Deka 8G VRLA System Monoblock VRLA System Installation Guide

Deka 8G VRLA System Monoblock VRLA System

PROPOSITION 65 WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals 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.

Renewable Energy applications that depend on battery power as part of the system operation must be at maximum performance at all times. To ensure this high rate of performance is achieved, the battery charging system must be set properly. A battery/battery bank that is undercharged or overcharged will affect the battery system’s performance & life, as well as the performance of the entire system. Key factors that affect an ability to provide the capacity and long life that is expected are System Design, Storage, Temperature, Depth of Discharge (DoD), Charging, and Maintenance.

SYSTEM DESIGN

Systems Design is the process of defining the architecture, components, modules, interfaces, and load data for a system to satisfy specified requirements. For a solar system, these components are the PV modules, inverter/charge controller & batteries, as well as the different interfaces of those components. To properly size a battery/battery bank for a renewable energy system the following parameters are required:

• Load – Amount of DC (Amps, Ah) or power (Watts, Wh) a battery is required to supply to a DC load or AC load through an inverter.
• Time – expressed in hours the battery will be required to provide the load.
• System Voltage – DC system operating voltage
• Ambient Temperature – Average temperature of battery room or enclosure.
• Depth of Discharge (DoD) – The proportion of energy that has been removed from a battery; typically within 24 hours
  • Example: 100% DoD is removing all of the energy from a battery.
• Autonomy – Length of time PV system can provide energy to load without energy from the PV array
• Design Margin – Factor (typically expressed as a percentage) to allow for future load additions.

A Renewable Energy Worksheet is provided in Appendix A listing the above requirements along with additional information requirements

BATTERY OPERATION

Several factors affect the operation of the battery concerning its ability to deliver capacity and life expectancy.

Temperature
Many chemical reactions are affected by temperature, and this is true of the reaction that occurs in a storage battery. The chemical reaction of a lead- acid battery is slowed down by a lowering of the electrolyte temperature which results in less capacity. A battery that will deliver 100% of rated capacity at 77°F (25°C) will only deliver approximately 65% of rated capacity at 32°F. At temperatures below 32°F (0°C) a battery can freeze depending on the DoD (Depth of Discharge). The higher the DoD, the closer to 32°F (0°C) before the battery will freeze. The graph in Appendix C should be consulted to verify the DoD of the battery/battery bank at the end of the discharge will not be susceptible to freezing in a particular application. If the electrolyte freezes, the internal damage would be irreversible requiring the battery to be replaced. Excessive heat will increase the natural corrosion factors of a lead-acid battery. This increased corrosion of the positive plates contributes greatly to reducing the overall life of the battery.

Depth of Discharge (DoD)
The depth of discharge is a function of design. The deeper the discharge per cycle, the shorter the life of the battery. A cycle is a discharge and its subsequent recharge regardless of the depth of discharge. Systems should be designed for shallow discharges. The result of shallower discharges is typically a larger capacity battery at prolonged battery life. A Cycle vs. DoD chart should be consulted to determine the number of cycles at a specific DoD and the projected life in years the battery/battery system will provide before needing replacement.

Charging

Example:
Consulting the chart in Appendix C; it indicates that at a 50% DoD, a battery is susceptible to freezing at -40°F (-40°C). To ensure the electrolyte will not freeze, the battery should be designed to limit the DoD to < 45% Majority of battery capacity/life issues can be traced to improper charging. Improper charging settings may lead to an overcharging or undercharging condition. Typical Inverters/Charge Controllers charging lead-acid batteries use 3-stage charging: Bulk, Absorption, and Float with an optional equalize stage. See Appendix B for an example of a typical 3-stage charging curve.

Inverter/Charge Controller Settings
Proper Inverter/Charge Controller settings are necessary to ensure peak battery performance and life. All bulk, absorption, float, and equalize settings should be verified they are within the battery manufacturer settings. These settings are included but not limited to; voltage, current, and time. Consult individual battery Installation & Operating manuals for inverter/charge controller setting recommendations. Default settings should not be presumed to be correct.
For battery systems located in an uncontrolled temperature environment, temperature compensation must be used.

Bulk
Current is applied to the batteries at the maximum safe rate they will accept until the voltage rises to near (80-85%) full charge level. The battery voltage rises because the charging current that is provided by the battery charger is replenishing its  Bulk continued internal charge capacity. The charger current is flat (constant) and the battery voltage is rising. Maximum allowable charge voltage & current allowed by the battery manufacturer should be used to ensure the most energy is returned within the bulk stage.

