SEC CELLYTE 2ETG OPzV Gel User manual

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CELLYTE 2ETG
OPzV Gel
STATIONARY BATTERIES
INSTALLATION and OPERATING
INSTRUCTIONS
Supplied Worldwide by :
SEC Industrial Battery
Last Revised May 2011

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TABLE OF CONTENTS
SECTION CONTENT PAGE SECTION CONTENT PAGE
1.0 GENERAL INFORMATION 3 5.4 Electrical Connections 5
1.1 Battery Characteristics 3 5.4.1 Cabling recommendations 5
5.4.2 Terminal Preparation 5
5.4.3 Connector Installation 5
2.0 SAFETY INFORMATION 3 5.4.4 Voltage Checks 6
2.1 General Information 3 5.4.5 Battery to Charger Connection 6
2.2 Sulphuric Acid 3 5.4.6 Paralleling of Batteries 6
2.3 Gassing 3
2.4 Electrical Shock 3 6.0 OPERATION 6
6.1 Initial Charge 6
3.0 RECEIPT OF EQUIPMENT 3 6.2 Float Voltage 6
3.1 Delivery Inspection 3 6.2.1 Float Voltage Requirements 7
3.2 Hidden Damage 3 6.2.2 Float Temp. Compensation 7
6.3 Maximum Charge Current 7
4.0 STORAGE 3 6.4 Recharge 7
4.1 General 3 6.5 Equalization Charge 7
4.2 Short Term Storage 4
7.0 STORAGE 7
5.0 INSTALLATION PROCEDURES 4
5.1 Battery Location 4
5.1.1 Temperature 4 8.0 MAINTENANCE & RECORDS 7
5.1.2 Temperature Variation 4 8.1 General Maintenance 7
5.1.3 Ventilation 4 8.2 General Records 7
5.1.3.1 Battery Temperature Variation 4 8.2.1 Installation Records 7
5.1.3.2 Ventilation and Gassing 4 8.2.2 Maintenance Records 8
5.1.4 Floor Loading 4
5.1.5 Seismic Considerations 4 9.0 CAPACITY TESTING
5.2 Unpacking 4 9.1 General 8
5.3 Installation 5 9.2 Test Procedure 8
9.3 Discharge Test Notes 9
5.3.1 General 5 10.0 Battery Maintenance Register 10
5.3.2 Location Layout 5 11.0 Technical Support 11
5.3.3 Horizontal Module Installation 5 12.0 Battery Report 12
5.3.4 Vertical Module Installation 5

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SECTION 1 - GENERAL INFORMATION
1.1 CELLYTE 2ETG Gel OPzV Battery Characteristics
The CELLYTE 2ETG Gel OPzV battery is a gelled
Tubular positive plate sealed, valve-regulated lead-
acid recombinant, low maintenance battery designed
for stationary or cycling applications. This type of
battery has no special ventilation or handling
requirements. Because the Gel electrolyte in the
battery is immobilized, the batteries are considered
dry and can be handled and shipped accordingly.
SECTION 2 - SAFETY INFORMATION
2.1 General Information
Lead acid batteries require care in installation and
maintenance. Unsafe installation or maintenance
procedures can cause severe injury or death.
Electrical shock or burns, acid burns and fire can
result if proper safety precautions are not followed.
The following precautions apply to all battery
installation and maintenance work. For more
information read the following sections.
- Disconnect all power before attempting to install,
remove or perform maintenance work on batteries.
When on-charge float voltages must be measured, be
particularly careful because shorting a battery at this
time can cause not only personal injury, but severe
equipment failure as well.
- Do not tamper with any parts of the battery, including
interconnect cables, vents, terminal bolts etc.
- Keep batteries clean and dry. Use ½ kg of baking
soda in 4 litres of water to neutralize any possible
acid. Do not use cleaners or solvents on any part of
the battery. Do not allow excessive dust to
accumulate on the battery or interconnect cabling.
- Keep battery inter connect cables clean, greased at
the terminal post and tight. A loose connection can
reduce battery standby time and cause cable fires.
WARNING Do not turn cells up side down or tilt to
the front more than horizontal as this will ‘wet’ the
vent with electrolyte which may be vented when
the cell is charged.
2.2 Sulphuric Acid
The CELLYTE 2ETG Gel OPzV battery is a lead acid
battery and contains sulphuric acid in gelled diluted
form. Because the electrolyte is immobilized, in the
event of a container rupture, no liquid acid will leak or
run from the battery. However, if the internal
components of the battery are touched or handled,
contact with the acid will result.
