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INSTALLATION & OPERATING INSTRUCTIONS

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1. GNB Industrial Power The Industry Leader GNB Flooded m ABS LYTE 2 13 amp GNB Industrial Power a division of Exide Technologies is a global leader in network power applications including commu nication data networks UPS systems for computers and con trol systems electrical power generation and distribution systems as well as a wide range of other industrial standby power applications With a strong manufacturing base in both North America and Europe and a truly global reach operati ons in more than 80 countries in sales and service GNB Industrial Power is best positioned to satisfy your back up power needs locally as well as all over the world GNB Industrial Power USA Tel 888 898 4462 Canada Tel 800 268 2698 www gnb com SECTION 93 10 2014 08 SIC MARATHON RELAY GEL WE 4 Sonnenschein Based on over 100 years of technological innovation the Network Power group leads the industry with the most recognized global brands such as ABSOLYTE GNB FLOODED CLASSIC MARATHON RELAY GEL SONNENSCHEIN and SPRINTER They have come to symbolize quality reliability performance and excellence in all the markets served GNB Industrial Power takes pride in its commitment to a better environment Its Total Battery Management program an inte grated approach to manufacturing distributing and recycling of lead acid batteries has been developed to ensure a safe and responsible life cycle for all
2. eral condition of all cells in the battery regarding specific gravities float voltage and temperature It serves as an indi cator of battery condition between scheduled overall indi vidual cell readings A slight amount of electrolyte may be lost each time a specific gravity reading is taken even though it is recommended that all electrolyte in the hydrometer be returned to the cell after read ing Therefore it is suggested that the pilot cell be changed to another cell annually to provide a representative specific gravity indicator for the battery SECTION 14 14 0 Records A complete recorded history of the battery operation is required Good records will also show when corrective action may be required to eliminate possible charging main tenance or environmental problems Data should be recorded on Stationary Battery Maintenance Report shown on page 15 Report headings should be filled in completely on the date of installation The following data should be read and permanently record ed for review by supervisory personnel A Upon completion of the initial charge and with the battery floating at the desired float voltage for one week read and record individual cell voltages connection resis tances specific gravities corrected to 77 F 25 C ambient temperature plus cell temperatures and elec trolyte levels for 1096 of the cells The cell temperature readings should be from each step or tier of the rack to reflect temp
3. 4 PDQ N amp H cells 150 Figure 2 TORQUE INCH LBS D cells only 100 amp N cells 100 M amp Ncells 150 Torque both the bolt head and the nut of stainless steel hardware to their prescribed torque values Torquing only one side of either combination will not provide the desired tightness Re torque stainless steel hardware 4 to 6 hours after initial torquing to allow for initial relaxation of connection compo nents Complete connecting of cells by installing necessary inter row inter tier or inter rack cable connectors Do not con nect battery to charger at this time Take and record connection resistances See Section 19 0 of cell to cell and cell to terminal including inter level and load connections This is particularly important on high rate applications Remake any connection that has a value more than 10 or 5 u Q whichever is greater Re check to be certain that the cells are connected positive to negative throughout the battery string Measure the total voltage at the battery terminals The voltage should be equal to the number of cells times the voltage of one of the cells Example 60 cells times 2 05 volts 123 volts INSTALLATION INFORMATION Battery Post Connection ue See Note 3 See Note 1 a Intercell connectors are paralleled for higher discharge rates See Note 3 Note 1 f Coat these surfaces with a THIN coating of 8 No Oxide Grease
4. 50 118 200 2 39 34 80 134 2 42 54 91 2 45 36 62 2 48 42 NOTE Time periods listed in Tables D and E are for cell temperatures from 70 F 21 C to 90 F 32 C Fortemper atures 55 F 13 C to 69 F 20 5 C double the number of hours For temperatures 40 F 4 C to 54 F 12 C use four times the number of hours 10 3 Equalizing Individual Cells When only a few cells in a battery require equalizing and system voltage limitations do not permit raising the battery voltage up to a recommended equalizing voltage a sepa rate voltage regulated charger may be used on the affected cells The charger must have complete AC line isolation and should be paralleled across the below normal cell Select the equalizing voltage values listed in Tables D or E for the type cell involved The hours of equalizing may have to be increased from listed values before stabilization of cell volt age and specific gravity is achieved especially where below normal condition has existed for a prolonged period CAUTION WHEN INDIVIDUAL CHARGER IS REMOVED FROM CELL WHICH HAS BEEN EQUALIZED ADROP IN VOLTAGE BELOW THE AVERAGE STRING VOLTAGE MAY OCCUR THIS IS NORMAL DUE TO THE EXCESS INTERNAL CELL GASES PRESENT AS THESE EXCESS GASES DISLODGE FROM INTERNAL CELL COMPONENTS THE CELL VOLTAGE WILL RISE GRADUALLY WHICH MAY TAKE FROM TWO TO FOUR WEEKS 10 4 Equalizing Charge Electrolyte Levels A battery which has el
5. 7 9 1 Floating Charge Method 7 9 2 Float Charge Float Voltages 7 9 3 Voltmeter Calibration 8 9 4 Cycle Method of Operation 8 9 5 Recharge 8 SECTION 10 10 0 Equalizing Charge 8 10 1 Equalizing Frequency 8 10 2 Equalizing Charge Method 9 10 3 Equalizing Individual Cells 9 10 4 Equalizing Charge Electrolyte Levels 9 SECTION 11 11 0 Specific Gravity 9 11 1 Hydrometer Readings 10 11 2 Correction for Temperature 10 11 3 Correction for Electrolyte Level 10 11 4 Specific Gravity Range 10 INDEX SECTION 12 12 0 Cell Voltage Variation 12 2 Cell Voltage Variation Damp Covers 12 2 Cell Voltage Temperature Correction 12 3 Correction Factor SECTION 13 13 0 Pilot SECTION 14 14 0 Records SECTION 15 15 0 Water Additions 15 1 Water Purity SECTION 16 16 0 Tap Connections SECTION 17 17 0 Temporary Nonuse SECTION 18 18 0 Battery Cleaning 18 1 Styrene Acrylonitrile Containers with Butadiene Styrene Covers 18 2 Polycarbonate Containers and Covers SECTION 19 19 0 Connections 19 1 Connection Resistance 19 2 Retorquing Connections 19 3 Connection Resistance Measurement TABLES TAB
6. Vents Certain cell sizes may have been shipped with GNB Pre Vent vent filling funnels in place These vents have flexi ble plastic caps installed for shipping purposes These caps may be removed and discarded or they may be left in place if the battery environment is dusty See Figure 3 Other cell sizes are supplied with Pre Vents which are not shipped in place A standard screw type vent is used for ship ping purposes If Pre Vent units were specified they would have been packed separately with other accessories Remove the screw type shipping vents one at a time and install a Pre Vent unit before charging Discard the shipping vent Other cell types are supplied with separate explosion resis tant vents installed at time of shipment Separate plastic fill ing funnels are supplied along with this type vent These funnels also have flexible plastic shipping caps Here again these may be removed and discarded or left in place if envi ronment is dusty The Pre Vent assembly and other explosion resistant vents are designed to prevent external sparks or flames from ignit ing and exploding internal cell gases See Figure 4 CAUTION BEFORE DISPOSING OF FLEXIBLE PLASTIC CAPS OR SCREW TYPE SHIPPING CAPS NEUTRALIZE ANY ELECTROLYTE ON THEM IN A BAKING SODA WATER SOLUTION TO PREVENT INJURY TO ANYONE HANDLING THESE DISCARDED ITEMS Figure 4 Electrolyte Withdrawal Tubes Certain calcium cells are equipp