Bulk Charge Stage Time Calculation:

• Max Time (Hr) = (Ahr x 1.2)/Avg. Current (A) Ahr = Amp hours removed during discharge. 1.2 = Recharge multiplier
• Avg. Current = Average current is available to the battery from the charger.

NOTE: Avg. current should be ≤ maximum current limits for the installed battery. Charge current limits available from your East Penn representative.

• Max Time (Hr) – Maximum charge time for battery to reach 80% – 85% state of charge

Absorption
The charger will attempt to hold its output voltage constant while the battery continues to absorb charge (draw charging current) from the charger. The rate at which the battery continues to absorb charge in this mode gradually slows down. The amplitude of the charger current is gradually decreasing. The charge current is falling and the battery voltage is flat (constant). Some Inverter/Charge Controllers can either use time or current to determine the length of the absorption stage. Time regulated absorption is based on a predetermined time after the battery has completed the bulk stage (charge voltage has reached its maximum set point). A lead-acid battery is said to be at 80% to 85% SOC (State of Charge) when the voltage set point is met and the current starts to taper; considered the start of absorption. The remaining time required to reach 100% SOC is based on ever changing factors: solar isolation (summer vs. winter), ambient temperature, battery type (flooded, VRLA), and battery age. Absorption stage time should be set to optimize the available sun hours during the winter and/or cloudy months. If improperly set, there is a risk of undercharging the battery system. It is recommended to set the absorption time to the maximum time setting possible to take advantage of all available charging light regardless of time of year or weather issues. Using this method, the sun availability will determine the absorption time. Following this recommendation, there is no risk of overcharging if the battery charge voltage is set within the recommended settings. The amount of available power (current) to the batteries is important for getting a battery charged. Available power (current) to the batteries is the remaining power (current) after connected loads are satisfied. Maximum charge voltage and current allowed by the battery manufacturer should be used to ensure the most energy is returned to the batteries. The following calculation will assist in identifying the necessary maximum charge current for the system. If the calculation shows the absorption time is greater than the minimum average peak sun hours for the installation location, the amount of available current to the batteries should be increased, which could be accomplished by a larger array or a secondary power source such as a generator.

Charge Current Verification:

Example:

Maximum Charge Current
Battery Rating: 1186 (C20) 2374A – Charge current (maximum) 1186Ah x 0.44/237 = 2.20 hrs

Minimum Charge Current
Battery Rating: 1186Ah (C20) 118A – Charge Current (minimum) 1186Ah x 0.44 / 118A = 4.42 hrs VRLA (8A & 8G) C20 x 0.39 / charge current available

Maximum Charge Current
Battery Rating: 183Ah (C20) 55A – Charge current (maximum) 183Ah x 0.39 / 55A = 1.30 hrs

Minimum Charge Current
Battery Rating: 183Ah (C20) 18.3A – Charge Current (minimum) 183Ah x 0.39 / 18.3A = 3.90 hrs

Current regulated absorption uses the charge current to determine the battery state of charge, which eliminates a majority of the variables previously mentioned with time-based absorption (solar insolation, ambient temperature, battery type). Charging in constant voltage, when a battery/battery system reaches the absorption voltage setting, the current will start to taper. The point at which the current stops tapering or declining is referred to as the stabilizing current. This is an indication that the battery is fully charged and the current the battery/battery system is drawing is only needed to keep the battery at the set voltage. This minimum or stabilizing current will change based on the charge voltage setting. Battery manufacturers should be consulted for current settings.

An additional option for determining the SOC of a battery is monitoring the Ah (amp hour) removed from a battery during a discharge and the amount of Ah returned during charge; similar to a gas gauge in a car. The Ah in and out should be monitored continuously to keep track of the overall SOC not just from day to day.

Float
The voltage at which the battery is maintained after being charged to 100% SOC (State of Charge) to maintain capacity by compensating for self-discharge of the battery.

Equalize
A charge, at a level higher than the normal float voltage, is applied for a limited period, to correct inequalities of voltage, specific gravity, or state of charge that may have developed between the cells during service.

NOTE: Equalize charging is not required on VRLA (8A & 8G) as part of a daily charge setup. Based on PV applications, unpredictable recharge availability, and periodic equalization may be required. Charge Controller/Inverter charge setting recommendations are detailed in the System Operation section of this manual. A voltage range is provided because of equipment setting availability/limitations, however, for optimal charge performance, all settings should be at the highest setting of the battery range that the charge controller/inverter can handle.

