Deka High Rate HRC Batteries Instruction Manual

HRC Batteries
Instruction Manual

High Rate HRC Batteries

BATTERIES AND OTHER RELATED PARTS CONTAIN LEAD

WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals are known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to the State of California to cause cancer.
WASH HANDS AFTER HANDLING!

IN REFERENCE TO THIS MANUAL:

• “Battery” is defined as an individual 12-volt unit.
• “Battery string” is defined as a series connected electrical system comprised of batteries (individual 12-volt units).

SAFETY PRECAUTIONS

Although all valve-regulated batteries have the electrolyte immobilized within the battery, the electrical hazard associated with batteries still exists.
Work performed on these batteries should be done with the tools and the protective equipment listed below. VRLA battery installations should be supervised by personnel familiar with batteries and battery safety precautions.
WARNING: Risk of fire, explosion or burns. Do not disassemble, heat above 65°C, or incinerate.

Protective Equipment
Although VRLA batteries can vent or leak small amounts of electrolyte, electrical safety is the principle but not the only concern for safe handling. Per IEEE 1188  recommendations, the following minimum set of equipment for safe handling of the battery and protection of personnel shall be available:

1. Safety glasses with side shields, or goggles, or face shields as appropriate. (Consult application-specific requirements)
2. Electrically insulated gloves, appropriate for the installation.
3. Protective aprons and safety shoes.
4. Portable or stationary water facilities in the battery vicinity for rinsing eyes and skin in case of contact with acid electrolyte.
5. Class C fire extinguisher.
6. Acid neutralizing agent.
7. Adequately insulated tools (as defined by ASTM F1505“Standard Specification for Insulated and Insulating Hand Tools”).
8. Lifting devices of adequate capacity, when required.

Procedures
The following safety procedures should be followed:
Always wear safety glasses or a face shields when working on or near batteries.

1. These batteries are sealed and contain no free electrolytes. Under normal operating conditions,  they do not present any acid danger. However, if the battery case or cover is damaged, acid could be present.
   Sulfuric acid is harmful to the skin and eyes. Flush the affected area with water immediately and consult a physician if splashed in the eyes. Consult SDS for additional precautions and first aid measures. SDS sheets can be obtained at www.eastpennmanufacturing.com

2. Prohibit smoking and open flames, and avoid arcing in the immediate vicinity of the battery.

3. Do not wear metallic objects, such as jewelry, while working on batteries. Do not store un-insulated tools in pockets or tool belt while working in vicinity of battery.

4. Keep the top of the battery dry and clear of tools and other foreign objects.

5. Provide adequate ventilation (per IEEE standard 1187 and/or local codes) and follow recommended charging voltages.

6. Never remove or tamper with the pressure relief valves. Warranty void if vent valve is removed.

7. Inspect all flooring and lifting equipment for functional adequacy.

8. Adequately secure battery modules, racks, or cabinets to the floor.

9. Connect support structures to the ground system in accordance with applicable codes.

10. The below IEEE Standards contain additional information.
    Other standards may be relevant to your specific application.
    IEEE 1184 – Guide for Batteries for UPS Systems
    IEEE 1187 – Recommended Practice for  Installation Design of VRLA Batteries
    IEEE 1188 – Recommended Practice for Maintenance, Testing, of VRLA Batteries
    IEEE 1189 – Selection of VRLA Batteries for Stationary Applications

RECEIVING & STORAGE

Receiving Inspection
Upon receipt, and at the time of actual unloading, each package should be visually inspected for any possible damage or electrolyte leakage. If either the entire shipment should  be conducted and noted on the bill of lading. Record receipt date, and inspection date and notify the carrier of any damage.
Unpacking

1. Always wear eye protection.
2. Check all batteries for visible defects such as cracked containers, loose terminal posts, or other unrepairable problems. Batteries with these defects must be replaced.
3. Check the contents of the packages against the packaging list. Report any missing parts or shipping damage to your East Penn agent or East Penn Mfg. Co. immediately.
4. Never lift batteries by the terminal posts.

Storage/Refresh
Batteries should be installed, and float charged upon delivery. If batteries are to be stored, the below requirements shall be followed.

1. Batteries shall be stored indoors in a clean, level, dry, cool location.

2. Store, charge, and ship in vertical position only.

3. Recommended storage temperature is 50°F (10°C) to 77°F (25°C). The acceptable storage temperature is 0°F (-18°C) to 90°F (32°C).