7. all types will be so designated A An equalizing charge should be given quarterly or as required by conditions in the following paragraphs Note lead calcium types at nominal 1 215 sp gr floated 2 20 V P C to 2 25 V P C nominal 1 250 sp gr floated at 2 27 V P C to 2 33 V P C and nominal 1 300 sp gr floated at 2 31 V PC to 2 37 V P C may not require equalizing charges B Equalize when the temperature corrected specific grav ity of the pilot cell or any cell for the quarterly reading is more than 10 points below its full charge value See Section 11 2 C Equalize when the floating voltage of the pilot cell or any cell for the quarterly reading is below 2 13 volts nominal 1 215 sp gr 2 18 volts nominal 1 250 sp gr and 2 23 volts nominal 1 300 sp gr or more than 04 volts below the average for the battery D Equalize to complete a recharge of the battery in a min imum length of time following an emergency discharge E If accurate quarterly records are maintained See Section 14 0 and the individual cell voltages and teper ature corrected specific gravities show no increase instead from the previous quarterly readings equalizing may be deferred See Section 11 2 F Equalize once a year even though preceding conditions did not require Lead calcium types floated per para graph A may not require annual equalizing 10 2 Equalizing Charge Method Constant voltage charging is the preferred me
8. classic Z INSTALLATION amp OPERATING INSTRUCTIONS InpusrRiAL POWER SECTION 93 10 2014 08 YOUR GNB REPRESENTATIVE SALESPERSON TELEPHONE LOCATION GNB SERVICE ASSISTANCE 1 800 241 4895 Page SECTION 1 1 0 General Information 1 SECTION 2 2 0 Safety Precautions 1 SECTION 3 3 0 Receipt of Shipment 1 3 1 Concealed 2 3 2 Electrolyte Levels 2 4 4 0 Storage Prior to Installation 2 4 1 Storage Location 2 4 2 Parts and Accessories 2 4 3 Storage 2 4 4 Dry Charged Batteries 2 SECTION 5 5 0 Rack Assembly 2 SECTION 6 6 0 Unpacking and Handling 2 SECTION 7 7 0 Installation 3 7 1 Battery 3 7 2 3 7 3 Temperature Variation 3 7 4 Ventilation i ee 3 7 5 Placement of 3 7 6 Connecting Cells 4 7 7 Completing Installation 6 SECTION 8 8 0 Initial Charge 7 8 1 Constant Voltage Method 7 8 2 Initial Charge Electrolyte Levels 7 SECTION 9 9 0 Operation
9. ground strap while working on a connected battery string is not recom mended NOTE If the foregoing precautions are not fully understood clarification should be obtained from your nearest GNB rep resentative Local conditions may introduce situations not covered by GNB Safety Precautions Here again contact the nearest GNB representative for guidance with your par ticular safety problem also refer to applicable federal state and local regulations as well as industry standards SECTION 3 3 0 Receipt of Shipment Immediately upon delivery by the carrier examine for possi ble damage caused in transit Damaged packing material or staining from leaking electrolyte would indicate rough handling If such conditions are found make description notation on delivery receipt before signing If cell damage is found request an inspection by the carrier and file a damage claim Also noti fy local GNB representative of action taken 3 1 Concealed Damage Shortly after receipt within 15 days examine all cells for con cealed damage Pay particular attention to packing material exhibiting damage or electrolyte staining Perform examination prior to installation and disposal of packing materials Cells with electrolyte levels more that 1 2 below top of plates have suf fered probable permanent damage due to plate exposure to air If this condition or other cell damage is found request an inspec tion by the carrier immediately
10. the hydrometer scale at the flat sur face of the electrolyte See Figure 5 kj i Je 11 260 1 i jt Figure 5 Clean the hydrometer glass barrel and float with soap and water as required for ease of reading and float accuracy When recharging a lead calcium cell the specific gravity reading lags behind the ampere hour input due mainly to the very low end of charge currents Mixing of the electrolyte is slow due to the small amount of gas generated so the grav ity readings do not reflect the actual state of charge A simi lar condition exists after water additions Therefore mean ingful gravity readings can only be obtained at the top of the cell after an equalizing charge or after six weeks on float For this reason most GNB lead calcium cells have elec trolyte withdrawal tubes to permit sampling of the electrolyte at a point one third down from the top of the plates A long rubber tip on the hydrometer is inserted into the tube to pro vide an average value of cell specific gravity and a more accurate indication on the state of the charge 10 When taking a hydrometer reading the base of the hydro meter syringe should be pressed firmly against the tube opening to prevent back splash of electrolyte Fill and empty the hydrometer at least once in each cell before read ing This will give a more accurate reading of the average electrolyte density Never inter mix usage of hydrometers on lea
11. to apply the 10 amperes DC to posts A and D such that equal current paths are provided Then the differ ences in readings across AB and CD will reflect con nector interface problems in either of the two external intercell connections Both intercell connections should be reworked as described in Section 19 0 Fae Q O LB Co Figure 6 Single connector hook ups Figure 7 Parallel connector hook ups EE ERECR I Figure 8 Four post four connector in line hook ups Figure 10 Four post four connector parallel hook ups GNB Industrial Power G N B InpusrRIAL Power A Division of Exide Technologies STATIONARY BATTERY MAINTENANCE REPORT Date Operating Company Address Battery location and or number No ofCell Tpe DatNew Date Installed Serial No Date amp amount of water added INDIVIDUAL CELL READINGS PILOT CELL READINGS Cell No To be recorded at least quarterly Ara Specific Gravily Readings Corracled for Temperatura Yas No Charger Output Air Temperature F BAR H RORD Yas Nu Totat Battery Meter
12. voltmeters used to indicate battery float voltages should be accurate at the operating voltage value The same holds true for portable meters used to read indi vidual cell voltages These meters should be checked against a standard every six months and calibrated when necessary 9 4 Cycle Method of Operation This method is recommended for lead antimony type cells only Lead calcium cells should not be cycle operated In cycle operation the degree of discharge will vary for var ious applications Therefore the frequency of recharging will also vary The recharge is conducted by manually start ing the charge generally using the normal finish rate The amount of charge necessary depends on the number of ampere hours discharge If a shorter recharge period is desired higher charge rates equal to the eight hour rate of discharge may be used when the battery is more than 25 discharged and the cell voltage on charge is below 2 33 volts When the cell voltage reaches 2 33 the charge rate should be reduced to the normal finish charge rate The finish charge rate is defined as amperes equal in numerical value to 5 of the cell s 8 hour capacity in ampere hours For example if the cell has an 8 hour capacity of 1680 AH its finish rate is 84 amperes The charge should be stopped when the specific gravity is ten 010 points below the nor mal fully charged value The battery is now available for the next discharge require ment The ba
