Power Battery Company, Inc. Field Service Manual
Contents
1. Power Battery Company Inc Field Service Manual Valve Regulated Lead Acid Battery Field Service and Application Manual First Edition February 2007 1 0 2 0 3 0 4 0 5 0 6 0 7 0 9 0 9 0 10 0 11 0 12 0 13 0 Table of Contents Scope Safety Storage Requirements Ventilation Temperature Floor Loading Neutralizing Spilled Acid Visual inspection and Open Circuit Voltage OCV Measurement Safety Procedures and Tool List for System Maintenance Battery Installation and Operating Instructions Field Service Report Form Power Battery Model Number Reference Guide Contact Information 4111114 3811 15153 5 8 E hd 1 Cag This manual has been designed to provide the user with some specific battery application and field service information It has been divided into nine sections by subject matter for ease of use By following these guidelines one can expect safe reliable cost effective service from Power Battery V R L A batteries Power Battery believes that with qualified experienced personnel following these instructions step by step adopting normal safety precautions for electrical installations paying particular attention to those emphasized in the attached specification and with the safety features built into the cabinets there should be no reason for personnel to be exposed to undue electrical hazards This in2. 1 6801 1111 13 20 645 210111 P 1290 E 1 4 30 12601 540 12 30 amp 15 12001 4 600 11 70 5 85 11 50 5 55 10 60 5 40 0 10 20 30 40 50 50 70 80 80 100 Remaining capacity x Full charge battery O C V 12 96 6 48 Minimum battery O C V for recommended recharge Notes When battery O C V is measured it is accurate to within 10 remaining capacity for batteries on charge or discharge within the last 24 hours After a minimum of 72 hours on open circuit accuracy increases to 2 5 Notes Using these parameters one can take advantage of the longest possible storage durations without subjecting the battery to any potential harm caused by the delirious effects of prolonged self discharge The open circuit voltage O C V can also be useful in approximating the remaining storage time available before the batteries reach the minimum O C V 12 40V 12V or 6 20V 6V before recharge A curve has been provided to show the relationship of Battery O C V vs Percent Storage Time Remaining DWG BSD OCV To use this curve take the O C V of the battery and locate the point on the curve which intersects with the percent remaining storage time This percentage is then multiplied by the storage time and temperature parameters given earlier to calculate the approximate storage time remaining before required recharge It should be noted that the battery
3. If Power Battery VRLA batteries are operated within the recommended guidelines and if cabinet ventilation slots are not impeded there is no possibility of reaching dangerous concentrations of hydrogen within the battery cabinet lemperature 5 0 lemperature Heat is the worst enemy of any battery Its effects must be seriously taken into account and steps must be taken to minimize these effects The application parameters to do so are covered below charge ycRa uma d mE cu T4 200 m IW vem Battery system location is the first part of the application detail needed to properly size and use any battery It is recommended that a battery system s average temperature be maintained between 68 77 F A cell to cell variation of 5 F maximum is also highly desirable When a system location calls for temperatures outside these parameters applications engineering may use one of the following methods Design the system with the added temperature environment controls ex change o system location forced air circulation and or cooling pro visions etc or use the temperature compensation float voltage coefficient of 0 0017 V P C or 0 0017 V P C per F For temperatures above 77 F subtract coefficient from float voltage For temperatures below 77 F add coefficient to float voltage battery system s discharge capacity A battery system
4. When Power Battery series of batteries are charged at constant potentials below 2 37 VPC at temperatures up to 929F 33 339C and below 2 25 VPC up to 1079F 41 679C 10096 of the gases produced are recombined internally so that no gas is evolved If the batteries are charged at higher voltages or temperatures small amounts of gas may be evolved Recombination efficiency is about 90 at 2 5 VPC 1072F 41 679C Power Battery VRLA batteries internally recombine all gasses generated within the batteries if they are charged or maintained on float within the recommended charge conditions If the batteries are charged at voltages above 2 37 VPC 14 22 volts for 12 volt batteries small amounts of gas may be evolved