4. The batteries shall be given a refresh charge at regular intervals as detailed below: 0°F(-18°C) to 77°F (25°C) Batteries shall be charged by the “battery charge date” marked on a pallet.
   Successive recharges shall be performed every 6 months. 78°F (26°C) to 90°F (32°C)
   Battery voltage readings shall be taken monthly.
   Batteries must be given a refresh charge within 3 months from date of receipt or if any battery voltage falls below 12.72 volts per battery, whichever occurs first.
   Successive refresh charges shall be performed every 3 months.

5. Whenever a refresh charge is required, it’s important that all batteries to be installed in the same series string and receive a charge at the same time to ensure continuity once placed in their intended application.

6. Each battery shall be charged for 24 hours at a constant voltage equal to 14.40 volts per battery. To ensure the batteries are fully charged within 24hrs, the charger used for this refresh charge must have the capacity to provide at least the minimum charge current specification and not exceed the maximum charge current for the given battery type (model), as called out in Appendix C.

7. All requested information on the “Refresh Record Form” in Appendix A should be completed for each refresh charge.

8. Batteries shall not be stored beyond 12 months.
   Storing beyond 12 months will affect the warranty.

9. If the storage/refresh requirements cannot be met, contact the East Penn Reserve Power Product Support Department for alternate instructions.

INSTALLATION

General
Caution should be taken when installing batteries to insure no damage occurs. The battery string cabinet, tray, rack, etc. shall be inspected for sharp edges that could cause damage to the battery casing. Batteries shall not be dropped, slid, or placed on rough or uneven surfaces such as tray lips or grated flooring. Mishandling of batteries could result in equipment damage or human injury. East Penn will not be liable for damage or injury as a result of mishandling or misuse of the product.

Grounding
When grounding the battery string, proper techniques should be applied per electrical standards such as NEC and/or Federal, State, and Local codes, as well as the User Manual of specific applications.
Cabinets
Cabinet systems come factory assembled and prewired. Do not tip or turn cabinets on their sides when positioning them in their intended installation area. Cabinets must be used in an upright position. These systems are pre- connected. Only inter-shelf, inter-cabinet, and connections to the load are required.
See the connection diagram inside the cabinet. Undercabinet and load connection cables are not included.
Racks
Assemble racks in accordance with the intended arrangement, align them with a level, and bolt them to the floor. See rack assembly instructions.

DEKA HRC BATTERIES ARE TESTED AND APPROVED TO BE INSTALLED AND OPERATED IN THEIR UPRIGHT POSITION.

FOR ANY OTHER INSTALLATION ORIENTATION, THE PRODUCT WILL NOT BE WARRANTED.

Venting
Under normal operation, VRLA batteries emit hydrogen gas, which is combustible at certain concentrations. Proper ventilation should be provided per IEEE 1187 and/or local codes. Some batteries are designed to accommodate the use of vent tubing.  Ventilation equipment is not designed or supplied by East Penn Mfg. Safe installation of any venting equipment is the responsibility of the installer.

BATTERY ASSEMBLY

(ALWAYS WEAR EYE PROTECTION.)

1. Set up the battery string so that the positive post (+) of one battery is connected to the negative post (–) of the next battery for all series connections. The inter battery connector contact surfaces shall be cleaned by rubbing gently with a non-metallic brush or pad before installing connectors. Only approved oxide inhibitors (No-Ox-ID  A” from Sanchem, Inc.) may be applied to connections or battery posts.

2. For future identification, individual batteries should be numbered in an electrical connection sequence, beginning with number one (1) at the positive end of the battery string.

3. Install all inner battery connectors using a lock washer and bolts loosely to allow for final alignment of batteries, then torque to 100 in lb+/-4 After torquing the connections on racked batteries, read the voltage of the battery string to assure that individual batteries are connected correctly.
   The total voltage should be approximately equal to the number of batteries times the measured voltage of one battery (when connected in series).
   If the measurement is less, recheck the connections for proper voltage and polarity.

4.  Read and record inner battery connection resistance and note the method of measurement. This helps determine a satisfactory initial installation and can be used as a  reference for future maintenance requirements. See Battery Maintenance Report. (Pg. 10 – Appendix D ). Clean, remake, and re-measure any connection having a resistance  measurement greater than 10% of the average of all the same type of connections (inner battery, inter-tier or shelf, inter-rack, or inner cabinet).

5. Battery performance is based on the output at the battery terminals. Therefore, the shortest electrical connections between the battery string and the operating equipment result in maximum total battery string performance.

Do not select cable size on current carrying capability only. Cable size should not provide a greater voltage drop between the battery system and operating equipment than specified. The excess voltage drops will reduce the desired support time of the battery system.