13. 0 Ferm Piet Call Pilot Conn Cail Conn Time Youn Sp Gr Temp No Vols Resist No Volts Rasist i 1 2 2 i 1 al T 7 3 Eee o 4 rf 4 1 11 5 5 Inc xp 6 J 7 H 8 9 19 uj 11 rE o 12 13 13 14 14 15 15 16 16 vito l1 1l T 8 us 1 19 al 1 20 _ al 1 1 4 2 zj 1 j 22 z2 Po z l L 4 p 3 25 Lig eel 26 26 27 2 28 NEN 28 29 28 1 1 30 i Ep 31 ES Eg WEEKLY RECORD s E 36 ss 38 39 D 1 1 40 Remarks and Recommendations M E 22 READINGS TAKEN BY WHEN ADVICE IS DESIRED PLEASE FORWARD A DUPLICATE OF THIS REPORT TO YOUR GNB REPRESENTATIVE GB 1000F 15 STATIONARY BATTERY PLASTIC CELL NUMERAL APPLICATION To insure proper adhesion of the pressure sensitive plastic cell numerals and polarity markings supplied with your GNB Stationary Battery the following procedure should be fol lowed 1 Numerals and polarity markings should not be applied until after the cells have been installed on the rack It is recommended that they be applied to jar surfaces only and not to cell covers or rack rails Clean the plastic jar surface in the area where the numeral is to be located by us
14. LE B os eins vcd fonts eee ires iE TABLE C TABLE D STATIONARY BATTERY MAINTENANCE REPORT voL chus FIGURES FIGURE 1 FIGURE 2 FIGURE 2A FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6 FIGURE 7 FIGURE 9 FIGURE 10 SECTION 1 1 0 General Information Caution Before proceeding with the unpacking handling installation and operation of this lead acid storage battery the following general information should be reviewed togeth er with the recommended safety precautions A lead acid battery is an electro chemical device containing electrolyte which is a dilute solution of sulfuric acid and water This electrolyte is corrosive and can cause injury Lead acid batteries when installed are capable of high volt age which can cause electrical shocks to personnel All lead acid batteries in the course of normal operation generate gases which could be explosive Stationary batteries when installed are usually on float charge continually unless on discharge in the event of AC failure or on recharge following a discharge SECTION 2 BATTERY WARNING STATEMENT DANGER HIGH VOLTAGE High voltages are present on most battery systems Exercise caution and REMOVE ALL METAL OBJECTS FROM PERSON when working on or around battery EXPLOSIVE GASES c5 Gases produced by battery can be explosive DO NOT e SMOKE USE AN OPEN FLAME CREATE AN ARC or SPARKS IN VICINITY OF BATTERY WEAR EYE PROTECTION Personnel should discharge stat
15. and file a concealed damage claim Examine cells for container damage misaligned ele ments broken plates or any other visible damage 3 2 Electrolyte Levels Cells are shipped with electrolyte levels about 1 8 below the high level line During shipment the levels drop due to the loss of gases from internal cell components The amount of drop in level will vary with each type of cell Electrolyte levels when received may range from the high level line to slightly below the low level line If this condition exists make no addition of elec trolyte or water at this time see Section 8 2 If certain cells have low electrolyte levels with less than 1 2 of plates exposed to air add battery grade sulphuric acid of the same specific grav ity as the remaining cells thus bringing low level cells up to the average level of other cells SECTION 4 4 0 Storage Prior to Installation 4 1 Storage Location If the battery is not to be installed at the time of the receipt it is recommended that it be stored indoors in a cool 60 F 15 6 C to 90 F 32 C clean dry location Do not top load pallets or possible cell damage may occur Storage or transport of flood ed lead acid batteries at temperatures exceeding 120 F 49 C can cause detimental effects on plastic components and battery state of health which may void warranty 4 2 Parts and Accessories Prior to planned installation of battery the separately packaged parts and acc
16. d antimony or lead calcium types as cell contamination will result Assign hydrometers for exclusive use on one type only 11 2 Correction for Temperature When taking specific gravity readings corrections must be made for variations in temperature of the electrolyte For each 3 F 1 67 C in temperature of the electrolyte above 77 F 25 C add one point 001 in specific gravity to the observed hydrometer readings and for each S F 1 67 C in temperature below 77 F 25 C subtract one 001 in spe cific gravity from the observed hydrometer reading Example Reading Hydrometer Cell Corrected to i Temperature Correction F F 25 G 1 213 sp gr 68 F 20 C 003points 1 210 sp gr 1 207 sp gr 86 F 30 C 003points 1 210 sp gr 1 204 sp gr 95 F 35 C 006 points 1 210 sp gr 11 3 Correction for Electrolyte Level The loss of water from the electrolyte due to evaporation as well as conversion of the water to hydrogen and oxygen by charging current also effects the specific gravity value For example A fully charged cell with a correct high level at 77 F 25 C will have a nominal specific gravity of 1 215 When the electrolyte level has been reduced from evapora tion and charging by 1 4 the specific gravity will be approx imately 6 points 006 higher or 1 221 77 F 25 C Therefore when taking hydrometer readings the electrolyte level referenced to the high level line should be recorded for pr
17. e packed in individual corrugated cartons Some smaller size cells are packed in a master carton con taining 2 two or 3 three cells Cartons are shipped on wood pallets E Figure 1 Remove material holding cartons to pallets exercising care when cutting banding material to prevent injury If individual cells are to be moved to another location do not remove carton at this time Exercise caution if using a two wheeled hand truck and to prevent spillage of electrolyte do not tilt cell more than 25 degrees from vertical When cells have been brought to the installation sight remove carton sleeve and top corrugated spacers DO NOT LIFT CELLS BY THEIR TERMINAL POSTS Support the cells from the bottom when handling and unpacking In general units weighing less than 75 pounds are handled manually being supported from the bottom After removal of outer carton and top spacers the cell should still be resting in the bottom corrugated tray This tray is designed to be easily broken away to permit positioning of a lifting strap under the cell with a minimal amount of cell tilting A lifting strap and a strap spreader are furnished for use with mechanical lifting devices when cells weigh 75 pounds or more See Figure 1 which shows typical positioning of strap and spreader Large cells are provided with 2 lifting straps and a special spreader for stability in handling during instal lation Always use lifting straps and spr
18. eaders when provided together with suitable mechanical lifting devices to prevent injury to personnel or damage to cells Platform lifts of adequate capacity to handle cell weights and dimensions may be used provided they are stable and capa ble of reaching needed heights and used on smooth and level floor conditions Never slide cells across rough surfaces as severe scratch ing of plastic container bottom may result in stressing and rupturing of the jar with subsequent loss of electrolyte At all times exercise care when handling cells to prevent scratch ing of plastic jars and covers SECTION 7 7 0 Installation 7 1 Battery Location It is recommended that the battery be installed in a clean cool dry location Cells should not be exposed to heating units strip heaters radiators steam pipes or sunshine through a window Any of these conditions can cause a seri ous electrolyte temperature variation among cells within a battery see Section 7 3 7 2 Temperature A battery location having an ambient temperature of 75 F 24 C to 77 F 25 C will result in optimum battery life Batteries operated in high ambient temperatures will result in reduced life Therefore for longer life and ease of main tenance locations having cooler ambient temperatures are recommended The normal battery operating temperatures are between 60 F 16 C and 90 F 32 C 7 3 Temperature Variation The location of rack arrangement should