particularly if the batteries are above ordinary temperature A typical UPS battery installation uses battery cabinets with an internal volume of 56 cubic feet Power 4 Such cabinets usually contain 40 batteries occupying 23 cubic feet and electronic gear occupying 1 cubic foot leaving 32 cubic feet of free air space The cabinet has ventilations slots with a total open area of 0 32 square feet Hydrogen will leave the cabinet both by diffusion through the ventilation slots and other openings and by convection Calculations based on the known diffusivity of hydrogen show that a maximum equilibrium concentration of 0 06296 hydrogen will be reached within the CR4 cabinet when the batteries are charged at 2 5 VPC at 779F 259C w
5. 12655 410 Za E ECE 2 9 221 KK BRE s were pun PRC TC 12905 PRC TC 121005 5 14 319 18 PRC TC 121205 CO c 14 New 12140 6 C2 PRC TC 62008 D C2 O Co 518 9 1 ms AH ELA Ro ELI Rud KL E ILLA PRC TC 62255 m 1 67 1 75 FEE 2 ee p 2550C nm 1 67 1 75 2600 O SLF 12105 New 12120 12205 N 1 75 12250 oy c oO C1 Oj 02 02 j j 25 BR NEN ES 211 22 ARARA x ITE Ip 1 1 ic LI mp eje PIT T 140 Tr ENEN 265 i48 96 256 ss ue ws II ssp om oo 15 minutes to 10 02 volts 1 67 volts per cell 30 minutes to 10 02 volts 1 67 volts per cell For extended discharge rates on any one battery please click below on the battery model number 15 minutes to 10 02 volts 1 67 volts per cell 30 minutes to 10 02 volts 1 67 volts per cell For extended discharge rates on any one bat
6. S 130 135X680X115 C 130 135X681X1082 _ HEAVYDUTYCASE C 29 T7XSI18XT19 0000 C 4 861X536X820 C 1022X667X904 0 DIDNOTEXIST 40 2 1200X668X909 S DIDNOTEXST DID NOT EXIST DID NOT EXIST DID NOT EXIST CSL 1280 CSL 12100 CSL 12170 CG 45 12SLC TC 2550XC C C TL 12120 TL 6195 TL 2480 NO CHANGE NO CHANGE C 135x681x845 c 135 681 1082 C 19 107X738X1098 C 107X738X1094 C 82 210X428X968 C 10 210x428x963 C Nocwance C 10 2112X87X104 casorsic sic 230810 C 30 717X518X738 SSS caastasic SLC 2458 SLC DID NOT EXIST 22 TL 12445SLC TL 1280SLC TC 2550C C 145 861x536x865 v C 82 1200X668X954 C 50 107X738X1098 Tezexc C 260 552 107X738X1094 12 0 General specifications Dimensions in mm Weight Terminal Standard Flame Retardant Volts ckw L w H Types PRC 12555 12655 12905 121005 121205 4 125 21 2 12555 9 00 229 5 50 140 5 6 5 no 12 12 12 12 12 12 6 6 2 5 SLF 1210 1 909 21 0 534 74 0 33 6 184 21 1 536 8 46 215 15 minutes to 10
7. They should also be placed away from any heat sources including heaters steam pipes equipment or in direct sunlight The table below represents the maximum allowable storage time at various battery storage temperatures Storage parameters Ambient Temperatures Typical storage time 66F 90F Gmonths 914 1046 Smonths 00 106 F 120 F 1 1 2 months Battery Open Circuit Voltage A useful tool in determining the battery s state of charge while in storage is the open circuit voltage O C V The is a relative measure of the electrolyte concentration specific gravity contained within the battery The electrolyte specific gravity is a direct measure of the battery s state of charge and can be used to determine the percentage of battery capacity remaining at any given point This relationship is exhibited on the Battery Open Circuit Voltage vs Percent Remaining Capacity curve DWG BSD From this curve it can be seen that a battery voltage of 1 98 V P C 11 88 for 12 volts 5 94 for 6 volts or less will have zero percent capacity remaining In order to prevent any possible permanent plate damage from occurring due to self discharge it is recommended that when any battery in storage has an O C V corresponding to the 50 capacity level 12 40 for 12 volts 6 20 for 6 volts it should be promptly recharged DWG BSD Battery open circuit voltage vs remaining capacity curve 13 80 4 75 13 50
8. s O C V has some limitations on its accuracy The percent capacity remaining is within 1096 or 10 if the battery has been on charge or discharge within the last 24 hours After a battery has remained on open circuit for a minimum of 72 hours the accuracy increases to 2 5 or 42 596 The battery O C V can also be used in approximating the state of charge after a discharge using the same parameters as described above However it should be noted that this does not apply for the percentage of remaining storage time curve as all batteries should be recharged immediately after a discharge All batteries should be recharged using a constant voltage of 2 27 2 30 V P C at 77 F for a minimum of 24 hours or until the float current stabilizes for 3 consecutive hourly readings Battery carton date coding battery cartons are date coded with a recommended recharge data The date code month year has been calculated for normal storage temperature conditions 66 F 90 F and dated 6 months from the battery s last full charge The battery s O C V should continue to be checked at frequencies described earlier to give a true indication of when a battery will require a recharge Battery terminal date coding consists of the month and year date of manufacture located on the negative battery terminal unless noted otherwise Due to the natural self discharge of the batteries many of the storage parameters discussed earlier would apply when shuttin