SYSTEM OPERATIONS

Charger Voltage
These batteries are designed for continuous float applications.
FLOAT / STANDBY (per battery)
13.50V +/- 0.06 @ 77°F (25°C)
When setting the float voltage on the charger, the battery string should be set to float at the nominal battery float voltage times the number of batteries in the string. The charger must be able to maintain the system voltage within ± 0.5% of the desired level at all times. The desired float voltage varies with temperature. Consult Voltage  Compensation Chart
(Pg. 8 – Appendix B).
TEMPERATURE COMPENSATION
Battery voltage should be adjusted for ambient temperature variations.
12mV per °C (1.8°F) per 12V battery
Consult Voltage Compensation Chart
(Pg. 8 – Appendix B) for temperature compensation voltage maximum and minimum limits.
Charger Current
Charge current should not exceed the recommended min. and max. requirements. Consult Appendix C for min. and max. charge current limits.
Battery Voltage
Although the charger must maintain the system voltage within ± 0.5%, individual battery voltages may vary by ± 0.30Vper battery of the average battery string float voltage.
Equalizing
Upon installation of the battery string, an optional charge of 14.40V per battery ± 0.06 @ 77°F (25°C) for 24 hours (not to exceed 24 hours) can be applied.
(NOTE: Verify that the higher battery voltage will not adversely affect any other connected equipment). If this is done, be sure to reset the charging equipment to the proper float voltage.
Battery Operation
Battery operating temperature will affect battery string capacity and operating life.
Temperatures greater than 77°F (25°C) will reduce the operating life of the battery. For every 13°F (7°C) increase in operating temperature above 77°F (25°C), the warranty  period will be proportionally reduced by 50% as shown below:

Battery Operation cont.
The battery string operating temperature should not exceed 95°F (35°C) and should never exceed 105°F (40.5°C) for more than an eight-hour period. If operating temperatures are expected to be in excess of 95°F (35°C), contact East Penn for recommendations.
Discharging at temperatures less than 77°F (25°C) will reduce the capacity of the battery. If operating temperatures are expected to be less than 50°F (10°C), contact East Penn for recommendations.
The battery string must be located in a manner that the individual batteries do not vary by more than 5°F (2.8°C) between the lowest and highest individual battery temperatures.

Rectifier Ripple Voltage
FREQUENCY
A ripple that has a frequency greater than 667Hz (duration less than 1.5ms) is acceptable unless it is causing additional battery heating.
A ripple that has a frequency less than 667Hz (duration greater than1.5ms), must meet the following voltage specification to be acceptable.
VOLTAGE SPECIFICATION
Ripple voltage shall be less than 0.5% peak to peak of the manufacturer’s recommended battery string voltage.
Failure to comply can void the warranty.

RECORD KEEPING

Voltages, Temperatures & Ohmic
READINGS
Record keeping is an important part of stationary battery maintenance and warranty coverage. This information will help in establishing a life history of the battery string and inform the user if and when corrective action needs to be taken. Consult Battery Maintenance Report. (Pg. 10 – Appendix D).
While it is acceptable to operate at temperatures less than 77°F (25°C), it will require longer charging time to become fully recharged. Also, the capacity will be less at operating temperatures below 77°F (25°C).
After installation and when the battery string has been on float charge for one week, the following data should be recorded:

1. Battery string voltage at battery terminals while the battery is on float charge.
2. Charger voltage at charger panel meter.
3. Individual battery float voltages.
4. Ambient temperatures within the area of the battery string.
5. Terminal connections should be checked to verify that the installer did torque all connections properly to 100 in-lb +/- 5. Micro-ohm readings should be taken across every connection. Refer to the meter manufacturer’s instructions for the proper placement of probes. If any reading differs by more than 20% from its initial installation value, re- torque the connection to 100 in-lb +/- 5. If the reading remains high, clean contact surfaces according to Step 1 under Battery Assembly.
   Failure to maintain proper records including information as detailed above may result in voiding any applicable warranty.

ACCEPTANCE TESTING

• Each battery should be at 100% State of Charge prior to performing an acceptance test on the battery system. To ensure the batteries are fully charged the following charge schedule should be followed.

• Batteries should be charged at the equalization rate of 14.40 volts per battery for 24 hours. Temperature-compensated charging parameters shall be applied as detailed in the “Voltage Compensation Chart” in Appendix B of this manual.

• To ensure the batteries are fully charged within 24hrs; the charger used for this charge must have a current equal to the maximum charge current for the given battery type (model), as called out in Appendix C of this manual.

• If these requirements cannot be met, contact the East Penn Product Support Department for alternate instructions.

• Upon completion, the charge voltage should be lowered to the float voltage of 13.50 volts per battery for a minimum period of 72 hours. Reference: IEEE 1188-2005 Section 7.2 for additional acceptance test requirements.

