SEC CELLYTE 6-12TLG User manual

1
CELLYTE 6-12TLG
STATIONARY GEL BATTERIES
INSTALLATION and OPERATING
INSTRUCTIONS
NON-SPILLABLE by DOT
(Department of Transportation)
ICAO (International Commercial Airline Organization)
and IATA (International Airline Transport Assocaiation)
Supplied Worldwide by :
SEC Industrial Battery Company
Last Revised May 2011

2
TABLE OF CONTENTS
SECTION CONTENT PAGE SECTION CONTENT
PAGE
1.0 GENERAL INFORMATION 3 5.5 Electrical Connections 5
1.1 Battery Characteristics 3 5.5.1 Cabling recommendations 5
5.5.2 Terminal Preparation 5
5.5.3 Connector Installation 5
2.0 SAFETY INFORMATION 3 5.5.4 Voltage Checks 6
2.1 General Information 3 5.5.5 Battery to Charger Connection 6
2.2 Sulphuric Acid 3 5.5.6 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 6
3.2 Hidden Damage 3 6.2.2 Float Temp. Compensation 6
6.3 Maximum Charge Current 7
4.0 STORAGE 4 6.4 Recharge 7
4.1 General 4 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 8
5.1.3.1 Battery Temperature Variation 4 8.2.1 Installation Records 8
5.1.3.2 Ventilation and Gassing 4 8.2.2 Maintenance Records 8
5.1.4 Floor Loading 4
5.2 Seismic Considerations 5 9.0 CAPACITY TESTING 8
5.3 Installation - Cabinets 5 9.1 General 8
5.4 Installation - Racks 5 9.2 Test Procedures 8
5.4.1 Existing racks 5 9.3 Discharge Test Notes 9
5.4.2 New racks 5
5.4.3 Installation 5 10.0 Battery Maintenance Register 10
11.0 SEC Technical Support 11
12.0 SEC Battery Report 12

3
SECTION 1 - GENERAL INFORMATION
1.1 CELLYTE 6-12TLG Bloc Battery Characteristics
The CELLYTE 6-12TLG Bloc battery is a valve-
regulated lead-acid recombinant battery designed for
stationary applications. The 6-12TLG Bloc battery uses
Gelled electrolyte technology. This type of battery has no
special ventilation or handling requirements. Because
the electrolyte in the battery is immobilized, the batteries
are considered dry batteries 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, see the
following sections.
- Disconnect all power before attempting to install, remove
or perform maintenance work. 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
cover, vents, terminal covers, etc.
- Keep batteries clean and dry. Use ½ kg of baking soda
in 4 liter’s 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 cabling.
- Keep battery connectors clean, greased and tight. A
loose connection can reduce battery standby time and
cause battery fires.
2.2 Sulphuric Acid
The CELLYTE 6-12TLG Bloc is a lead acid battery and
contains Sulphuric acid in diluted form. Because the
electrolyte is immobilized, in the event of case 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 (1kg in 4 liter’s of
water). Seek medical attention immediately. Do not
handle batteries that have been dropped or where
the container has been ruptured except while
wearing rubber gloves. Do not try to disassemble a
battery.
2.3 Gassing
All lead acid batteries emit some gases during charging
and float operation. Conventional flooded batteries
release all the gases produced to the environment
whereas 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 6-12TLG Bloc 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 lead acid batteries,
never charge or use batteries in an unventilated space
or container. 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 Shock
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 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. SAFETY is always the
primary concern.
SECTION 3 - RECEIPT OF EQUIPMENT
3.1 Delivery Inspection
Immediately upon delivery, inspect the batteries for
damage caused in transit. Damaged pallets or packing
material or disarrayed batteries could indicate rough,
improper handling in transit. Describe in detail (and take
photographs if necessary) any damage on the delivery
receipt before signature. If any damage is found,
contact the carrier immediately, request an inspection,
and file damage claim.
3.2 Hidden Damage
Within 10 days of receipt, inspect all batteries for hidden
damage. 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.