19. ectrolyte levels at the high level line while on a float and then placed on equalizing charge will result in a rise in electrolyte above the high level line This is a normal condition DO NOT remove any electrolyte as the levels will return to their former condition when the bat tery is returned to normal float Removal of the electrolyte with subsequent restoration to proper electrolyte levels by water addition could result in variations or sub normal spe cific gravity values SECTION 11 11 0 Specific Gravity In a lead acid cell the electrolyte is a dilute solution of water and sulfuric acid Specific gravity is a measure of the weight of acid in the electrolyte as compared to an equal volume of water Therefore electrolyte with a specific gravity of 1 215 means it is 1 215 times heavier than an equal volume of water which has a specific gravity of 1 000 11 1 Hydrometer Readings Specific gravity is used in determining a cell s state of charge It decreases as the cell discharges and increases as the cell is charged reaching its original value when the cell is fully charged Specific gravity is expressed to the third decimal place 1 215 and is measured by a hydrome ter float enclosed in a glass barrel rubber bulb syringe Draw sufficient electrolyte into the barrels holding the syringe vertical and with no hand pressure on bulb so that float is freely floating without touching sides or top of syringe The gravity is read on
20. ed with two electrolyte with drawal tubes which are installed in the diagonal corners of the cell These permit the taking of specific gravity readings at a point about one third from the top of the plates See Section 11 1 Refer to Figure 3 A flexible shipping cap and shipping plug is installed on each withdrawal tube The cap may be removed and discarded after neutralizing or left in place as dust covers The red plug should be discarded Plastic Numerals See Page 16 Plastic cell numerals and battery terminal polarity labels are provided for 12 cell batteries of 40 ampere hours and over The positive terminal cell is usually designated as cell 1 in the series string Battery to Charger Connection The positive terminal of the battery should be connected to the positive terminal of the charger and the negative terminal of the battery to the negative terminal of the charger Battery Warning Statement and Nameplate See Page 1 A nameplate is shipped with the parts for each battery sys tem It has a peel off backing to allow mounting on or near the battery Nameplate information should be completed by the installer at the time of the initial charge and start of bat tery operation The installer must make the contents of the Battery Warning Statement known to all personnel in the vicinity of the battery SECTION 8 8 0 Initial Charge Batteries lose some charge during shipment as well as during the s
21. erature range of the battery This first set of readings will be the basis for comparison with subsequent readings to reflect possible operating problems and the need for corrective action B Monthly Observe the general appearance and cleanli ness of the battery Record battery terminal voltage Check electrolyte levels and adjust if necessary Check for cracks in cells and leakage Note any evidence of corrosion at terminals and connectors Record pilot cell voltage specific gravity and temperature Quarterly Supplement the monthly inspection and record keeping with these additional measures Check and record the specific gravity and voltage of each cell Check and record the electrolyte temperature of one cell on each level of individual racks Annual Supplement quarterly reports with these extra procedures Make a detailed visual inspection of each cell Tighten all bolted connections to the specified torque values Take and record connection resistances of each cell to cell cell to terminal inter level and load connections Remake any connections that are more than 20 above installation base value Check integrity of the rack E Any time the battery is given an equalizing charge see Section 10 1 an additional set of individual cell readings should be taken after battery has been returned to normal float for one week These will serve as an updated basis for comparison with future readings F Record dates of an
22. essories should be opened and checked against shipping invoice for completeness Discovery of missing or incorrect parts during installation may cause delays resulting from reordering and shipment of replacements Store parts in safe location to prevent loss 4 3 Storage Interval For batteries shipped wet fully charged the following storage intervals from date of shipment to date of installation and initial charge should not be exceeded Lead Antimony Types Three 3 Months Lead Calcium Types Six 6 Months Storage beyond the above stated periods can result in sul phated plates which can be detrimental to battery life and performance The battery should be given its initial charge see Section 8 0 before the end of the above stated storage intervals and repeated for each additional storage interval If permanent installation is deferred for an extended time period the battery may be temporarily connected and main tained on a floating charge see Section 9 Failure to charge in accordance with the above can void the battery s warranty 4 4 Dry Charged Batteries For batteries shipped dry charged follow special handling and preparation instructions supplied as well as appropriate sections of this Manual SECTION 5 5 0 Rack Assembly Assembly of the battery rack should be completed in accor dance with the GNB drawing and or instructions included with the rack SECTION 6 6 0 Unpacking and Handling Most cells ar
23. eted before installation of intercell connectors Use two 1 2 thick pieces of plywood cut to cell width and 1 higher than jar height to expedite positioning of cells Space cells by placing one piece between the first cell positioned and the next cell In positioning the third cell use the sec ond piece of plywood for spacing The first piece is removed and used for the next cell placement etc The cell post surfaces have a coating of NO OX ID grease or approved equal applied at the factory Do not remove any grease from posts Re coat any surfaces that may have been exposed during handling of cells Also closely examine factory coated post contact surfaces for presence of foreign substances which may have been introduced through handling or construction activity in the installation area If the foregoing is noted remove the NO OX ID grease or approved equal with paper wipers and apply a new coating Also inspect posts for corrosion If corrosion is found clean posts with brass suede brush or plastic scouring pad and re grease CAUTION FAILURE TO OBSERVE ABOVE PROCEDURE MAY IMPAIR INTEGRITY OF ELECTRICAL CONNECTION AND CELL PERFORMANCE 7 6 Connecting Cells Refer to the cell arrangement drawing to determine the quantity size and correct positioning of the intercell con nectors On the N type cells using 1 1 4 wide connectors the bolt holes are located off center Position the connector so that the
24. h or flush with plenty of clean water Secure medical treatment immediately F Exercise care when handling cells When lifting straps and strap spreaders are provided use them with appro priate mechanical equipment to safely handle cells and avoid injury to personnel G Promptly neutralize and remove any electrolyte spilled when handling or installing cells Use a baking soda water solution 1 Ib per gallon of water to prevent possible injury to personnel H Make sure that all battery connections are properly pre pared and tightened to prevent possible injury to per sonnel or failure of system l Familiarize personnel with battery installation charging and maintenance procedures Restrict access to battery area permitting trained personnel only to reduce the possibility of injury J Whenever possible when making repairs to charging equipment and or batteries interrupt AC and DC circuits to reduce the possibility of injury to personnel and dam age to system equipment This is particularly important with high voltage systems 110 volts and above K When maintaining a connected battery string care must be taken to prevent a build up of static charge This danger is particularly significant when the worker is elec trically isolated ie working on a rubber mat or an epoxy painted floor or wearing rubber shoes Prior to making contact with the cell discharge static electricity by touch ing a grounded surface Wearing a