9. s discharge capacity is directly related to the battery s temperature PRC Series batteries are rated 10096 at 77 F The percentage of capacity available at a specific rate of discharge can be taken directly from the Percent Capacity VS Temperature curve DWGZ BTD 377 enclosed To use one must first select the rate of discharge closest to the actual rate the application calls for then travel along the curve to the expected operating temperature on the horizontal axis Now find the point on the vertical axis that corresponds to the temperature and rate curve selected Multiply this percent capacity by the ampere or wattage rate on the published discharge curves to arrive at the temperature corrected discharge rate The designed float service life The designed float service life of Power Battery batteries is 10 years at 77 using a 2 27 2 30 V P C temperature compensated float charge voltage The float service life is directly related to the application s operating temperature For temperatures above 77 F standard grid growth corrosion is accelerated and battery life is shortened The actual amount in which the life will be affected is given on the Temperature effects on long term float life curve DWG BTD 277 enclosed This curve was derived from experimentation based on the developments by the scientist E Willihnganz in a paper presented in Electrochemical Technology Oct 1968 This paper titled Accelerated Life Testing of S
10. to performing work on the batteries 3 Do not smoke light matches or cause sparks near any storage battery 4 Remove rings and metal watchbands and jewelry before working on batteries 5 Do not place tools or metal objects on battery 6 Use insulated tools when working on battery 7 Make sure installation is in accordance with engineering instructions prior to battery start up 8 Review all battery specifications from instructions 9 Perform routine maintenance from instructions 1382 2 0203 Field Service Report Form POWERZ AND OPERATING Power for a World of Applications INSTRUCTIONS FIELD SERVICE REPORT FORM Power 5 system model no Customer s system ID no Date of installation 11111112 Inspection date Type of inspection C Monthly C Semi annual C C Bi annual System Information Charger model Environmental conditions Charge voltage at battery Charge current Float setting Hi rate setting Physical condition Retorqued Full discharge test Temperature of the Batteries Individual Battery Checks test from positive to negative Battery B Battery faz 15 z 29 30 11 12 13 14 15 16 17 18 0 2 1 NN 19 4 2 U S A CANADA UK ITALY CHINA Power Battery Company Power Battery Iberville Ltd Power Batteries Ltd Power Battery 51 Power Ba
11. 02 volts 1 67 volts per 30 minutes to 10 02 volts 1 67 volts per cell 3 o 220 2 2 gt gt 12 12 12 General Specifications Continued Battery model number i Dmensions in mm Weight Standard Flame returdant Volts AH KW L W H Ibs kgs 215 975 26 7 12 1 37 0716 8 10 50 7 16 0 60 6 27 5 Po oS On Go N lt 719 327 818372 SLF 12205 SLF 12250 18 2 850 13 5 344 6 76 172 10 87 276 100 1 45 5 3 030 13 5 344 6 76 172 10 87 276 100 1 45 5 0 295 6 25 159 3 35 85 7 00 178 13 0 5 90 1 856 10 7 272 7 38 187 11 6 295 77 2 35 1 2 058 10 7 272 7 38 187 11 6 295 82 2 37 4 1 063 10 7 272 7 38 187 10 9 278 81 9 37 2 87 0 39 6 74 0133 6 78 35 4 146 5 66 5 5 030 21 1 536 8 46 215 10 1 256 150 67 9 ai on pol po mco Cl HI Slo Pol Pol pol pol pol po HIGH RATE SERI ES WATT CONSTANT CURRENT DISCHARGE RATES 9 77 Watts per battery 77 25 C minutes hours Battery Em 4 3 d PRC TC 1225 169 1 75 PRC TC 1235L 199 188 PRC TC 12555 rw pue pue pee re Lust 3 PRC TC
12. 5 SLF 12205 MC 100X DIDNOTEXST DIDNOTEXST DID NOT EXIST DIDNOTEXST DIDNOTEXST DIDNOTEXST DIDNOTEXST DID NOT EXIST DID NOT EXIST DID NOT EXIST DID NOT EXIST xw TERM TERM cig DIMENSIONS L X W X COMMENTS TYPE NEW MODEL 8 TYPE H PRC1225X or TC 1225X PRC12225 or TC 1225 L 6 5 X 6 81 X 4 94 L L C C NON 12908 or TC 12908 S 76 102X667X944 121008 12108 S 91 120X686X958 O PRC12120S 121208 S 110 135X681X9 2 NEWCASE W HANDLE amp COVER PRC12150C 12150 C 130 135X681X115 NEWCASE W HANDLE amp COVER PRC12150C 12150 C 130 135X681X115 NEWCASE W HANDLE amp COVER MC 90 MC 90P MC 100 MC 100P MC 120 MC 120P MC 150 MC 150P TL 1230 TL 1245 TL 1270 TL 1295 pu 1 BICONTNUED 7 2000 PRC1250S 12508 S 50 88 536 868 00000000 PRC1235L 1235 L 32 71X518X7 19 PRC 1265 126588 S 63 102X667X944 2241 41 12 DISCONTINUED 7 2000 DISCONTINUED 7 2000 DISCONTINUED 7 2000 c 911 210X428X9 3 s 7e 109x667x944 C 76 1023X667X904 _ MHEAVYDUTYCASE S 1911 206 668 58 o oS c o 1206 668 909 HEAVYDUTYCASE S 10 135x681x920 C no 135 681 84 HEAVYDUTYCASE