Maintenance
IEEE (Institute of Electrical and Electronics Engineers) suggests batteries be checked on a monthly, quarterly, and yearly basis. Each period requires different checks. A maintenance log should be initiated at the time of installation. Typical checks consist of voltage, specific gravity (not required for VRLA), and visual inspections. Periodic verification of voltages will ensure the battery is being fully charged and operating properly. If any conditions are found that are out of specification, corrections should be made. A good battery maintenance program is necessary to protect the life expectancy and capacity of the battery. Reference 1188 IEEE for VRLA (Valve Regulated Lead-Acid) batteries.

BATTERY LOCATION

When planning a battery system the following requirements should be considered:

• Space
• Floor Preparation
• Battery Racking System
• Ventilation
• Environment
• Operating Equipment

Space
It is recommended that aisle space be provided in front of all battery racks be a minimum of 36.0″ (915mm). The design should meet all applicable local, state, and federal codes and regulations.

Floor Preparation
It is recommended to consult with a structural engineer to determine if the existing floor will withstand the weight of the battery and the battery racking system. The floors in which the battery will be located should have an acid-resistant coating. Any battery spills should be neutralized with a non- corrosive, water-based neutralizing chemical (ex: baking soda/water solution) that is user-safe and environmentally compliant. The area should always be washed with clean water to remove any acid-neutralizing chemical residue.

Battery Racking System
The battery should not be installed directly on the floor. There should be some type of barrier/racking between the floor and the batteries. This barrier/racking should be sufficient to handle the weight of the battery. The battery racking system must be suitably insulated to prevent sparking and eliminate any grounding paths. Adequate space and accessibility for taking individual battery or cell voltage, hydrometer readings, and adding water should be considered. If installed in an earthquake seismic zone, the battery racking system must be of sufficient strength and adequately anchored to the floor. Battery rack design and anchoring should be reviewed by a structural engineer.

Ventilation
It is the responsibility of the installer to provide detailed methods or engineering design required by Federal, State, and local regulations to maintain safe levels of hydrogen in battery rooms/enclosures. The rate of hydrogen evolution is highest when the battery is on charge. Explosive mixtures of hydrogen in air are present when the hydrogen concentration is greater than or equal to 4% by volume. To provide a margin of safety, the battery room/enclosure must be ventilated to limit the accumulation of hydrogen gas under all anticipated conditions. This margin of safety is regulated by Federal, State, and Local codes and is typically limited to 1% to 2% by volume of the battery room/enclosure. Consult all applicable codes to determine a specific margin of safety. Hydrogen gas calculations can be determined by using proper formulas. Hydrogen gas is lighter than air and will accumulate, creating pockets of gas in the ceiling. The ventilation system should be designed to account for and eliminate this situation. The ventilation system must be designed to vent to the outside atmosphere by either natural or mechanical means to eliminate the hydrogen from the battery room/enclosure.

Environment
Batteries should be located in a clean, cool, and dry place and isolated from outside elements. The selected area should be free of any water, oil, and dirt from accumulating on the batteries.

Operating Equipment
Battery systems are sized based on a specific load (Amps or Watts) for a specific run time to a specific end voltage. Battery performance is based on these values, as measured at the battery terminals. For proper operation of the battery system, the following should be considered:

• Distance between the battery system and operating systems should be kept at the shortest distance possible
• Cables are to be of proper gauge to handle system loads and minimize voltage drops.
• All cable lengths from the battery system to the operating system should be of the same wire gauge and length.

The above is to ensure the battery cable used will be able to carry the charge/discharge current & minimize the voltage drop between equipment. Electrical equipment should not be installed above the batteries, because of the possibility of corrosive fumes being released from the battery(s).

Series/Parallel Wiring
Series and parallel wiring of batteries as well as battery to inverter/charge controller wiring should be designed to minimize voltage drop. Wire gauge, wire length, as well as inter-battery connection layout, are all variables in reducing voltage drop as well as providing battery balance between parallel battery strings. Proceedings are examples of common wiring layouts with the narrative of the advantages and/or disadvantages of each. Daisy Chain Wiring is a wiring scheme in which multiple devices are wired together in sequence. All interconnecting wiring should be of the same length to minimize voltage drop.

Disadvantages:

• The interunit cables are required to increase in gauge size to accommodate the increase in the current of each connected string.
• Maintenance and battery diagnostics require the entire battery system to be disconnected from the renewable energy system, leaving no backup energy source.
• Wiring connection assessment is difficult to follow with multiple wirings connected to the same battery terminal, increasing the chance of re-connection wiring errors.