CAUTION: Sulphuric acid can cause burns and
serious injury if it comes in contact with your skin
or eyes. In the event of contact with sulphuric
acid, flush thoroughly with water and neutralize
any residual acid with baking soda (1 kg in 4
liter’s of water). Seek medical attention
immediately. Do not handle batteries if the
container has been ruptured except while wearing
rubber gloves. Do not try to disassemble a cell.
2.3 Gassing
All VRLA lead acid batteries emit some gases during
charging and float operation. Conventional flooded
batteries release all the gases produced to the
environment whereas gelled sealed, valve-regulated
batteries re-combine most of the gases internally,
releasing very little to the environment. Compared to
a flooded battery of equal capacity, a CELLYTE 2ETG
Gel OPzV battery releases a gas volume of 1% or
less than the flooded battery. Because of this
characteristic, no special ventilation is required under
normal usage conditions.
Because some gas is released from gelled sealed
lead acid batteries, never charge or use batteries in
an unventilated space. This gas consists of mostly
hydrogen gas and can explode if ignited in a confined
area or space. Keep sparks, flame or any other
ignition source (including smoking materials) away
from batteries.
CAUTION: Hydrogen gas can explode and cause
serious injuries and fire. Do not allow any flame
or ignition source near batteries. Always allow
some ventilation around operating batteries.
Contact SEC if there are any questions regarding
gassing or ventilation.
2.4 Electrical Shocks
Batteries store large amounts of electrical energy.
Even a discharged battery can deliver a high short
circuit current. Keep all metallic objects away from
the battery terminals. Multi-cell systems can attain
lethal voltages. Remove watches and all jewelry
before working on batteries. Cover all tools with vinyl
electrical tape to minimize the possibility of shorting a
battery during installation. Never lay tools or other
metallic objects on batteries. Do not allow
construction work over batteries to proceed unless the
battery is protected by insulating rubber mats.
CAUTION: Shorting a battery can cause serious
injury, fire or explosion. Do not attempt to work
on a battery unless you are familiar with battery
installation procedures and have adequate safety
information and equipment. Read this manual
thoroughly before attempting to install the battery.
If there are any questions about safety, contact
SEC before installing the batteries. Remember,
safety is always the prime concern.
SECTION 3 - RECEIPT OF EQUIPMENT
3.1 Delivery Inspection
Immediately upon delivery, inspect the cells & rack for
damage caused in transit. Damaged pallets could
indicate rough, improper handling in transit. Describe
in detail and take photographs if possible, note any
damage on the delivery receipt before signature. If
any damage is found, contact the carrier immediately,
request an inspection and file a damage claim.
3.2 Hidden Damage
Within 10 days of receipt, measure and record open
circuit voltages (OCV's). If any damage is found,
request an inspection by the carrier and file a hidden
damage claim. Do not delay this step as it may result
in a loss of right of reimbursement for hidden
damages.
SECTION 4 - STORAGE
4.1 General
Do not store batteries outside, exposed to the
elements. Store indoors in a cool, dry location. Do
not store batteries in temperatures over 35ºC. The
recommended storage temperature is 20  C or below.

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Do not stack / top load pallets, or allow any other
material to be stored on top of the pallets or possible
battery damage may occur. Do not store where the
possibility of metallic objects falling on the battery
may occur.
4.2 Short Term Storage
CELLYTE 2ETG Gel OPzV batteries are shipped fully
charged from the factory. If the batteries are to be
stored for 9 months or less at 20ºC or below before
being put into service, nothing need be done at this
time. If the batteries are to be stored longer than 9
months, at temperatures greater than 20ºC, or
installation is delayed beyond expected time, a
storage charge may be required. A storage charge is
an equalizing charge applied to a battery that is
stored in open circuit (not float charging) condition.
See Section 6.5 for details.
If the storage temperature is 20ºC or less, CELLYTE
2ETG Gel OPzV batteries must be charged at least
every 9 months while in storage. For every 8ºC
increase above 20ºC, the storage time between
charges is cut in half. Therefore, at 28ºC the
maximum storage time is 4.5 months. At 24ºC the
maximum storage time would be 6 months.
Storage of batteries beyond the recommended
temperatures or storage times, without charging, can
result in permanent loss of capacity, cell shorting and
loss of float life. It can also void the battery's
warranty. Keep careful records of battery time of
arrival, storage time and when last charged.