13. able to a UPS and a remote battery supply not having a grounded supply circuit Tool List needed for System Maintenance Digital Voltmeter 3 1 2 digit minimum 0 2596 accuracy rated 600 V D C minimum Due to the close tolerances needed for battery maintenance typically 20 40 MV on a 20V scale analog meters are not recommended The voltmeter should be checked and calibrated at yearly intervals Thermometer Thermocouple contact type 1 F 0 5 C accuracy Mercury in glass thermometers can be used for ambient air temperature readings However a surface contact type is needed for individual battery temperatures Infrared sensing optical thermometers may also be used for this application Capacity Tester This can be an external load tester or the UPS It is recommended that all battery systems be tested for rated capacity at least every two years or until the batteries reach 8596 capacity Annual testing should be performed thereafter until the batteries reach 80 capacity Microhmeter Biddle Instrument DLRO or equivalent low resistance ohmmeter Torque Wrench 0 120 1 105 5 in Ibs graduations The wrench and all other equipment used in battery maintenance must be insulated to prevent short circuit and calibrated every year Other tools needed End wrenches insulated screwdrivers insulated socket sets insulated plastic handled cleaning brushes tools must be insulated to ensure the safety needed batte
14. arging severe swelling cover deformation vent caps missing Disconnect and isolate the battery system from all charging and discharging circuitry before approaching the system DO NOT circumvent any device installed by Power Battery or the Charger Manufacturer for the purpose of protecting the battery system These devices include Fuses and Circuit Breakers Disconnects Switches and any other protection devices 2 0 Storage Requirements 3 0 Storage All lead acid batteries will self discharge when allowed to stand on open circuit This self discharge is due to Local Action caused by dissimilar metals positive vs negative plates used within the cell s construction The result of the self discharge is loss of cell open circuit voltage consequently loss of capacity allowed to progress beyond the normal limits excessive plate sulfation may occur causing permanent loss of capacity and premature battery failure These batteries have been designed to minimize the effects with the use of the purest plate materials available This has resulted in a reduction of the self discharge rate to approximately one fifth of a conventional lead acid battery The rate of self discharge will also be dependent upon the battery s storage temperature Lower storage temperatures will reduce the self discharge rate higher temperatures will increase the rate A cool dry area is the recommended environment in which batteries should be stored
15. batteries 6 Servicing of battery or batteries should be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries 7 When replacing batteries use the same number and type specified on the battery or drawing The battery or batteries should be valve regulated lead acid type 8 Caution Do not dispose of battery or batteries a fire The battery may explode 9 Caution Do not open or mutilate the battery or batteries Released electrolyte is harmful to the skin and eyes It may be toxic 10 Caution A battery can present a risk of electrical shock and high short circuit current Observe proper precautions 11 Proper disposal of battery or batteries is required Refer to your local codes for disposal requirements 12 The following safety procedures shall be followed A Remove watches rings and other metal objects Use tools with insolated handles Where rubber gloves and boots Do not lay tools or metal parts on top of batteries m J O UJ Disconnect charging source prior to connecting or disconnecting battery terminals 13 Determine if the battery is inadvertently grounded If inadvertently grounded remove source of ground Contact with any part of a grounded battery can result in electrical shock The likelihood of such shocks will be reduced if such grounds are removed during maintenance This paragraph is applic