• Upon completion of the above charge, the desired acceptance test can be performed.
  NOTE: There shall be no discharges of any duration between the start of the equalization and the completion of the float period. If a discharge does occur, the charging regime detailed above shall be repeated.

• Upon completion of the acceptance test, the battery system should be placed on float charge at 13.50 volts per battery to restore the battery to its’ rated capacity.

• Batteries should not require an equalization charge once they have passed their initial acceptance test. Consult with the East Penn Product Support Department before performing additional equalizing charges on batteries that have successfully passed their initial acceptance test.

MAINTENANCE

Always wear eye protection when working on or near batteries. Keep sparks and open flames away from batteries at all times. Review “Safety Precautions” (Pg. 1).

Annual Inspection (1)

1. Conduct a visual inspection of each battery.

2. Record the battery string voltage at battery terminals while the battery is on float charge.

3. Record the charger voltage at the charger panel meter.

4. Record the individual battery voltages. The accuracy of the DMM (Digital Multimeter) must be 0.05% (on dc scale) or better. The DMM must be calibrated to NIST  traceable standards. Because float readings are affected by discharge and recharge, these readings must be taken when the battery string has been on a continuous,  uninterrupted float for at least one month.
   The battery should be within ± 0.30 volts of the average battery string voltage.

5. Record the ambient temperatures.

6. Record the battery string temperature at the negative terminal.

7. Record individual battery Ohmic readings.

8. Record all inner battery and terminal connection resistances. Micro-ohm readings should be taken during this inspection. If any reading differs by more than 20% from the initial readings taken, retorque the connection. The resource value is equal to the initial torque value as indicated in the BATTERY ASSEMBLY section.
   Recheck the micro-ohm reading. If the reading remains high, clean the contact surface according to the installation portion of this manual. (1)  Other Maintenance Inspection  intervals follow IEEE 1188

Battery Cleaning
Do not use any chemical compounds to clean batteries. Batteries, cabinets, and racks shall only be cleaned with: clear water, a mixture of baking soda and water or East Penn  Mfg battery cleaner (part # 00321).
Any other types of chemical compounds or solvents other than those listed above, to clean the battery may damage the battery case and/or cover causing possible exposure to sulfuric acid.
Capacity Testing
Per IEEE 1188 “Capacity testing is used to trend battery aging. The result of a capacity test is a calculation of the capacity of the battery. The calculated capacity is also used to  determine if the battery requires replacement.”
When performing capacity testing and recording data refer to IEEE 1188 recommendations.
NOTE: When discharging at higher rates, extra connectors may need to be added to prevent excessive voltage drop and/or excessive temperature rise.
Should it be determined that only individual battery(ies) need to be replaced, contact East Penn?

APPENDIX A

| REFRESH RECORD FORM
---|---
EPM Order Number*| Pallet ID Number| Individual Performing Test (Full Name)| Date of
Refresh| Refresh Duration
| | | |
Model
Number| Information Prior to Refresh| ti
Information within 1 hour of
Refresh Completion| Notes & Comments
Date
Code| Battery
Serial
Number| Open Circuit Voltage| Battery
Voltage
Reading| Charging
Current| ry
Battery
Temperature
Battery 1| | | | | | | |
Battery 2| | | | | | | |
Battery 3| | | | | | | |
Battery 4| | | | | | | |
Battery 5| | | | | | | |
Battery 6| | | | | | | |
Battery 7| | | | | | | |
Battery 8| | | | | | | |
Battery 9| | | | | | | |
Battery 10| | | | | | | |
Battery 11| | | | | | | |
Battery 12| | | | | | | |
Battery 13| | | | | | | |
Battery 14| | | | | | | |
Battery 15| | | | | | | |
Battery 16| | | | | | | |
Battery 17| | | | | | | |
Battery 18| | | | | | | |
Battery 19| | | | | | | |
Battery 20| | | | | | | |
Battery 21| | | | | | | |
Battery 22| | | | | | | |
Battery 23| | | | | | | |
Battery 24| | | | | | | |

ALL FIELDS TO THE RIGHT OF THE CELL NUMBER ABOVE MUST BE COMPLETED
EPM ORDER NUMBER WILL APPEAR ON THE SHIPPING LABEL ON THE CARTON COVERING EACH PALLET OF CELLS
TO ENSURE CONTINUATION OF WARRANTY, SUBMIT FORMS TO: East Penn Mfg. Co, Inc.,
Reserve Power Division, Product Support & Warranty Dept. ([email protected])

APPENDIX B
VOLTAGE COMPENSATION CHART

APPENDIX C
DEKA HRC CHARGE CURRENT LIMITS

Battery Type| Max. Charge
Current (A)| Max. Charge
Current (A)**
---|---|---
HRC800| 17.| 5.
HRC950| 24.| 7.

