standards Maintenance
Total float
charging
voltage of
battery group
Measure output end
voltage of positive
and negative end of
battery group with
voltage meter.
1. Test data complies with the
data displayed on the
meter and meets the
voltage standard under the
temperature conditions
2. The error of float charge
voltage after temperature
compensation Is ≤±50mV
1. If data attained by testing is varies
from the standard, the tested data
should prevail.
2. For those adjusted by monitor module
and still can’t reach the allowed error
range after module adjustment, repair
is to be applied or send them back to
factory.
Battery
appearance
Inspect battery case
and cover for bulge,
leakage or damage.
Normal Find out the reasons if abnormal
appearance exist, please change battery
if it effects the normal use of battery group
Inspect for dust or
stains
Clean Clean the dust and stain with damp
cloth.
Inspect the harness
and terminal for rust
or corrosion.
No rust Clean the rust, change the harness and
paste with antirust coating/paste.
Temperature
of the battery
Test the
temperature of the
terminal and battery
surface by infrared
thermometer
Under 35 Determine reason for temperature being
above standard value and proceed on
relevant course of action.
pg.13
7.2.1 Monthly Inspection items:

Connection Tighten the loosen bolt/screw in time
Parts
Torque values - please
refer to the table of torque
Check the tightness
of terminal
bolt/screw with
torque spanner
Without appearance of corrosion
or dirt
Check the
connection cable
and terminals for dirt
and corrosion
Take out the connection cable and clear it
in water if it is light corrosion, for serious
corrosion please replace the cable and
clear the connection point with a steel
brush before attaching new connectors
Check safety
valves
(2V series)
Shake the valve
lightly to check the
valve is fixed tightly.
Valve is fixed tightly. Please tighten the value if there is
appearance of looseness
Staggered air bubble appears Cover the valve with
bubble liquid(soap
solution) to check if
the valve can
exhaust gas cleanly
The frequent tighten the valve if there is
appearance of open and close the value
is abnormal, in case happens, please
replace the valve at the same time,
please check the water lost status of the
battery.
Switch DC Correct the potential difference
power supply
AC power supply switch to UPS
or DC power supply smoothly
Cut off AC power
supply and change
to UPS or DC power
supply
7.2.2 Quarterly Inspection items
Additional to Monthly Maintenance items:
Items Contents Standards Maintenance
Float voltage
of each battery
Measure the end voltage of each
battery in battery group.
Float voltage value
after temperature
equalization ±50mV
If float voltage is over standard value,
please apply equalization charge the
battery group after discharging them
and then float charge them for 1-2
month, please contact us if still have
any deviation from standard.
pg.14
7.2.1 Monthly Inspection items continued :

Correct string
with
low single cell
1. Equalization charge of the
battery string: charge the battery at
upper limit voltage for 10 hrs, 3
discharge cycles may be necessary
when condition is serious.
The difference of float
charge voltage between
single cell in a string of
battery should meet the
below standard:
2Vseries 90mv
6vseries 240mv
12Vseries 480mv
.
Single cell should be replaced if it
fails in repair
2. On-line repair of single cell:
connect the cell the activation
meter or charger with the laggard
battery and charge the single cell.
Activation
charge and
discharge
Charge and discharge the battery
by one cycle, then charge the
battery by the lower limit of the
equalization voltage
About 30% of the rated
capacity is released.
Produced this text on the batteries
which float charge more than 6
months but without discharge.
7.2.3 Yearly Inspection items
Additional to Quarterly and Monthly Maintenance items:
Items Contents Standards Maintenance
Checking
discharge test
Cut off AC power supply,
discharge battery with load,
and discharging 30% to
40% rated capacity.
Battery voltage should
be over 1.90V/cell
after discharging.
If battery voltage is lower than standard
value, please equalization charge the battery
group after discharging and then float
charging it for 1 2 month, please contact us
if still have an issue
Capacity test Utilize a capacity test
instrument with load bank
discharge battery and
discharge 60~80% of the
rated capacity
More than 80% of the
capacity is reserved.
Verify that string has at least 80% capacity.
Capacity test should only be performed
once every 5 years or when less than 80%
capacity is suspected.
pg.15
7.2.2 Quarterly Inspection items continued:
Additional to Monthly Maintenance items:

7.2.4 Basic requirements and precautions on maintenance routines:
1) Principle to discover areas of concern and insure the safe operation. Should be documented
while testing the batteries.
2) Preventative maintenance and performance analysis should be carried out routinely.
3) Battery parameter and operation should be complied with the maintenance documentation and
reviewed.
4) Always wear insulated gloves when handling the batteries to avoid electric shock. Make tools
and instruments are properly insulated.
5) Use calibrated instrument and meters which meet test requirement.
6) Physical articles:
a) Check whether the post and connection is clean, with no appearance of oxidation or
corrosion. Clean and lubricate connections to reduce the resistance.
b) Check for any loose connections, if any tighten per specification in previous torque tables.
c) Check if there is any appearance of acid seepage, pooling of liquid, or liquid around the
safety valve.
d) Check if there is any damage, leakage and distortion on the battery case and the post; it
should be without any damage and distortion.
e) Check for abnormal temperature increase on the battery and its connection.
7) Check and adjust the set points of related parameters.
a) Check the float voltage, equalization voltage, float charging current is normal or not on the
base of technical parameters and site environment. Please handle it in time.
b) Check the current limited charge is set correctly and adjust immediately.
c) Check the alarm voltages (low voltage and over voltage alarm) of the battery is set correctly,
if not, adjust promptly.
pg.16

CAUTIONS
Keep batteries out of reach of children.
Do NOT use batteries for application other than those specified in its specification.
Do NOT attempt to dis-assemble, repair, damaged, impacted, disposed batteries, otherwise the
battery would leak, get hot, or explode.
Do NOT dispose of the batteries in water, fire, and do not heat the batteries.
Do NOT cause any short circuit
If the voltage of battery pack is above 45V, please be sure to wear insulated gloves when working;
otherwise, there is a risk of severe electrical shock.
Do NOT bring face close to the top of batteries, please keep a sensible distance when you are
measuring and repairing, you must wear safety goggles.
There is sulfuric acid in the battery, do not allow contact of sulfuric acid with skin, cloths, especially
eyes. If eyes come in contact with sulfuric acid, flush eyes in eyewash and consult a physician
immediately.
Longer service life will be attained when the battery is operated within an ambient temperature
range of 20~30°C
8. Exchange of Batteries
8.1 Exchange Considerations:
The batteries are discharged 80% (refer the corresponding discharge rates, such as C10, C2 etc.) of
rated capacity, at the same time, the voltage is below 1.8V/cell (the discharge rate for 1 hour is 1.7V/
cell). It should be exchanged.
8.2 Exchange Time
The VRLA battery has a certain service life; replace old batteries with the new one before end of
service life so that the application run safely and uninterrupted.
9. Maintenance Records
Good records will assist in determining if corrective action is needed to correct charging,
maintenance, or environmental issues that may reduce the maximum life of your battery. If you have any
questions or concerns, please call Power Storage Solutions for assistance (888-813-5049).
Taking measurements is recommended after the battery is installed, and after the battery has been in float
service for 6 months (Base Line Readings for warranty records). Quarterly, or semi-annual maintenance
records are suggested to give customer system protection predictability, however annual maintenance
readings are the minimum to maintain the warranty coverage. Maintenance records will be required for
warranty claims.
Below please find some suggested maintenance forms to assist the customer’s record keeping on the
battery. pg.17

Note: Baseline reading is completed after 6 months on float in operation. Keep the baseline
readings for your permanant record.