16. erminal temperatures on discharge resulting in reduced capacity possible personal injury and equipment damage Caution DO NOT over torque terminal connections Excessive pressure on the terminal will cause creep flow of lead resulting in low contact pressure loose connections and possible permanent damage to the terminals SAFETY PROCEDURES AND TOOL LIST NEEDED FOR SYSTEM MAI NTENANCE 15 mri 2 wi jul J T PP 9 0 Protective Equipment 1 Goggles and face shields 2 Acid resistant insulated gloves 3 Protective aprons and overshoes 4 Lifting devices of adequate capacity when required 5 tools used during battery installation and system hook up must be insulated 6 Use rubber mats on floor and over batteries when working on the battery system connections Safety Procedures 1 Inspect all lifting equipment for functional adequacy and to make sure it is of sufficient capacity to lift the weight involved 2 Prohibit smoking and open flame and avoid arcing in the immediate vicinity of the battery 3 Ensure that adequate illumination requirements for inside the battery system are met 4 Always make sure that there is an unobstructed path from the battery area to the exit 5 Avoid static buildup by having personnel contact ground prior to working on
17. eview battery system drawings and assemble according to provided instructions Normal battery operating temperatures are between 68 F 20 and 77 F 25 C Cabinet enclosed battery systems are shipped fully assembled and internally pre wired Internal battery connections should be retorqued annually Install cabinet s in a cool clean and dry area Battery Connections When installing batteries in a system prepare contact surface of terminals to a clean metallic finish Use a wire brush to clean battery terminals and a plastic bristle brush to clean cable lugs Apply a thin coat of an approved anti corrosive compound to all contact surfaces of battery terminals Torque all connections to the recommended value Apply a final thin coat of anti corrosive compound to all metal surfaces Charging Batteries are shipped from Power Battery at approximately 9596 capacity and will attain 10096 capacity after 6 months on float charge Batteries must be maintained on float charge and should be fully recharged within 24hrs after any discharge A high rate charge may be used to speed up the charging process but only after a discharge High rate charging should last for 6 8 hrs maximum then all batteries should be put back on float charge charging must be at fixed voltage Recommended Charging Parameters Float voltage 2 27 2 30 volts cells High charge voltage 2 31 2 35 volts cells gt Above 2 37 volts cell batteries may emit hydroge
18. formation is presented in good faith but no additional warranty is expressed or implied In as much as any assistance furnished by Power Battery Company Inc with reference to the proper use of its products without charge power Battery Company Inc assumes no obligation or liability therefore 1 0 ISAFETY7 General Safety Rules for Handling Power Battery Company Inc Batteries DO use qualified personnel only for battery handling and maintenance DO follow all Power Battery and charger maintenance instructions DO wear protective equipment face shield goggles gloves when working with or around battery systems DO make sure that all charging discharging circuitry is completely disconnected from the battery system before making or breaking any connections DO check with Power Battery before making any design changes to the battery system DO use proper lifting techniques when working with the batteries DO NOT lift any battery by the battery terminals DO NOT allow tools or unconnected cables to rest on top of the batteries or touch the battery terminals DO NOT use power tools that can develop more torque than the torque specified for connections DO NOT use any chemical cleaners to clean the batteries DO NOT remove vent caps or add anything to the batteries DO NOT smoke or carry open flames near any battery or system DO NOT approach any energized battery system that shows signs of severe over charging or over disch
19. g down and storing a battery system As before the battery s O C V is a useful tool in determining when a recharge would be required All batteries placed in storage should be fully charged before shutting down and disconnecting from the system The batteries may also need to be relocated if the environment is not suitable for storage refer to storage parameters When shutting down a battery system that has been in use some additional considerations will need to be made First and foremost the batteries must be fully charged before the equipment is shutdown Second the battery must be disconnected via disconnected breaker etc completely from the equipment circuitry One must insure that all possible loads are also disconnected so that the batteries are not unknowingly discharging during the shutdown period Examples of other small loads may be shunted devices or other small resistive loads tied into the circuit As an additional safety measure one of the battery fuses or intercell connections can be removed Caution Be sure battery system is disconnected from circuit before removal of any intercell connectors Finally record the date when the system was shut down and include this with the regularly scheduled maintenance records for future use It may also be advisable to place a recharge date directly on the batteries as an additional visual aid to indicate when a recharge would be required Ventilation 4 0 Ventilation