SECTION 5 - GENERAL INSTALLATION PROCEDURES
CAUTION: Before attempting to install tubular
plate CELLYTE 2ETG Gel OPzV batteries, study
this section and the section on safety thoroughly.
Failure to do so could result in personal injury
and battery or equipment damage.
5.1 Battery Location.
5.1.1 Temperature
Battery location is very important in determining life
and performance of the battery. The ideal
environment would be a dry, indoors, temperature
regulated area. The ideal operational temperature is
20ºC. Operation at temperatures below this will result
in a loss of battery performance and may result in a
larger, more costly battery being needed. Operation
at temperatures above 20ºC will result in loss of
battery operational life. For every 8ºC rise in battery
temperature above 20ºC, the life of the battery will be
cut in half. For example, the CELLYTE 2ETG Gel
OPzV battery is designed for an 18+ year float service
life at 20ºC. If the battery were to be continuously
operated at 28ºC, the life expectancy would be
halved.
5.1.2 Temperature Variation
Maintaining temperature balance across the string is
very important for maximum battery life. The
difference between the maximum and minimum cell
temperature in a series string can be no more than
3ºC. Excessive temperature variation will result in the
need for equalization and may result in loss of battery
operational life.
Sources of battery temperature variation can be
placement of the battery system near a heat source
such as radiators, power equipment, windows or
heating vents. Air conditioning vents can also cause
temperature variations. It is recommended that the
battery location be designed, engineered and
monitored to minimize temperature variations.
5.1.3 Ventilation
Proper ventilation of CELLYTE 2ETG Gel OPzV
batteries is important for two reasons:
1) to minimize battery temperature variation
and
2) to minimize build up of potentially explosive
hydrogen gas.
5.1.3.1 Ventilation and Battery Temperature Variation
Recombinant batteries such as CELLYTE 2ETG Gel
OPzV give off a small amount of heat during charging
and float operations. Proper ventilation is important to
remove this heat and to prevent temperature
differences from arising in the string. Sufficient air
circulation should be present to prevent temperature
layering effects. In an improperly designed room,
there can easily be a 5ºC difference in temperature
between the floor and the ceiling. If this difference
exists in a series string, it will result in a need for
equalization and in reduced battery life.
5.1.3.2 Ventilation and Gassing
As noted, VRLA batteries emit small amounts of gas
during normal charging and floating. The gas
composition, while on float, is approximately 80% by
volume hydrogen with the remainder being oxygen.
CAUTION: Hydrogen gas can be explosive. Never
install batteries in an air-tight space. Ventilation
must be provided to remove this hydrogen gas.
Allow about 1 litre per hour per cell of air
exchange to prevent hydrogen accumulation.
NOTE: In virtually all cases, the amount of air
circulation required for battery cooling and
temperature variation maintenance will far exceed
the amount of air circulation required to prevent
gas build-up. However, ensure some air
exchange is present in the ventilation.
5.1.4 Floor Loading
Before installing the cells/batteries, it should be
ascertained that the floor has the capability to support
the weight of the battery and related equipment. The
total system weight will be the sum of the cells plus
about 5% for the inter connectors and battery rack. It
is the responsibility of the installer to ensure
adequate floor load carrying capabilities.
5.1.5 Seismic Considerations.
When specified CELLYTE 2ETG Gel OPzV battery
racks are capable of withstanding seismic events of
UBC Zone 4 magnitude in horizontal stacks of up to 8
tiers and when properly installed. When seismic
capability is desired, suitable floor anchoring should
be provided. Proper floor anchoring is the
responsibility of the installer. Ensure that the
anchor bolts used are of sufficient strength to
withstand the maximum seismic load foreseeable.
5.2 Unpacking
CELLYTE 2ETG Gel OPzV batteries cells/racks are
shipped on pallets. All the accessories needed for
installation and use are packed in boxes and secured
to the pallet. Unpack all items carefully and note the
quantities received.

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5.3 Installation
5.3.1 General
CELLYTE 2ETG Gel OPzV cells up to 1500 ah (ETG
1700) can be installed in the vertical and horizontal
position. The horizontally positioned cells may be
stacked up to 8 tiers high. Where possible, racks are
configured to provide the termination at the top of the
battery while providing the shortest possible
connections. When a system requires fewer cells than
are needed to completely fill the rack, the extra
spaces will be filled with a dummy cell(s). When
possible, the tiers with the dummy cells will be at the
top of the rack.