25. ic charges from their person to ground before working on il battery Ventilate well in an enclosed space and when charging z ACID BURNS Battery contains SULFURIC ACID WHICH CAN CAUSE SEVERE BURNS Avoid getting in eyes on tz Skin or on clothing In case of contact flush immediate i ly and thoroughly with clean water OBTAIN MEDICAL ATTENTION 2 0 Safety Precautions A Wear rubber apron gloves and safety goggles or face shield when handling installing or working with batter ies This will help prevent injury due to splashing or spillage of sulfuric acid B Prohibit smoking Keep flames and sparks of all kinds away from vicinity of storage batteries as liberated or entrapped hydrogen gas in the cells may be exploded causing injury to personnel and damage to cells C Never place metal tools on top of cells since sparks due to shorting across cell terminals may result in an explosion of hydrogen gas in or near the cells Insulate tool handles to protect against shorting D When preparing electrolyte always pour acid into water NEVER water into acid Failure to follow this precaution will result in excess heat and violent chemical reaction which may cause serious injury to personnel E If electrolyte comes into contact with skin or clothing immediately wash with water and neutralize with a solu tion of baking soda and water Secure medical treat ment If electrolyte comes into contact with the eyes was
26. ing a cloth dampened with a washing soda solution Immediately dry the area using a soft dry cloth to remove residual washing soda CAUTION Do not use any solvent type materials as they may cause damage to the plastic jar material It is a general practice to designate the positive terminal cell as 1 with succeeding cells in series in ascending order 4 Numerals are shipped mounted on a plastic backing strip They are easily removed by peeling back the plas tic strip Keep finger contact with adhesive backing on numeral to a minimum Locate and place numeral on side of jar being careful that there is no conflict with electrolyte level lines or side rails of SEISMIC TYPE RACKS For clean appearance exercise care in numeral placement so that all the numerals are in the same relative position on each cell Install polarity markings on the appropriate cells in the same manner Following application of cell numerals and polarity mark ings use a dry cloth to rub entire surface of each label to insure proper surface contact Note Design and or specifications subject to change without notice If questions arise contact your local sales representative for clarification TYPICAL BATTERY NAMEPLATE GNB InousTRIAL POWER A Division of Exide Technologies NO OF CELLS TYPE SERIAL NO CAPACITY SPECIFIC GRAVITY AMPERE HRS AT HR RATE GNB INDUSTRIAL POWER Aurora IL 60504 NOTES
27. is made in two steps First between points A and C and then between points B and D The measured values should be the same Values appreciably different 5 micrhoms or more require reworking of connections as described in Section 19 0 14 iv Four Post Two Connector Staggered Hook Ups Figure 9 Cells with four post staggered connector hook ups require two step measurement as described above in iii In addition the probe point locations for points A and D See Figure 9 must be centered as described above in i Four Post Connector Parallel Hook Ups Figure 10 Cells arranged end to end have parallel current paths above and below the cell covers and require that resis tance measurement make allowance for the same The current paths above the cover are provided by the con nectors and the path under the cover is provided by the busbars shown by dotted lines in Figure 10 Most resistance meters apply 10 amperes DC to the connec tions being monitored If this was done between posts A and B in Figure 10 the current will divide through the busbars between AB and CD and the resistance value will be about half of the actual value provided all con nections are good If the process is repeated for posts C and D and the two resistance values are compared the difference if any indicates differences in the two parallel paths as well as poor connections at the post connector interfaces A better and preferred technique is
28. lesser dimension faces downward on the cell post Gently clean contact surfaces only of the lead plated inter cell connectors terminal plates and cable lugs using a brass suede brush or 3M Scotch Brite scouring pad Caution Do not use powered wire brush or course abrasives as lead plating may be removed exposing copper As contact surfaces of posts and connectors are cleaned apply a thin coating of NO OX ID grease or approved equal to these surfaces only Starting at center of the cell row install connectors per wiring diagram and cell arrangement drawing furnished with the battery On cells using stainless steel bolts washers and nuts make sure a washer is placed between the bolt head and connec tor as well as between the nut and connector with the rolled edge against the connector Never install washers between the connector and the cell post See figure 2A CAUTION WHEN INSTALLING TERMINAL HARDWARE DO NOT PERMIT ANY ITEMS TO FALL INTO CELL IF SUCH MATERIAL REMAINS IN THE CELL CONTAMINATION WILL RESULT REQUIRING REPLACEMENT OF THE CELL As intercell connectors are installed adjust them to a level position and finger tighten hardware After all connectors are installed the hardware should be tightened using insulated tools as outlined in the following illustration Figure 2 QUANTITY AND THICKNESS OF INTERCELL CONNECTORS CY eue Er se 18 xor e 1 4 or two 1 8 pp s cmm 1
29. lev els may be above high level When battery is placed on floating charge See Section 9 2 the electrolyte levels should return close to the high level line Removal of electrolyte during the initial charge with subse quent restoration with water of levels which have fallen fol lowing placement on float charge mode could result in vari ations or sub normal specific gravity values SECTION 9 9 0 Operation 9 1 Floating Charge Method In this type of operation the battery is connected in parallel with a constant voltage charger and the critical load circuits The charger should be capable of maintaining the required constant voltage at battery terminals and also supply a nor mal connected load were applicable This will then sustain the battery in a fully charged condition and also make it available to assume the emergency power requirements in the event of an AC power interruption or charger failure 9 2 Float Charge Float Voltages The following are the float voltage ranges recommended for the various types of batteries Select any volts per cell value within the range listed that will result in the series string having an average volts per cell equal to that value Do not interchange voltage ranges from one type to another TABLE C Recommended Float Voltages Lead Antimony Types Nominal 1 215 sp gr Nominal 1 250 sp gr 2 15 to 2 17 VPC 2 19 to 2 23 VPC Lead Calcium Types Nominal 1 215 sp gr Nomi
30. lished for terminal plates where used as well as cable connections Benchmark val ues should preferably be established upon installation However if that was not done they may be established later provided the special procedure described below is followed Disconnect the battery from the charger and load and dis assemble at least three 3 of the intercell connections Clean neutralize and burnish these connection components as though they had corrosion See Section 19 0 Reassemble each connection per Section 7 7 and deter mine its resistance Measure the resistance of all similar connections in the battery If any connection resistance exceeds the average of the three remade connections by 10 or 5 microhms whichever is greater that connection should be remade to establish an acceptable benchmark value All benchmark values should be recorded Annually all con nection resistances should be remeasured Any connection which has a resistance value more than 20 above the benchmark value should be corrected Increase in connection resistance of more than 20 above the recorded benchmark definitely indicates a degrading connection Such degradation may be caused by corrosion See Section 19 0 or by relaxation in hardware torque value If there is no sign of corrosion the higher resistance at the connection may be corrected by retorquing See Section19 2 If connection resistance is reduced to within 20 of the benchmark value no f