20. ithout any convection If the batteries are charged under the extreme condition of 2 5 VPC at 1079F 41 679C about 80ml per hour will escape from each battery so that diffusion alone will result from each battery so that diffusion alone will result in a maximum cabinet concentration of 0 23 hydrogen Since some convection will occur the actual hydrogen concentrations will be well below these calculated equilibrium concentrations The calculation of Gas Produced and Recombination Efficiency is not strictly correct since some small current will be accepted by all batteries without the production of gas The error is very small and since the calculation provides a convenient way to compare recombinant batteries of different design many battery researchers have used the method The data shown in the table has been plotted on the attached charts that show Gas Recombination Efficiency and Actual Gas Evolution as a function of Cell Voltage The minimum concentration of hydrogen in air that is required for combustion is 4 196 The current IEEE standard for the maximum safe concentration of hydrogen in air is 296 The maximum diffusion limited equilibrium concentration of 0 2396 obtained at 2 5 VPC and 1079F 41 679C is about 10 of this If charging is done under the more normal conditions of 2 37 VPC hydrogen concentration within the cabinet will not exceed 0 0296 and will approach the natural atmospheric hydrogen concentration of 0 0196
21. ively simple to accomplish as the compensation factor is linear in nature over a wide range of temperatures Please refer to the curve DWG 177 for further details Percent eapaeity vs temperature Series batteries rale 100 77 F 25 C 120 Floor Loading TOP VIEW Bottom View 6 0 Location and Mounting Mounting holes are provided on the cabinet for securing the cabinet to the floor when necessary If a multi cabinet system was installed consult the inter cabinet connection drawings supplied with the system for proper positioning and spacing between each cabinet Cabinets must be bolted to the floor if UBC seismic zone and Underwriters Laboratories requirements are to be met Cabinets may also have levelers casters or both When installed one or both should have been adjusted properly by a qualified service person Some cabinets may not have levelers casters or both instead a floor loading plate may have been installed for proper cabinet weight distribution NEUTRALIZING SPILLED ACID Sulfuric acid Sulfuric acid is a strong corrosive Contact with the acid can cause severe burns to the skin and eyes Ingestion of sulfuric acid will cause gastro intestinal tract burns First aid Sulfuric acid Skin contact Flush with water for 15 minutes Remove contaminated clothing Call physician if contact area is large or if blisters form Eye contact Call physician i
22. mmediately flush with water until physician arrives Ingestion Call physician DO NOT INDUCE VOMITING DO NOT GIVE ANYTHING TO AN UNCONSCI OUS PERSON Spill or leak procedures If sulfuric acid is spilled from a battery neutralize the acid with sodium bicarbonate baking soda sodium carbonate soda ash or calcium oxide lime Flush the area and dispose of as hazardous waste 7 0 Waste disposal method NJ Spent lead acid batteries are disposed of using three 3 acceptable methods send the batteries to Licensed secondary lead smelters for recycling Reputable battery handlers Reputable scrap dealers If the user has to transport these batteries to the smelters the user must follow department of transportation DOT regulations A copy of this material safety data she et must be supplied to any scrap dealer or secondary lead smelter Follow applicable Federal State and Local regulations Protection Skin rubber gloves apron Respiratory Protective equipment must be worn if the battery is cracked or otherwise damaged HEPA respirator should be worn during reclaim operations if the OSHAPEL is exceeded Eyes safety Goggles face shield Electrical safety Due to the low internal resistance of Power Batteries and high power density high levels of short circuit current can be developed across the battery terminals Do not rest tools or cables on the battery Use insulated tools only Follow any installati
