SEC CELLYTE 6TSG Operating instructions

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CELLYTE 6-12TSG
STATIONARY Gel BATTERIES
Fitted with Catalyst
INSTALLATION and OPERATING
INSTRUCTIONS
Supplied Worldwide by :
SEC Industrial Battery Co.
Last Revised May 2011

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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 6.1.1 Cyclic Charge Voltage 6
3.1 Delivery Inspection 3 6.2 Float Voltage 7
3.2 Hidden Damage 3 6.2.1 Float Voltage Requirements 7
6.2 Float Temp. Compensation 7
4.0 STORAGE 4 6.3 Maximum Charge Current 7
4.1 General 4 6.4 Recharge 7
4.2 Short Term Storage 4 6.5 Equalization Charge
7.0 STORAGE 7
5.0 INSTALLATION PROCEDURES 4 Long term
5.1 Battery Location 4
5.1.1 Temperature 4 8.0 MAINTENANCE & RECORDS
5.1.2 Temperature Variation 4 8.1 General Maintenance 8
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 Technical Support 11
12.0 Battery Report 12

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SECTION 1 - GENERAL INFORMATION
1.1 CELLYTE 6-12TSG Solar Battery Characteristics
The CELLYTE 6-12TSG Solar battery is a valve-
regulated lead-acid recombinant battery designed
for stationary applications. The 6&12TSG Solar
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 6-12TSG Solar 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-
12TSG Solar 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.

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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 6-12TSG Solar 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.
SECTION5-GENERAL INSTALLATION PROCEDURES
CAUTION: Before attempting to install
CELLYTE 6-12TSG Solar 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
nvironment 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 6-12TSG Solar 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 6-12TSG Solar
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-
12TSG Solar 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

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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
carrying capabilities.
5.2 Seismic Considerations.
CELLYTE 6-12TSG Solar 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 6-12TSG Solar 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 6-12TSG Solar 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 blocks is
12 mm. 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 6-12TSG Solar 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 :
12TSG-20 to 12TSG-50 5.1 N-m (45 in pound)
12TSG-60 to 12TSG-130 7.4 N-m (65 in pounds)
12TSG-150 to 12TSG-300 10.2N-m (90in.-pounds))
Do not over-torque.

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CAUTION: Use extreme care not to short the
battery connections. CELLYTE 6-12TSG Solar
batteries are capable of very high short circuit
currents containing a very high energy level.
Install the inter-tier cabling at this time, following
the same general instructions as for installing the
inter-block connections. Attach the inter-tier
cabling to the wall or the rack so that the weight of
the cable is not on the battery terminal. If using a
stiff cable, pre-bend the cable so no 'spring' force is
placed on the battery terminals. Failure to support
the cable weight could result in a premature battery
failure and loss of battery integrity.
5.5.4 Voltage Checks
Visually check that all connections are properly
made (positive to negative) and are tight. Measure
the total string voltage.
CAUTION:High voltage present.
The total string voltage should be approximately
12.5 volts or 6.25 volts for 6 volt, batteries,
multiplied by the number of blocks 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 block voltages. Calculate the
average Bloc voltage and use this value to refigure
the string voltage. If the recalculated and
measured string voltages do not match reasonably
well, contact your SEC representative for further
instructions.
5.5.5 Battery to Charger Connection
Ensure that the charger is disconnected from the
power line. If a battery disconnect is installed,
open it. 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.
5.5.6 Paralleling of Batteries
When greater battery capacity is desired than what
is 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 as the
charge voltages differ between the types of
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 10%.
SECTION 6 - OPERATION
6.1 Initial Charge
SEC recommends that 12TSG batteries be given
an initial charge / equalization charge at the time of
installation in order to ensure that the batteries are
fully charged and the Bloc voltages are uniform. If
an initial charge is not given at the time of
installation then block float voltages may take some
months to become uniform.
The initial or equalize charge voltage for the
CELLYTE 6-12TSG Solar batteries is 2.35 volts
per cell at 20ºC. Calculate the initial charge
voltage for your installation based on either the
number of cells in the string or the number of
blocks 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 24 hours. At the end of this
time, reduce the charger output voltage to the float
voltage level. See Section 6.2. Just prior to
reducing the string voltage to the float voltage,
measure the block voltages and charge current if
possible.
If the charger output 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 per cell.
Use the following as a guideline:
Max. Voltage Charge Time
Obtained (20ºC) (Hrs.) Min./Max.
2.33 - 2.35 VPC 12 / 24
2.31 - 2.33 VPC 36 / 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 20ºC, the initial
charge voltage will have to be temperature
compensated (TC). T C is the process whereby
the charge voltage is changed as the function of
the battery temperature. The temperature
correction factor (TCF) for CELLYTE 6- 12TSG
Solar batteries is -0.003 volts / cell / ºC from a
20ºC baseline temperature. 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 = CV (20ºC) +/- [T-20 ºC] x (-0.003 v/c)
As an example, if the initial charge were going to
be performed at 32ºC the temperature corrected,
reduced, charge voltage would be :
TCV = 2.35 - (32-20) x (-0.003 v/c) = 2.31 vpc
6.1.2 Cyclic Charge voltage
For batteries used in cyclic applications for
Renewable energy applications the re charge
voltage will depend on the depth of charge and the
time available for re charge. The charge voltage
will be from 2.35 vpc to 2.45 vpc or higher if only
very short recharge time. Please contact SEC for
more site specific charging information.