31. nal 1 250 sp gr Nominal 1 300 sp gr 2 17 to 2 25 VPC 2 23 to 2 33 VPC 2 28 to 2 37 VPC Modern constant voltage output charging equipment is rec ommended for the floating charger method of operation of GNB stationary type batteries This type of charger proper ly adjusted to the recommended float voltages together with adherence to recommended maintenance procedures will assist in obtaining consistent serviceability and optimum life After the battery has been given its initial charge see Section 8 0 the charger should be adjusted to provide the recommended float voltage see Table C at the battery ter minals For example a 60 cell lead antimony battery should have 130 volts maintained at its terminals 60 cells 2 17 volts per cell V P C 2 130 volts Do not use voltages for lead antimony types higher than shown in table C as excessive water consumption and reduced battery life will result Lead calcium types may be floated at any of the voltage val ues Table C shown for a particular nominal specific gravi ty Use the lower VPC value in the appropriate nominal spe cific gravity group where system equipment voltage limita tions will not permit higher values The use of higher VPC values may make it unnecessary to give an equalizing charge However the use of higher float voltages where high ambient temperatures prevail may result in reduced battery life 9 3 Voltmeter Calibration Panel and portable
32. ns should be corrosion free and tight to provide satisfactory operation while supplying emer gency power and when on floating charging Visual moni toring of all connections should be made quarterly When corrosion is observed on any connection DO NOT retorque Retorquing does not improve electrical integrity but only restores mechanical compression Any connection suspected of having corrosion should be disassembled cleaned and neutralized All post contact surfaces intercell connectors terminal plates cable lugs and hardware should be neutralized using a solution of baking soda 1 Ib gallon water After allowing to dry all contact surfaces should be burnished using 3M Scotch Brite scouring pads or a brass suede brush Stubborn oxidized coatings on solid lead parts may be removed using a narrow paint scraper CAUTION 1 DO NOT USE POWER WIRE BRUSH AS THIS MAY REMOVE LEAD PLATING EXPOSING COPPER OR CAUSE RIP PLING OF LEAD CONTACT SURFACES 2 DONOT USE PAINT SCRAPER ON POSTS WITH COPPER INSERTS INTERCELL CON NECTORS OR TERMINAL PLATES AS LEAD PLATING WILL BE REMOVED EXPOSING COPPER After contact surfaces are burnished a thin coating of NO OX ID grease should be applied to all contact surfaces and hardware The connectors and hardware should then be reassembled and torqued per Section 7 6 Connecting Cells It is important that properly prepared contact surfaces be coated with a thin film of NO OX ID grease
33. nt tech nique allows for these differences i Single Connector Hook ups Figure 6 When measuring the resistance of single connec tor hook ups between adjacent cell posts or in the case of flag terminals between multi cell units the probe point locations must be at the same location for each similar type connection If the probe part departs from the center point indicated by X in Figure 6 the measured resistance value can vary due to either an increase or decrease in the lead mass included in the measuring points When con ducting subsequent monitoring of connection resis tance it is important that the same probe point locations are used so that any measured increase or decrease is a true increase or decrease due to connection degradation and not due to using a dif ferent probe point location ii Parallel Connector Hook Ups Figure 7 Parallel paths exist in this hook up and measure ment of connection resistance include all four con nector post interfaces The location of probe points is not critical here because of the existence of par allel paths An increase decrease in the lead mass between post and connector interface on one side is cancelled by an equal decrease increase in the mass on the opposite side ii Four Post Four Connector In Line Hook Ups Figure 8 Cells with four post connector hook ups require two measurements to monitor all eight post connector interfaces Measurement
34. of its products 1 POWER A Division of Exide Technologies
35. oper evaluation of the specific gravity value This applies when taking a pilot cell reading or for 10 of the cells when taking a quarterly set of readings 11 4 Specific Gravity Range GNB stationary batteries are furnished with a nominal fully charged specific gravity of 1 215 77 F 25 C For special applications nominal specific gravity such as 1 250 or 1 300 77 F 25 C may be used The specific gravity may range 010 points within a battery for any of the nominal values 77 F 25 C with the elec trolyte level at the high level line and still be considered sat isfactory SECTION 12 12 0 Cell Voltage Variation The tabulation on the following page indicates the normal cell voltage variation that may exist with the battery on float and no greater than a 5 F 2 78 C variation in cell temperature NORMAL VOLTAGE RANGE Average Type Float Voltage Variation Lead Antimony Nominal 1 215 sp gr 2 15 to 2 17 VP C 04V P C Nominal 1 250 sp gr 2 19 to 2228 VP C 04V P C Lead Calcium Nominal 1 215 sp gr 2 17 to 2 25 V C 05 V P C Nominal 1 250 sp gr 2 23 to 2 33 VP C 05 Nominal 1 300 sp gr 2 28 to 2 37 V P C 05 V P C 12 1 Cell Voltage Variation Damp Covers Cell voltage variation can also be the result of damp cell cover tops Spilled electrolyte when taking hydrometer readings can result in parasitic currents paths across the tops of cell covers This reduces the float current th
36. or a GNB approved equivalent Note 2 A Torque all connection bolts we STAINLESS STEEL PDO cells are torqued to 150 inch pounds HARDWARE M N amp H ceils with 1 4 inch or more thickness of intercell connectors are tarqued ta 150 inch pounds See Note 2 M cells with 1 8 inch thickness af intercell connectors are torqued to 100 inch pounds Note 3 Terminal plate connections are torqued at 100 inch pounds Flat washers must be installed with the rounded rolled edge against the Intercell Connector Backing Plate or Row Int erc nn e ct lo n Terminal Plata to insure corrosion protection and contact integrity See detail A Note 4 The installation illustrations on Ihis page are typical ol connections made to all battery post and do not represent a specific cell type Cable to post Cable to Termina Plate Connector Rolled edge Sea ake See Note 1 i Fx Sharp edge STAINLESS STEEL HARDWARE Supplied with cable kit DETAIL A Washer STAINLESS STEEL HARDWARE Hardware is supplied with terminal plate kits Cable lugs may be See Note 2 3 mounted on both sides of the Terminal Plate i TERMINAL PLATE Can be installed for vertical or horizontal cable exit BACKING PLATES Used when connecting to only one side of the battery post See Nate 1 DUST CAPS ELECTROLYTE WITHDRAWAL Figure 3 7 7 Completing Installation Explosion Resistant
37. own in the appropriate table and for the battery temperature at the time of stabilization until the lowest cell voltage ceases to rise Monitoring of cell voltages should be started during the latter 1096 of the applicable time period to determine lowest cell in battery INITIAL CHARGE Recommended Voltages and Time Periods TABLE A Lead Antimony Types NOTE Time Periods listed in tables A and B are for cell Time Hrs Time Hrs 1 215 1 250 Cell Volts Sp gr Sp gr 2 24 200 2 27 150 2 30 120 2 33 90 146 2 36 75 129 2 39 60 97 2 42 73 2 45 54 2 49 36 2 50 30 temperatures from 70 F 21 C to 90 F 32 For temper atures 55 F 13 C to 69 F 20 5 C double the number of hours For temperatures 40 F 4 C to 54 F 12 C use four times the number of hours TABLE B Lead Calcium Types Time Hrs Time Hrs Time Hrs 1 215 1 250 1 300 Cell Volts Sp gr Sp gr Sp gr 2 24 444 2 27 333 2 30 210 2 33 148 333 2 36 100 235 400 2 39 67 160 267 2 42 48 108 182 2 45 38 73 125 2 48 36 55 83 2 50 32 44 60 8 2 Initial Charge Electrolyte Levels During the initial charge there will be an increase in the electrolyte levels and they may go above the high level mark See Section 3 2 This is due to gases that were lost during transportation or standing in storage being restored to the cells Do not remove any electrolyte even though