23. n gas gt Average ambient temperature 77 F 25 C Maintenance The following minimum maintenance procedures must be followed and recorded in the Field Service Report Insufficient records and or failure to perform maintenance on the battery system may conditionally void the warranty Monthly I nspections General inspection of batteries rack s or cabinet s Check charger voltage and current operation Measure float charge voltage at battery terminals Measure charge float current Check battery environment and ambient temperatures Semi Annual perform monthly inspection plus 1 Spot check individual battery temperatures 2 Measure individual battery float voltages Annual perform semi annual inspection plus Detailed visual inspection of individual batteries Inspected all connections for cleanliness corrosion etc Measure micro OHM meter value of all terminal connections Restore all connections as required Retorque all connections to recommended values Perform general system maintenance clean batteries cabinet s or rack s Ssmo IE Bi Annual perform annual inspection plus 1 Perform discharge test at rated capacity monitoring parameters continuously Note Some larger and or custom designed battery systems may require more frequent specialized maintenance inspections Safety tips 1 Limit access to authorized personnel only 2 Read all instructions and specifications prior
24. on instructions and diagrams when installing or maintaining battery systems VISUAL INSPECTI AND OPEN CIRCUIT VOLTAGE OCV MEASUREMENT 9 0 Battery nspection A detailed visual inspection of each battery should be performed Items to be checked are 1 Signs of damage to the case cover or terminals 2 Staining of the case terminals or surrounding areas 3 Excessive swelling of battery case 4 Evidence of melting or thermal damage to the case cover and terminal post seal 5 supporting cabinet rack or tray should be checked confirming that there is no physical damage or corrosion Cable Connections Care must be taken to insure that all cables within the cabinet s are mechanically and electrically secure connections should be retorqued annually to 5 IN LB less than initial values specified on the battery label For first time battery cable installation connections should be torqued to the stipulated value on the battery label located on the battery In all other cases torque cable connections to 5 IN LB less than the labeled torque value The connections must be retorqued with a torque wrench Using only a wrench will cause strain on the terminal and internal battery connections resulting in permanent battery damage The retorging is necessary to insure good low resistance connections and equal battery float voltage distribution Loose connections can result in high power drains and high t
25. ry service life If the float charge voltage is too low the battery will not be maintained in a full charge state This will cause the accumulation of the lead sulfate resulting in degradation of capacity followed by a reduction in service life Battery temperatures play an important role in the selection of the float charge voltage used in any stationary application The PRC Series batteries are designed for 10 years full float charge operation o 77 F and 2 27 2 30 V P C When the application s environment is such that the battery s temperature varies from the 77 F standard changes occur in the float charge voltage requirements These changes are due to variations in the battery self discharge rate internal resistance current acceptance and electrolyte viscosity It is therefore recommended that the float charge voltage be temperature compensated to accommodate the variations Enclosed is a copy of the Battery Temperature vs Float Charge Voltage curve DWG BTD 177 developed for this purpose This curve can be used in one of two ways If the average temperature profile of the application is a known constant or is well controlled the float charge voltage can be set on the charger according to the compensation curve If the application calls for unknown battery temperatures or variations ex day night winter summer ect the charger design can be modified to automatically compensate for these variations This modification is relat