CELLYTE 2ETG Gel OPzV cells when mounted in the
vertical position may be placed end-to-end or side-by-
side or a combination of the two. Note that standard
vertical configuration will be supplied unless
specified differently at time of order. Also note that
cells ETG 2300, 2900 & 3500 can only be mounted
vertically. The racks can be designed to meet seismic
zone 0 to 4 qualifications.
NOTE: Handle cells and rack carefully. Do not
try to lift the rack when the cells are in place
because damage to the cells may result.
5.3.2 Location Layout
Locate and mark on the floor the position of the
battery system/rack. Locate and mark the position of
the floor anchor bolts. Determine the polarity location
of the battery system and mark accordingly. Ensure
that sufficient space is available in front or above for
cell handling and placement. Do not locate the battery
system near a source of heat or in direct sunlight.
5.3.3 Horizontal Cell Installation
Using the rack layout supplied assemble the steel
rack, fit all the bolts but leave the bolts loose. With the
wiring diagram supplied, identify the polarity of the
cells to be placed in the bottom tier. Then, noting the
cell polarity, slide each cell carefully into the steel
rack. Repeat this procedure for the cells in each tier.
When all the cells are in place, tighten the bolts to
130 in-lbs (15 N-m).
If the system consists of multiple stacks of racks, the
racks are positioned directly next to each other. The
vertical sections are bolted together between stacks
using the connecting studs provided.
5.3.4 Vertical Module Installation
When the cells are to be installed in the vertical
position, the rack must be first fully assembled. Then
the cells must be individually (carefully) lowered into
the rack. It is highly recommended to attach the rack /
battery system to the floor using suitable floor anchor
bolts. Rack for cells installed in a vertical position may
be designed to meet seismic Zone 0 to 4.
WARNING Do not turn cells upside down or tilt to
the front more than horizontal as this will ‘wet’ the
vent with electrolyte which may be vented when
the cell is charged.
5.4 Electrical Connections
Proper battery electrical connections are very
important for the best battery performance. Improper
battery connections can cause a loss of standby time
or even a battery fire. Follow the electrical connection
instructions carefully and review Section 2.4
thoroughly before working on the battery. Make sure,
before connection, that all terminals and interconnects
are cleaned and are covered with the No-Oxide
grease provided.
CAUTION: Remove all rings and watches before
installing the intercell inter connectors on the
cells. Ensure that all tools are insulated with vinyl
electrical tape to prevent shorting. Do not reach
or lean across batteries. Remember, hazardous
voltages may be present. Be aware of what you
are touching at all times.
5.4.1 Cabling Recommendations
Battery ratings are specified at the terminals of the
battery. The cabling used to connect the battery
terminals to the load has a voltage drop (when the
battery is discharging) that is dependent on cable
length and conductor diameter/size. The longer the
cable run, the greater the voltage drop.
The smaller the cable wire diameter, the greater the
voltage drop.
Therefore, to get the best performance from the
battery short, heavy duty cables are recommended.
Do not size the cables based on current carrying
capacity only. A general rule of thumb is to allow no
more than a 30 mv or less of voltage drop per meter
of cable run. As an example, if it is 10 meter’s from
the battery to the load, the cable should be sized to
allow no more than 2 x 10 x .030 = 0.6 volt drop.
In order to help select cable sizes for load
connections, the following table should be consulted :
CABLE PROPERTIES AT 20ºC
U.S. CABLE AREA MAX AMPS
SIZE mm² 30mv DROP/M
8 AWG 8.4 15
6 13.3 23
4 21.2 37
2 33.6 59
1 42.4 74
0 53.5 93
00 67.4 117
000 85.0 148
0000 107.2 187
250 MCM 126.7 221
350 MCM 177.4 309
400 MCM 202.4 353
500 MCM 253.4 442
Use 1.74 amps/mm² for other cable sizes.
5.4.2 Terminal Preparation
If corroded gently clean the contact surface of the
terminals with a brass bristle brush or a Scotch Brite
pad. Immediately after this cleaning, apply a thin
layer of No-Ox-Id "A" or NCP-2 antioxidant grease to
the contact areas. A petroleum jelly such as
"Vaseline" may also be used.
5.4.3 Connector Installation
The CELLYTE 2ETG Gel OPzV batteries are supplied
with intercell cables sized for the specified discharge
time. If stored for some time the insulated cables may
need to be cleaned at the contact points prior to
installation.