38. result in no greater than 5 F 2 78 C variation in cell temperatures in a series string at any given time If a greater variation is found steps should be taken to correct the condition When uniform cell temperature is maintained the need for equalizing charges may be eliminated or reduced in frequency 7 4 Ventilation In the operation of lead acid battery whether it be on initial charge float charge equalizing charge or recharge follow ing a discharge hydrogen and oxygen gases are produced This results from electrolysis of the water portion of the elec trolyte by the charging current Ventilation should be provided in the battery room or area to prevent hydrogen liberated from the cells in service from exceeding a 1 concentration Concentrations above this percentage can result in an explosive mixture which could be ignited by sparks from adjacent electrical equipment as well as accidental sparks or open flames introduced by per sonnel All air moved by ventilation in the battery room or area should be exhausted into the outside atmosphere and should not be allowed to recirculate into other confined areas 7 5 Placement of Cells It is assumed at this point that the battery rack has been assembled Study the rack layout and wiring drawings to determine proper location of the positive and negative ter minals of the battery this will establish correct positioning of the initial cell on each rack row Cells are normally ins
39. rough the cell resulting in volt age variations See Section 18 0 Battery Cleaning to correct damp cover condition 12 2 Cell Voltage Temperature Correction To properly analyze cell uniformity within the string cell voltages should be corrected for cell electrolyte temperature Cell voltage variation that may have developed since a previous quarterly set of readings may be due to cell temperature variations within the string that may have resulted from a change in ambient condi tions Therefore correcting cell voltage for cell temperature may make it unnecessary to apply an equalizing charge which oth erwise had been believed necessary See Section 10 1 Equalizing Frequency 12 3 Correction Factor The temperature correction factor for cell voltage equals 0 003 volts for each degree fahrenheit 0 0055V C using a base 77 F 25 C The correction is added to the measured cell voltage above 77 F 25 C and subtracted below 77 F 25 C Example Measured cell voltage 2 19V 87 F 30 5 C cell temperature Correction 10 F x 003V 3 5 C x 0055V 03V Therefore corrected cell voltage 2 19V 03V 2 22 volts If the cell temperature in the example had been 67 F 19 C the correction would be 03 volts which is subtracted from the mea sured voltage of 2 19V The corrected cell voltage 2 19V 03V 2 16V SECTION 13 13 0 Pilot Cell A pilot cell is selected in the series string to reflect the gen
40. s Also at unheated installations arrange water additions when bat tery temperature is above 50 F 10 C Never introduce battery additives into a GNB battery 15 1 Water Purity The maximum allowable limits of impurities in the water used in GNB stationary batteries shall be as follows Total solids 500 ppm Fixed solids 350ppm Organic amp volatile matter 200ppm Iron as Fe 4 0 ppm Manganese as Mn 0 007 ppm Nitrates as N02 15 0 ppm Ammonia as NH4 5 0 ppm Chlorides as CL 25 0 ppm Distilled water or deionized water satisfying the above requirements may be used SECTION 16 16 0 Tap Connections It is not recommended that tap connections be used on a battery as possible unbalance between groups of cells may result This can cause overcharging of the untapped group of cells and undercharging of the tapped cells supplying the load This condition can cause unsatisfactory operation and reduced battery life SECTION 17 17 0 Temporary Nonuse An installed battery that is permitted to stand idle for a peri od of time should be treated in the following manner With the battery on normal float add approved water to cells to bring electrolyte level to the high level line Give the battery an equalizing charge per Section 10 2 Following comple tion of the equalizing charge open connections at the bat tery terminals to separate charger and load circuit from bat tery Every three months for lead antimony and every six mon
41. talled with plate edges perpendicular to rack length Measure and mark the center of the rack stringer length Determine the number of cells to be placed in each row When an odd number of cells are in the row place the cen ter of the initial cell at the center point of the rack stringer length When an even number of cells are in the row locate the ini tial cells so that the center of the space between the cells coincides with the center mark of the stringer length To reduce friction and facilitate the sliding of cells from plat form lift into position on the battery rack only Dow Corning 111 silicone grease is permitted for use USE OF LUBRICANTS OTHER THAN DOW CORNING 111 SILICONE GREASE WILL VOID WARRANTY DO NOT USE METAL RODS SCREW DRIVERS ETC THROUGH POST HOLES TO POSITION CELLS AS THIS PRACTICE CAN CAUSE SHORTING AND POST DAMAGE AND WILL ALSO VOID WAR RANTY When installing cells on the rack start at the lower step or tier for stability and safety reasons Place cells on the rack so that the positive terminal marked of each cell adjoins the negative terminal marked of the next cell The standard spacing between cells is 1 2 at the top of the jars Adjacent cells should not touch nor should any cell contact the metal rack supports or metal cable conduits Check for proper alignment and 1 2 spacing between cells Adjust cell position where necessary This should be compl
42. thod for giving an equalizing charge Determine the maximum voltage that may be applied to system equipment This voltage divided by the number of cells connected in series will establish the maximum voltage per cell that may be used to perform the equalizing charge in the shortest period of time For lead antimony types refer to Table D and for lead calci um type refer to Table E to obtain various voltage and asso ciated time period recommended The recommended time periods below are considered mini mum Raise the voltage to the maximum value permitted by the system equipment When charging current has tapered and stabilized no further reduction for three hours charge for the hours shown in the appropriate table and for the bat tery temperature at the time of stabilization until the lowest cell voltage ceases to rise Monitoring of cell voltages should be started during the latter 1096 of the applicable time period to determine the lowest cell in battery EQUALIZING CHARGE Recommended Voltages and Time Periods TABLE D Lead Antimony Types Time Hrs Time Hrs 1 215 1 250 Cell Volts Sp gr Sp gr 2 24 8 2 27 60 2 30 48 2 33 36 58 2 36 30 51 2 39 24 39 2 42 29 2 45 26 2 48 24 TABLE E Lead Calcium Types Time Hrs Time Hrs Time Hr s 1 215 1 250 1 300 Cell Volts Sp gr Sp gr Sp gr 2 24 222 2 27 166 2 30 105 2 33 74 166 2 36