26. ry system maintenance Battery Installation and Operating I nstructions Applicable for CG CSL CSL MC MCG MRV PL PL C PM PM F PRC PS SL SLF TC TG TL TL SLC WC and WCG Batteries General nformation In normal use POWER BATTERY VRLA batteries will emit no gases However there is the possibility that under abnormal operating conditions or as a result of damage or abuse the batteries might release hydrogen In order to insure the proper function of its batteries POWER BATTERY strongly recommends compliance to its operating installation and maintenance instructions Receiving Upon receipt of shipment all cartons should be inspected and matched against packing list Any shortages of batteries cables or hardware should be immediately reported to Power Battery Any damages upon receipt of shipment should be claimed as freight damage to the shipper No replacement will be made unless missing or damaged items are properly noted on receiving documents before customer signature Storage All batteries are shipped in a charged condition If batteries are not installed immediately they should be stored in a cool clean and dry area These batteries should ideally be stored on a float charge If not then batteries should be recharged when open circuit voltage falls to 2 07 volts per cell and or every 6 months whichever occurs first see charging section for specifications Location Before proceeding with installation r
27. tationary Batteries describes the test procedures performed to obtain the experimental data on battery float service life This procedure is the most widely accepted method of accelerated testing used today because the primary cause of battery failure grid growth corrosion has been found to correspond with the failure mechanisms found in actual field tests One final note with regards to the use of valve regulated lead acid batteries is that most immobilized electrolyte systems are less forgiving than the traditional flooded battery systems These designs are such that many application advantages are inherent but careful attention must be paid to all the parameters of the application s environment As discussed with proper maintenance and monitoring of these parameters the batteries will perform and provide the level of service in which they re designed Temperature effects on long term ftoaat life Trag ha agg if pesar COM merded cum 451 US C 7 00 1 2 cun Float charge voltage The selection and maintenance of a specific float charge voltage is essential to achieving the designed service life and rated capacity of the battery If the float charge voltage is too high more float charge current Will flow through the battery causing accelerated grid growth corrosion hence shortening the batte
28. tery please click below on the battery model number Obsolete models PRC TC 1230X PRC TC 1280X PRC TC 12110X PRC TC 6165X Specifications are subject to change No transport restrictions Surface transport Classified as non hazardous material as relates to DOT CFR Title 49 part 171 189 Marine transport Classified as non hazardous material as per IMDG amendment 27 Air transport Complies with IATA ICAO special provision A67 No transport restrictions Surface transport Classified as non hazardous material as relates to DOT CFR Title 49 part 171 189 Marine transport Classified as non hazardous material as per IMDG amendment 27 Air transport Complies with IATA ICAO special provision A67 Power Battery has two main headquarters and representation worldwide Headquarters Corporate Headquarters Power Battery Company Inc 25 McLean Blvd Paterson N J U S A 07514 1507 Tel 1 973 523 8630 Fax 1 973 523 3023 Canadian Headquarters Power Battery Iberville Ltd 7 0 Thomas Avenue St J ean sur Richelieu Qu bec Canada J2X 5E7 Tel 1 450 346 3273 Fax 1 450 346 8003 To contact our headquarters fill out the form below To find a specific Power Battery Employee Check our worldwide employee directory request literature from Power Battery you can use our online literature request form 13 0
29. ttery Co Inc 25 McLean Blvd 770 Thomas Ave Premier Way Abbey Park Industrial Estate Via Locatelli 105 Room 806 Paterson N J 07514 1507 Iberville Qu bec J2X 5E7 Romsey Hampshire 50051 20046 Biassono MI ITALY Shanghai Chun Shen Jian Phone 973 523 8630 Phone 450 346 3273 Phone 44 0 1794 835900 Phone 39 039 2324571 400 Zhejiang Road Fax 973 523 3023 Fax 450 346 8003 Fax 44 0 1794 835910 Fax 4 39 039 2499200 Shanghai China E mail sales powbat com E mail powerbat sympatico ca E mail sales powbat co uk E mail calberti powbat co uk Phone 021 6236 8297 Web page www powerbattery com Web page www powerbattery com Web page www powbat co uk Web page www powbat co uk Fax 021 6352 1984 E mail power sh china com 11 0 POWER BATTERY MODEL NUMBER REFERENCE GUI DE CURRENT MODEL 9 PRC1230X or TC 1230X PRC1235X or TC 1235X PRC1250XL or TC 1250XL L L EN PRC1290X or TC 1290X PRC12100X or TC 12100X PRC1265 or TC 1265 L 12110 12110 L 12120 12120 PRC12150X TC 12150X 121505 or 121505 PRC6165X 6165 1 PRC6200X or TC 6200X PRC6200S 62006 S 208 10 62X7 38 X 11 63 PRC6225S 62258 S 220 1062X738X1163 NO CHANGE NOCHANGE C C 184 2142X87X103 68 DIDNOTEXST EN PRC6225X or TC 6225X 1 SLF 1210
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