4
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 30ºC. The recommended
storage temperature is 20ºC or less. Do not stack 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
If the batteries are to be stored for 9 months or less at
20ºC, before being put into service, nothing need be
done at this time. If the batteries are to be stored for
longer than 6 months, at temperatures greater than
20ºC, or installation is delayed beyond expected time, a
storage charge may be required. A storage charge is an
equalization 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 6-
12TLG Bloc 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 25ºC the maximum storage time would be 5
to 6 months.
Storage of batteries beyond the recommended
temperatures or storage time, without charging, can
result in loss of capacity, cell shorting and loss of float
life. It can also void the battery's warranty. Keep careful
records of battery storage time and handling.
SECTION 5 - GENERAL INSTALLATION PROCEDURES
CAUTION: Before attempting to install CELLYTE 6-
12TLG Bloc 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 operation life. For every
8ºC rise in battery temperature above 20 ºC, the life of
the battery will be cut in half. For example, the
CELLYTE 6-12TLG Bloc battery is designed for a 10
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 block temperature
in a series string can be no more than 3ºC. Excessive
temperature variation will result in the need for
equalization and will shorten battery 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 6-12TLG Bloc batteries
is important for two reasons :
(1) to minimize battery temperature variations
and
(2) to minimize build up of potentially explosive
hydrogen gas.
5.1.3.1 Ventilation & Battery Temperature Variation
Recombinant batteries such as CELLYTE 6-12TLG
Bloc batteries, 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. If the
batteries are installed in a cabinet, it should be designed
to allow unobstructed air circulation and prevent
temperature build-up. Use angle iron support rails
instead of shelves. If the batteries are on racks,
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, lead acid 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 airtight enclosure. Ventilation
must be provided to remove this hydrogen gas.
Allow about 1 litre per hour per battery of air
exchange to prevent hydrogen accumulation.
NOTE: In most 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 batteries, it should be
ascertained that the floor has the capability to support
the weight of the battery, rack or cabinet and related
equipment. The total system weight will be the sum
of the batteries, rack or cabinet plus 5% for the
battery connectors. It is the responsibility of the installer
to ensure adequate floor load carring capacity.

5
5.2 Seismic Considerations.
CELLYTE 6-12TLG Bloc batteries are capable of with
standing seismic events of UBC Zone 4 magnitude when
properly installed in a suitably designed cabinet or rack.
When seismic capability is desired, suitable floor
anchoring should be provided. Proper floor anchoring is
the responsibility of the installer.
5.3 Installation – Cabinets
When installing CELLYTE 6-12TLG Bloc batteries in
cabinets, follow the recommendations of Section 5.1.3.1
regarding cabinet ventilation. Ensure that the batteries
are electrically insulated from the cabinet frame.
Standard battery spacing is 12 mm minimum between
battery blocks. If the cabinets are to be seismic rated,
the batteries must be firmly strapped or otherwise
attached to the cabinet to prevent battery shifting during
a seismic event. Proper installation is the responsibility
of the installer.
5.4 Installation - Racks.
5.4.1 Existing Racks
When CELLYTE 6-12TLG Bloc batteries are to be
installed on existing racks, ensure that the racks are:
1. of proper size for the intended battery;
2. have sufficient weight carrying capability for the intended
battery, including seismic considerations, and of
sufficient size to hold the number of blocks (plus the 12
mm needed between blocks) for the complete system.
Before the new batteries are installed, touch up any
nicks, scratches or acid marks on the rack with the paint
provided by the manufacturer. Ensure that the rail
insulators are in good condition or replace. Check that
the rack is level and re-level if necessary. Check the
floor anchors and re torque all bolts of the rack to
manufacturer's specifications.
5.4.2 New Racks
Assemble the rack according to the manufacturer's
instructions. Ensure that the rack is level and all bolts
are properly torqued.
5.4.3 Installation
Determine the location of the positive and negative
terminals of the battery with respect to the rack
location. When placing batteries on the rack, alternate
the polarities for proper intercell connection. Standard
spacing between blocs is 12 mm. Gently position the
batteries on the rack. Do not drop.
5.5 Electrical Connections
Proper battery electrical connections are very important
for the best battery performance and utility. 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.
CAUTION: Remove all rings and watches before
installing the connectors on the batteries. Ensure
that all tools are insulated with vinyl electrical tape
to prevent shorting. Do not reach or lean across
batteries on step racks. Remember, hazardous
voltages are present. Be aware of what you are
touching at all times.
5.5.1 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 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
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 of voltage drop
per meter of cable run. As an example, if it is 10 meters
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.
Interblock cables are provided, in order to help select
cable sizes for inter-tier and 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
Use 1.74 amps/mm² for other cable sizes.
5.5.2 Terminal Preparation
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.
5.5.3 Connector Installation
The CELLYTE 6-12TLG Bloc batteries are supplied with
hardware to attach the cables. Install the copper
interconnect or cables (positive of one battery to
negative of the next) and the hardware. Hand tighten
only at this time to allow room for positioning of the
blocks. Once all cables are in place, all connections
should be torqued to the values below :
12TLG-20 to 12TLG-50 5.1 N-m (45 in pound)
12TLG-60 to 12TLG 130 7.4 N-m (65 in -pounds)
12TLG-150 to 12TLG-300 10.2 N-m (90 in.-pounds))
Do not over-torque.
CAUTION: Use extreme care not to short the battery
connections. CELLYTE 6-12TLG Bloc batteries are
capable of very high short circuit currents
containing a very high energy level.