If the interconnect cables need to be cleaned,
carefully use a Scotch-Brite pad or a soft brass bristle
brush to clean the lug to bright metal. Lightly grease
the contact surfaces of the cable lug before
installation. Following the supplied wiring diagram,
install the intercell interconnects connecting positive
to negative terminals. Carefully using the supplied 10
M bolts and tighten the insulated bolts finger tight.

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CAUTION: Use extreme care not to short the
battery connections. CELLYTE 2ETG Gel OPzV
batteries are capable of very high short circuit
currents containing a very high energy level.
Before the final tightening of the intercell
connections, visually check that the connections are
properly made and in the proper sequence. See
Section 5.4.4 for the proper procedure for checking
string voltage. When proper connection has been
verified, torque all intercell connections to 130 in-lbs
(15 N-m).
When installing the battery load cabling, attach the
load cabling to the wall or the cable tray so that the
weight of the cable is not on the battery terminal plate.
If using a stiff cable, pre-bend the cable so no "spring"
force is placed on the terminal plate. Failure to
support the cable weight could result in unnecessary
load being placed on the terminal support plate and
the steel rack.
5.4.4 Voltage Checks
Visually check that all connections are properly made
(positive to negative) and are tight. Measure string
voltage, check that this is about 2.15 x No. of
cells.
CAUTION: High voltage may be present.
The total string voltage should be approximately 2.12
to 2.15 volts multiplied by the number of cells in the
string. If the measured string voltage is not close to
the calculated value, recheck the battery connections
to ensure proper polarity sequence and measure the
individual cell voltages. Calculate the average cell
voltage and use this value to recalculate the string
voltage. If the recalculated and measured string
voltages do not match reasonably well, contact
your SEC representative for further instructions.
5.4.5 Battery to Charger Connection
Ensure that the charger is disconnected from the
power line. If a battery disconnect is installed, open
it.
Note: The positive terminal of the battery bank
should be connected to the positive terminal of
the charger and the negative terminal of the
battery bank should be connected to the negative
terminal of the charger.
5.4.6 Paralleling of Batteries
When greater capacity is desired than available from
a single cell or string, paralleling of batteries becomes
necessary. Batteries must be properly paralleled in
order to get the best system performance and longest
battery life. The battery strings must be treated as
equally as possible. This means equal length cabling
to a common collection point for the load cables,
uniform temperature between the strings and equal
strings of batteries. Do not parallel flooded
batteries with valve-regulated batteries if the
charge voltages differ between the batteries.
Ask SEC for advice on paralleling flooded and VR
batteries.
To check the proper paralleling of the strings, connect
the strings in the final form and place a load on the
battery. Measure the load cable voltage drops. The
voltage drops should match within 5%.
SECTION 6 - OPERATION
6.1 Initial Charge
The initial charge on the battery is essentially an
equalization charge of the battery. Always perform
this charge of the battery when it is first installed.
Failure to do so could result in uneven float
voltages and low initial capacity.
The equalization, or initial charge voltage in this case,
for the CELLYTE 2ETG Gel OPzV battery is 2.4 volts
per cell at 20ºC or 2.38 at 25  C. Calculate the initial
charge voltage for your installation, based on the
number of cells in the string. Turn on the charger and
raise the charger output voltage (using the
equalization control) to the calculated value. Leave
the string charging at this level for 12 hours,
maximum of 24 hours.(The battery is fully charged
when the string voltage has not changed for 3
hours.) At the end of this time, reduce the charger
output voltage to the float voltage 2.23 vpc at
20ºC. See Section 6.2.1 Just prior to reducing the
string voltage to the float voltage, measure and
record the individual cell voltages.
If the charger output voltage cannot be raised to the
calculated initial charge voltage or the load cannot
tolerate a charge voltage this high, raise the charger
output voltage to the maximum permissible level.
Measure the charger output voltage and calculate the
voltage per cell. Use the following as a guideline:
Max. Voltage Charge Time
Obtained (20ºC) (Hrs) Min/Max.
2.32 - 2.35 vpc 12 / 24
2.29 - 2.31 vpc 24 / 48
At voltages below 2.29 vpc, adequate equalization will
not be obtained. Contact your SEC representative for
additional details on procedures to equalize a battery
under these conditions.
If the ambient temperature is not in the range of 20-
25ºC, the initial charge voltage will have to be
temperature compensated.