** = Using minimum charge current will extend recharge time and increase the risk of the battery being undercharged

APPENDIX D
BATTERY MAINTENANCE REPORT

Inspection Date __
Company ___
Address ____
Battery location and/or number _
No. of Units/String _
Type ___
Date New __
Date Installed ___

Individual Battery Readings

Charger Output __
Amp Air Temperature __°F
Total Battery String Voltage
Panel Meter Volts ____

Unit No.| Volts| Ohms or
Mhos| Unit
No.| Volts| Ohms or
Mhos| Unit
No.| Volts| Ohms or
Mhos| Unit
No.| Volts| Ohms or
Mhos| Unit
No.| Volts| Ohms or
Mhos| Unit
No.| Volts| Ohms or
Mhos
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---
1| | | 41| | | 81| | | 121| | | 161| | | 201| |
2| | | 42| | | 82| | | 122| | | 162| | | 202| |
3| | | 43| | | 83| | | 123| | | 163| | | 203| |
4| | | 44| | | 84| | | 124| | | 164| | | 204| |
5| | | 45| | | 85| | | 125| | | 165| | | 205| |
6| | | 46| | | 86| | | 126| | | 166| | | 206| |
7| | | 47| | | 87| | | 127| | | 167| | | 207| |
8| | | 48| | | 88| | | 128| | | 168| | | 208| |
9| | | 49| | | 89| | | 129| | | 169| | | 209| |
10| | | 50| | | 90| | | 130| | | 170| | | 210| |
11| | | 51| | | 91| | | 131| | | 171| | | 211| |
12| | | 52| | | 92| | | 132| | | 172| | | 212| |
13| | | 53| | | 93| | | 133| | | 173| | | 213| |
14| | | 54| | | 94| | | 134| | | 174| | | 214| |
15| | | 55| | | 95| | | 135| | | 175| | | 215| |
16| | | 56| | | 96| | | 136| | | 176| | | 216| |
17| | | 57| | | 97| | | 137| | | 177| | | 217| |
18| | | 58| | | 98| | | 138| | | 178| | | 218| |
19| | | 59| | | 99| | | 139| | | 179| | | 219| |
20| | | 60| | | 100| | | 140| | | 180| | | 220| |
21| | | 61| | | 101| | | 141| | | 181| | | 221| |
22| | | 62| | | 102| | | 142| | | 182| | | 222| |
23| | | 63| | | 103| | | 142| | | 183| | | 223| |
24| | | 64| | | 104| | | 144| | | 184| | | 224| |
25| | | 65| | | 105| | | 145| | | 185| | | 225| |
26| | | 66| | | 106| | | 146| | | 186| | | 226| |
27| | | 67| | | 107| | | 147| | | 187| | | 227| |
28| | | 68| | | 108| | | 148| | | 188| | | 228| |
29| | | 69| | | 109| | | 149| | | 189| | | 229| |
30| | | 70| | | 110| | | 150| | | 190| | | 230| |
31| | | 71| | | 111| | | 151| | | 191| | | 231| |
32| | | 72| | | 112| | | 152| | | 192| | | 232| |
33| | | 73| | | 113| | | 153| | | 193| | | 233| |
34| | | 74| | | 114| | | 154| | | 194| | | 234| |
35| | | 75| | | 115| | | 155| | | 195| | | 235| |
36| | | 76| | | 116| | | 156| | | 196| | | 236| |
37| | | 77| | | 117| | | 157| | | 197| | | 237| |
38| | | 78| | | 118| | | 158| | | 198| | | 238| |
39| | | 79| | | 119| | | 159| | | 199| | | 239| |
40| | | 80| | | 120| | | 160| | | 200| | | 240| |
Avg. Voltage| Avg. Voltage| Avg Voltage| Avg. Voltage| Avg. Voltage| Avg. Voltage

e-mail: [email protected]

East Penn Manufacturing Co. Lyon Station,
PA 19536-0147 Phone: 610-682-3263 F
E.P.M. Form No. 2531 02/22
© 2022 by EPM Printed in the U.S.A.
Fax: 610-682-4781
www.dekabatteries.com
All data is subject to change without notice. No part of this document may be copied or reproduced, electronically or mechanically, without written permission from the company.

References

• East Penn Manufacturing – The world's largest single site, family-owned lead-acid battery manufacturer
• East Penn Manufacturing – The world's largest single site, family-owned lead-acid battery manufacturer

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