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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 the battery
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.
6.2.1 Float Voltage Requirement
The recommended float voltage for the CELLYTE
6-12TSG Solar batteries is 2.25 volts/cell at 20ºC.
6.2.2 Float Voltage Temperature Compensation
The float voltage temperature compensation factor
is: 0.003 volts per cell per ºC from at 20ºC baseline
(the same as the equalization TCF).
For other temperatures use the following table.
Temperature (ºC) Float Charge V/C
10 2.290
15 2.270
20 Baseline 2.250
25 2.250
30 2.230
35 2.210
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 charge current is normally limited by using the
recommended float voltage. At higher charge
voltages the maximum charge current should be
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 charge currents are :
Maximum Charge Rates for CELLYTE 6 &12TSG
SOLAR TYPE AMPS
6TSG130 18.6
6TSG220 31.0
6TSG250 35.6
12TSG-20 2.63
12TSG-30 4.02
12TSG-40 4.80
12TSG-50 6.50
12TSG-60 8.51
12TSG-70 10.1
12TSG-80 10.8
12TSG-90 12.4
12TSG-100 13.9
12TSG-110 15.5
12TSG-120 17.0
12TSG-130 18.6
12TSG-150 21.1
12TSG-170 23.5
12TSG-190 26.5
12TSG-210 29.4
12TSG-250 35.6
12TSG-300 41.5
6.4 Recharge
Recharge 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 = charge time Hr.
Available charge current
where F = 3 if the batteries are charged at the float
voltage and F = 2 if an equalization voltage is
needed.
Do not exceed the maximum charge currents listed
in Section 6.3.
6.5 Equalization Charge
The equalization charge voltage of the CELLYTE 6
-12TSG Solar battery is 2.35 vpc at 20°C.. While
equalization is not required 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
Lowoperationaltemperaturewithoutemperaturecom
pensa
tion 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
24 hours at a constant voltage of 2.35 VPC at
20ºC. or 2.33 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 6-12TSG Solar 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 6 months when
the storage temperature is 20ºC or less. For every
8ºC rise in storage temperature, reduce the
storage/equalization interval by half.
4. Perform an 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.

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Section 8 - 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 6-12TSG Solar 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; see Table 1 in Section 5.5.1 for re
torque values. Review Section 2.4 on Electrical
Shock before performing this action.
CAUTION: Use only 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 liters of water
may be used as a multipurpose cleaner if more
stubborn stains or dirt accumulations are present.
Follow the rack or cabinet manufacturer's
instructions for maintenance if required.
8.2 General Records
8.2.1 Installation Records
When the battery is first received, record:
- Date of receipt,
- Condition of the battery blocs,
- Open circuit voltage of each block,
- Date of installation
- Original P.O. number
- Installer (s)
- Equalization time and voltage
- Any unusual storage conditions.
- Individual block float voltages,
- Ambient temperature,
- Float current,
- Battery temperature,
- String float voltage
8.2.2 Maintenance Records
Twice per year, record the following :
- Block float voltages
- String voltage
- Float current
- Ambient temperature
- Battery temperature
- Battery conditions
- Any unusual charges or discharges - last 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 percent of battery capacity as
compared to the rated capacity. This is typically an
8 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
DC current load to the battery. The test is
performed for the specified period of time to an
end-point voltage per cell (usually 1.67 - 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
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.
If the battery has not been on float for at least one
week, perform an equalization charge, return the
battery to float charge and allow at least 1 hour to
stabilize.
(2) Prepare the load bank or test load system. Ensure
all temporary cable connections are 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 6 blocs.
Average the readings to determine average battery
temperature. Measure the battery temperature in
the middle of the side (preferably) or the end wall of
the container.
(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,

9
where CF is the capacity Correction Factor for
temperature.
The following table should be used :
Test Temperature Capacity Correction
(ºC) Factor (CF)
0 0.84
5 0.89
10 0.94
15 0.97
20 1.00
25 1.02
30 1.04
35 1.05
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 bloc voltages, the string
voltage and float current (if available).
(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 (this is
called the coup de fouet and is indicative of a fully
charged battery).
(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 4 hours of an 8 hour rating
Test.
For the following 3 hours take readings every ½
hour. For the last hour, take readings every 15
minutes. For a 15 minute UPS discharge,
readings every 1 to 3 minutes would be 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 exemple:
1.75 VPC x 60 cells = 105.0 Volts - Stop
discharge
(10) Stop the timer and remove the load from the
battery.
(11) Recharge the battery using the existing charger or
an external charger. An equalize voltage may be
used to reduce charge time.
(12) Record the discharge time and calculate %
capacity if a ratings test was performed.
(13) Keep a copy of all the test data with the battery
records.
9.3 Discharge Test Notes:
(1) .CELLYTE 6-12TSG Solar batteries are shipped at
about 95% capacity, full capacity will be achieved
after 10 to 15 deep cycles or 3 months on float
charge.
(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 that all meters, shunts, etc., are
properly calibrated 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
recommended.

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 6-12TSG 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]

12
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
Open
Circuit
Voltage Open
Circuit
Voltage Open
Circuit
Voltage
Cell
I.D.
No.
Cell
I.D.
No.
Cell
I.D.
No.
Cell/
bloc
No.
Cell/
bloc
No.
Cell/
bloc
No.
INDIVIDUAL CELL READINGS
1
2
3
4
5
6
7
8
9
10
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13
14
15
16
17
18
19
20
21
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35
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58
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60
61
62
63
64
65
66
Signed:
Remarks and Recommendations:
SEC
Industrial Battery Co.
SEC
Industrial Battery Co.