Temperature compensation is the process whereby
the charge voltage is changed as the function of the
battery temperature. The temperature correction
factor (TCF) for CELLYTE 2ETG Gel OPzV batteries
is -0.003 volts / cell / ºC from a 20ºC baseline
temperature. This means that as the battery
temperature rises (falls) above (beneath) 20ºC, the
charge voltage must be reduced (raised) the TCF
amount for every degree of change. The formula to
calculate the temperature corrected voltage is :
TCV= chg. voltage (20ºC) - [T -20ºC] x (-0.003 v/c)
As an example, if the initial charge were going to be
performed at 30ºC the temperature corrected charge
voltage would be :
TCV = 2.40 - (30-20) x (-0.003 v/c) = 2.31 volts/cell
6.2 Float Voltage
The float voltage is sometimes known as the
continuous charge voltage. It is very important that it
be calculated and set properly for maximum battery
life and performance. The purpose of the float voltage
is to provide enough float voltage and current to the
battery to compensate for self-discharge and maintain
the battery in a fully charged condition of readiness.
Failure to properly follow float voltage
recommendations can result in loss of warranty
and premature battery failure.

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6.2.1 Float Voltage Requirement
The allowable float voltage range for CELLYTE 2ETG
Gel OPzV batteries is 2.22 to 2.24 volts/cell at 20ºC.
The recommended float voltage setting is 2.23
volts/cell at 20  C or 2.21 volts/cell at 25  C.
6.2.2 Float Voltage Temperature Compensation
The float voltage temperature compensation factor is -
0.004 volts / cell / ºC from a 20ºC baseline (the same
as the equalization TCF). For temperatures around
20ºC, use the following table :
Temperature Float Charge
°C volts / cell
5 2.290
10 2.270
15 2.250
20 2.230 <<<Baseline
25 2.210
30 2.190
35 2.170
For temperatures outside of this range see Section
6.1 for the equation used for calculation of the
temperature corrected float voltage.
6.3 Maximum Charge Current
The maximum charge current is limited to prevent the
possibility of charging the batteries at a higher rate
than they can efficiently accept. Greater than
recommended maximum charge currents can result in
excessive battery heating and gassing and a
shortened battery life.
The maximum normal charge current is the C/5
rate in amps, for a 500 AH C/5 rated battery this is
100 amps. If a very rapid recharge is desired,
please contact SEC for more instructions.
6.4 Recharge
Recharge VRLA Gel batteries immediately or as soon
as possible after a discharge. Do not wait more than
24 hours to initiate the recharge after the batteries
have been discharged. Failure to follow this
recommendation could result in a permanent loss
of capacity due to plate sulphation.
The approximate recharge time can be calculated as
follows:
AH discharged
---------------------- x F = number of hours to charge
Available charge current
where F = 3 if the batteries are charged at the float
voltage and F = 2 if an equalization voltage is needed.
6.5 Equalization Charge
The equalization charge voltage of the CELLYTE
2ETG Gel OPzV battery is 2.40 to 2.38 volts per cell at
20  C to 25  C. While equalization is not required by
the CELLYTE Gel OPzV battery under normal
operating conditions, it is possible to operate the
battery in such a way that equalization would be
needed. These conditions would include:
-Temperature variation in the string greater than 3ºC
-Low float voltage
-Low operational temperature without temperature
compensation
-Frequent deep discharges
-Rapid recharge required
-Long delay in recharging the battery after a
discharge
-Unevenly paralleled string balance
Equalization should be performed on an 'as needed'
basis. The standard equalization would be 12 / 24
hours at a constant voltage of 2.40 VPC at 20  C or
2.38 VPC at 25ºC. For equalization at voltages and
temperatures other than the above, see Section 6.1
for methods to compensate.
Section 7 - STORAGE
When installed CELLYTE 2ETG Gel OPzV batteries
will not be used (floated) for a period of time, the
following procedure should be followed:
1. Equalize charge the battery (refer to Section 6.5).
2. Disconnect the battery from all loads. Do not allow
any loads, no matter how small, to remain connected.
3. Equalize charge the battery every 9 months when the
storage temperature is 20ºC or less. For every 8ºC
rise in storage temperature, reduce the equalization
interval by half.
4. Perform a full equalization charge on the battery prior
to returning to service.
During the storage time, particularly if it is extended, it
is recommended to continue to monitor and record
battery voltage levels. Measure and record the battery
open circuit voltage just before equalization and then
record the on-charge voltage and current just prior to
completing the charge. Refer to Section 4.0 for more
information.