43. ths for lead calcium temporarily connect battery to charger and give it an equalizing charge To return to normal service re connect all open connec tions give equalizing charge and then return battery to nor mal float voltage SECTION 18 18 0 Battery Cleaning CAUTION DO NOT CLEAN PLASTIC CELL JARS OR COVERS WITH SOLVENTS DETER GENTS OILS OR SPRAY TYPE CLEAN ERS AS THESE MATERIALS MAY CAUSE CRAZING AND CRACKING OF THE PLAS TIC MATERIALS 18 1 Styrene Acrylonitrile Containers with Butadiene Styrene Covers and PVC Containers and Covers Periodically clean cell jars and covers with a water damp ened cloth to remove accumulated dust Cell parts damp with electrolyte should be neutralized with baking soda water solution 1 Ib of soda per gallon of water Apply with cloth dampened with the solution making sure none is allowed to enter the cell Continue to neutralize until fizzing action ceases then wipe area with a water dampened cloth to remove soda solution Wipe dry with a clean cloth 18 2 Polycarbonate Containers and Covers Cells with containers and covers made from polycarbonate plastic should be cleaned ONLY with a WATER dampened cloth Any surface that is damp with electrolyte should be neutralized with a baking soda water solution 1 Ib of bak ing soda per gallon of water DO NOT USE AMMONIA SODIUM HYDROXIDE OR ANY STRONG ALKALIES SECTION 19 19 0 Connections Battery terminal connectio
44. to reduce possi bility of oxidation or corrosion Tests reveal that this will also prevent measurable increase in the connection resistance 19 1 Connection Resistance Electrical integrity of connections can be objectively estab lished by measuring the resistance of each connection These resistances are typically in the microhm range Meters are available which determine connection resistance in microhms by measuring voltage drop upon the applica tion of a fixed direct current DC through the external cell connections Some precautions must be observed to get consistent and meaningful values however and these are described in Section 19 3 Resistance measurements or microhm measurements should be taken at the time of the installation and annually thereafter Initial measurements at installation become the benchmark values and should be recorded for future moni toring of electrical integrity Specific values of connection resistance vary with cell type quantity of connectors etc It is important that the bench mark value for all similar connections should be no greater than 10 or 5 microhms whichever is greater above the average resistance of all such connections in the battery If any connection resistance exceed the average by more than 10 or 5 microhms whichever is greater the connec tion should be remade so that an acceptable benchmark value is established Benchmark values for connection resistances should also be estab
45. torage period prior to installation The battery should be installed and given its initial charge as soon after receipt as possible At the completion of initial charge record voltage and specific gravity of each cell while still on charge and retain records for future reference per Section 14 0 8 1 Constant Voltage Method Constant voltage is the principal method to give the initial charge as most modern chargers are of the constant volt age design In addition some systems have equipment with voltage limitations making the use of constant current charg ing undesirable Determine the maximum voltage that may be applied to the system equipment The voltage divided by the number of cells connected in series will establish the maximum voltage per cell that may be used Establish whether the battery is of lead antimony or lead calcium construction by referring to type on cell name plate and compare this with the proper GNB sales literature For lead antimony types refer to Table A and for lead calci um types refer to Table B to obtain various voltages and associated time periods recommended Select the highest voltage the system will allow to perform the initial charge in the shortest period of time The recommended time periods are considered minimum Raise the voltage to the maximum value permitted by the system equipment When charging current has tapered and stabilized no further reduction for 3 hours charge for the hours sh
46. ttery should be given an equalizing charge monthly by continuing the regular charge until there is no increase in specific gravity of the pilot cell for three hours when using the finish charge rate 9 5 Recharge All batteries should be recharged as soon as possible fol lowing a discharge within 8 hours With constant voltage chargers this will be accomplished automatically However to recharge in the shortest period of time raise the charger output voltage to the highest value which the connected sys tem will permit Do not exceed those voltage values listed in Table D or Table E on page 9 SECTION 10 10 0 Equalizing Charge An equalizing charge is a special charge given a battery when non uniformity in voltage or specific gravity has devel oped between cells It is given to restore all cells to a fully charged condition using a charging voltage higher than the normal float voltage and for a specified number of hours as determined by the voltage used Non uniformity of cells may result from low floating voltage due to improper adjustment of the charger or a panel volt meter which reads incorrect higher output voltage Also variations in cell temperatures greater than 5 F 2 78 C in the series string at a given time due to environmental con ditions or rack arrangement can cause low cells 10 1 Equalizing Frequency The following guidelines cover lead antimony and lead calcium types Recommendations not applying to
47. urther action will be nec essary Failure to restore resistance to an acceptable value will necessitate reworking the connection Maintaining electrical integrity of connections is important as poor connection will result in reduced battery output and in extreme cases may cause melted cell posts circuit inter ruptions or battery fires 19 2 Retorquing Connections Retorquing of connections should be performed annually See Section 9 14 and when connection resistances have increased to more than 20 over the benchmark Retorquing should not be done if visual inspection shows evidence of corrosion Retorquing when corrosion is pre sent only restores mechanical compression but will not improve electrical integrity Tests reveal that a reduction in the original torque value of 30 still provides a functional electrical connection if there is no corrosion between contact surfaces Retorquing of connections should always be to the recom mended value See Section 7 7 CAUTION TOO FREQUENT RETORQUING OF CONNECTIONS IS NOT RECOMMEND ED AS THIS WILL RESULT IN DISTOR TION OF CELL POSTS CONNECTORS ETC THUS DEGRADING RATHER THAN IMPROVING THE CONNECTIONS 19 3 Connection Resistance Measurements Connection resistances are very small usually in microhms Therefore precautions must be observed so that the mea sured values are meaningful and not misleading Different connector hook ups require that the measureme
48. y equalizing charges as well as total quantity of water when added Also record any mainte nance and or testing performed The foregoing frequency of record taking may have to be modified somewhat to suit local requirements See Page 16 for Battery nameplate SECTION 15 15 0 Water Additions There are two conditions in the operation of batteries which cause a reduction in the amount of water in the electrolyte resulting in a lowering of the electrolyte level These are normal evaporation and the conversion of water into hydro gen and oxygen gases by the charging current These gases are liberated through the cell vents Periodically this water loss must be replaced with approved or distilled water to maintain the electrolyte level at the mid point between the high and low level lines If suitability of the local water supply for use in storage bat teries is questionable contact your nearest GNB represen tative for instructions regarding procedure for submitting a sample for analysis Areport will be rendered as to whether or not the water is suitable If water is to be stored in containers they should be clean and of non metallic material such as glass hard rubber porcelain or plastic Infrequently used water lines should be purged to remove accumulated impurities thus preventing their introduction into the battery Water additions should be scheduled prior to an equalizing charge so that mixing with the electrolyte occur

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