Section 8.0 - MAINTENANCE AND RECORD KEEPING
Maintenance and record keeping is critical to battery
life and warranty continuance. Proper maintenance
will ensure that the batteries are being correctly used
and will be available when needed. Proper record
keeping will ensure that, if there is a problem with a
battery, the customer can demonstrate the batteries
were correctly used and so maintain the warranty.
8.1 General Maintenance
General maintenance of the battery means keeping
the battery and surrounding area clean and dry.
Since CELLYTE 2ETG Gel OPzV batteries are of low
maintenance design, there is no addition of water or
specific gravity checks needed for the life of the
battery. The only required maintenance action is an
annual retorque of the battery connections to 130 in-
lbs, (15 N-m). Review Section 2.4 on Electrical Shock
before performing this action.
CAUTION: Only use insulated tools.
Do not use any solvents or strong cleaners on or
around the batteries. A dry brush may be used to
remove any dust accumulations. If required, a solution
of 1 kg of baking soda in 4 litres of water may be used
as a multipurpose cleaner if more stubborn stains or
dirt accumulations are present.
8.2 General Records
8.2.1 Installation Records
When the battery is received, record such things as :
- Date of receipt,
- Condition of the modules,
- Open circuit voltages (if measured)
- Date of installation
- Original P.O. number
- Installer (s) name
- Equalization time and voltage
- Any unusual storage conditions.

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8.2.2 Maintenance Records
At least twice per year, record the following :
- Cell float voltage
- String voltage
- Float current
- Ambient temperature
- Battery temperature
- Battery conditions
- Any unusual charges or discharges - 6 months.
Keep the above records in a safe place for review by
maintenance personnel. Remember, these records
are mandatory for any warranty claim on the
battery.
Section 9 - CAPACITY TESTING
9.1 General
Discharge testing of the battery is performed to
determine the battery capacity. There are two reasons
for performing this test:
(1) A ratings test discharge. The intention here is to
determine the percentage of battery capacity as
compared to the rated capacity. This is typically a
3, 8 or 10 hour discharge test.
(2) A service test discharge. This test is to determine
the battery standby time under the actual load
conditions of intended battery usage.
The ratings test discharge is usually performed
using a suitably designed and sized load bank to
provide a constant current load to the battery. The
test is performed for the specified period of time to
an end-point voltage per cell (usually 1.75 or 1.80
VPC) with the ampere hour capacity of the battery
calculated by multiplying the load current by the
number of hours of run time. The actual AH
capacity can be compared to the rated AH
capacity to determine percentage capacity. This
type of test is usually used as an acceptance test
of the battery.
The service test is usually performed by placing
the actual load on the battery and determining the
actual time the battery will support the load. This
test is done, in the case of a UPS, by switching
into a test mode where the battery becomes the
primary power source and the normal AC line
becomes the back-up. If the load is not critical,
the AC input can simply be shut off to simulate a
loss of power event and total system operation
can be verified as well. A load bank can be used if
the normal battery load is well defined.
9.2 Test Procedure
The battery test procedure for either test is :
(1) Ensure the battery is fully charged before capacity
testing and that all connections are clean and
tight. An equalization charge is highly
recommended before performing a capacity test
and is mandatory if the battery has not been on
continuous float for at least one week or if
there is any questions about the battery's state
of charge.
(2) Prepare the load bank or test load system. Ensure
all temporary cable connections are heavy duty,
secure and connected to the proper polarity, and
have sufficient current carrying capacity.
(3) Determine the battery temperature by measuring
and recording the temperature of every 6th cells.
Average the readings to determine average
battery temperature. Measure the cell temperature
in the middle of the rack (preferably) or the inner
wall of the cell.
(4) If a ratings test is being performed, the load current or
power must be temperature corrected if the battery
temperature is significantly different from 20ºC. The
formula for calculating corrected load is :
Temperature corrected load = load at 20ºC x CF,
where CF is the C/10 capacity correction factor for
temperature. The following table should be used :
Test Temperature Capacity Correction Float
ºC) Factor (CF) voltage
0 0.87 2.310
5 0.91 2.295
10 0.94 2.270
15 0.97 2.250
20 1.00 2.230
25 1.03 2,210
30 1.05 2.190
35 1.07 2.170
If the service test is being performed, no temperature
correction is necessary.
(5) Just prior to starting the discharge test, measure and
record the individual cell voltages, the string voltage
and float current (if available).This can be accurately
measured using the SEC recommended shunt. Which
can be supplied as an optional extra with the battery.
(6) Remove or disconnect the charger from the
battery string.
(7) Connect the load to the battery and start a timer.
Monitor the string voltage and record the lowest
voltage reached and the time reached.
(8) Record the load current, string and individual cell
voltages on a regular basis. A minimum of three sets
of readings should be taken. The time interval
between sets of readings will vary based on the
expected test time. For example, take readings every
hour for the first 5 hours of an 10 hour rating test. For
the following 4 hours take readings every ½ hour. For
the last hour, take readings every 15 minutes. For a
15 minute UPS discharge, readings every 5 minutes
is desirable.
(9) Continue the discharge until the string voltage drops
below the end-point voltage per cell times the number
of cells in the string.
For example: 1.75 VPC x 60 cells = 105.0 Volts
is the stop discharge voltage. Do not be concerned if
the voltage of some cells falls a little below 1.75 on a
new battery these cells will be restored to full capacity
when the battery is recharged.
(10) Stop the timer and remove the load from the battery.
(11) Immediately recharge the battery using the existing
charger or an external charger. An equalize voltage of
2.4 vpc at 20ºC may be used to reduce charge time.
(12) Record the discharge time and calculate percentage
capacity if a ratings test was performed.
(13) Keep a copy of all the test data with the battery
records.

9
DISCHARGE TEST NOTES:
(1) When batteries are new, the battery may deliver only
95% of rated capacity. Full capacity will be obtained
after 3-6 months in float service or after 10 cycles.
(2) String voltage should be measured at the battery
terminals, not at the load connections.
(3) Accurate meters are essential for correct test results.
Ensure all meters, shunts, etc., have been properly
calibrated not more than 6 months before use.
(4) If a long duration test is being performed, the terminal
to terminal voltage drop across the intercell
connections should be measured and recorded. This
will serve as a reference for any needed terminal
maintenance work and will assist in verifying the
battery integrity.
(5) A float voltage check after the test and recharge is
desirable, but not required information.

10
SEC BATTERY MAINTENANCE REGISTER
Date Maintenance Description
SEC SEC
Industrial Battery Co. Industrial Battery Co.

11
11 TECHNICAL SUPPORT
SEC is always ready to assist you in your
installation and operation of SEC CELLYTE
2ETG OPzV range batteries. If you have
any questions on any portion of this manual,
please do not hesitate to call or fax any of
our offices listed below and request
assistance.
SEC Industrial Battery Co. Ltd.
Thorney Weir House
Iver, Bucks, SLO 9AQ,
United Kingdom.
Tel.: [phone]
Fax.: [phone]
SEC Website: www.secbattery.com
Email:[email protected]
SEC European Sales Office
42 rue de la Rochette
77000 Melum
France.
Tel.: [phone]
SEC Website: www.secbattery.com
Email: Christian.dhai[email protected]
SEC Industrial Battery Co. BSC
P.O. Box 32225,
Kingdom of Bahrain
Tel.: [phone]
Fax.: [phone]
SEC Website: www.secbattery.com
Email: [email protected]
SEC Industrial Battery Co. Ltd.,
Unit 6, 6F Hewlett Centre,
No.54 Hoi Yuen Road, Kwun Tong
Kowloon, Hong Kong.
Tel.: [phone]
Fax.: [phone]
SEC Website: www.secbattery.com
Email: [e-mail]

13
Installed by:
Operating Company:
Address/Location:
SEC BATTERY REPORT
Representative:
Date: Time:
No. of Cells/String:
No. of Strings/Battery:
Battery Code:
Ambient Temperature:
Battery Information
Battery Charger Information
Type of Battery:
Make
Installation Date:
Model
Battery Charge Current:
Year of manufacture
Charging Equipment:
Type Charging voltage Current rating
String Float Voltage:
Float Voltage/ Cell:
Float Current:
Cell Temperature:
Float
Charge
Voltage
Float
Charge
Voltage
Float
Charge
Voltage
Float
Charge
Voltage
Float
Charge
Voltage
Open
Circuit
Voltage
Open
Circuit
Voltage
Open
Circuit
Voltage
Open
Circuit
Voltage
Open
Circuit
Voltage
Cell/
Unit
No.
Cell/
Unit
No.
Cell/
Unit
No.
Cell/
Unit
No.
Cell/
Unit
No.
INDIVIDUAL CELL READINGS
Signed:
Remarks and Recommendations:
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SEC
Industrial Battery Co. SEC
Industrial Battery Co.