Common Bus Wiring is a wiring scheme in which the same polarity terminals are connected to a single termination point. All interconnecting wiring should be of the same length
to minimize voltage drop.

Advantages:

• Cables can be of the same gauge.
• Maintenance and battery diagnostics can be performed on a single string while maintaining a level of backup energy source from the other strings staying connected to the renewable energy system.
• Wiring connection assessment simplified by single

Daisy Chain Wiring

Common Bus Wiring

ONLY TRAINED AND AUTHORIZED PERSONNEL SHOULD INSTALL, REPAIR OR CHARGE BATTERIES. When used properly, a lead-acid renewable energy battery is a safe, dependable source of electrical power. However, if proper care and safety precautions aren’t exercised when handling a battery, it can be an extremely dangerous piece of equipment. There are four hazardous elements in a lead-acid battery: sulfuric acid, explosive gases, electricity, and weight.

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. Valve-regulated 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 104ºF (40°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 batteries and protection of personnel shall be available:

1. Safety glasses with side shields, 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 during installation: (Always wear safety glasses or face shield 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 cell jar 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 near the battery.
3. Do not wear metallic objects, such as jewelry, while working on cells. Do not store un-insulated tools in pockets or tool belts while working in the vicinity of the battery. Keep the top of the battery string dry and clear of tools and other foreign objects.
4. Provide adequate ventilation (per IEEE standard 1187 and/or local codes) and follow recommended charging voltages.
5. Never remove or tamper with the pressure relief valves, except for cell replacement. Warranty void if vent valve is removed.
6. Inspect flooring and lifting equipment for functional adequacy.
7. Adequately secure cell modules, racks, or cabinets to the floor.
8. Connect support structures to the ground system by applicable codes.

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 is evident, a more detailed inspection of the entire shipment should be conducted and noted on the bill of lading. Record receipt date, and inspection data and notify 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. Cells 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 the date of receipt or if any battery voltage falls below 12.72 volts per battery (6.36V of 6V battery), whichever occurs first. Successive refresh charges shall be performed every 3 months. Whenever a refresh charge is required, all batteries te installed in the same series string must receive a charge at the same time to ensure continuity once placed in their intended application.

5. Each battery shall be charged for 24 hours at a constant voltage equal to 14.40 volts per battery (7.20V for 6V battery). To ensure the batteries are fully charged within 24 hours, 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).

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

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

8. If the storage/refresh requirements cannot be met, contact East Penn Reserve Power’s Product Support group for alternate instructions.

INSTALLATION

General
Caution should be taken when installing batteries to ensure no damage occurs. 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 system, proper techniques should be applied per electrical standards, such as NEC and/or local codes, as well as the User Manual of specific applications.

BATTERY ASSEMBLY (Always wear eye protection.)

1. Set up the batteries so that the positive post (+) of one battery is connected to the negative post (–) of the next battery for all series connections.

2. All battery electrical contact surfaces shall be cleaned by rubbing gently with a non-metallic brush or pad before installing connectors. No-Ox-ID grease can be used but is not required.

3. Install all electrical connectors / cables and bolting hardware loosely to allow for the final alignment of batteries. Torque to manufacturer recommendations.

4. After torquing, read the voltage of the battery string to ensure the 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.

5. Read and record 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 Appendix B, recording forms, in the back of the manual. Clean, remake, and re-measure any connection having a resistance measurement greater than 10% of the average of all the same type of connections.

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

7. Cable size selection should be determined by current carrying requirements as well as by providing a minimum voltage drop between the battery system and operation equipment. Proper techniques should be applied per electrical standards, such as NEC and/or local codes. Note: Excess voltage drop will reduce the support time of the battery system.

SYSTEM OPERATION

Several factors affect the operation of the battery system concerning its ability to deliver capacity and life expectancy. Many chemical reactions are affected by temperature, and this is true of the reaction that occurs in a storage battery. The chemical reaction of a lead-acid battery is slowed down by a lowering of the electrolyte temperature which results in less capacity. A battery that will deliver 100% of rated capacity at 77° F (25°C) will only deliver 65% of rated capacity at 32°F (0°C).

Charging

Consult Charger User Manual of specific applications for Safety and Operating requirements.
For cyclic applications, the battery system must be charged fully after each discharge. It is recommended that 108% to 115% of the Ah (Amp Hour) capacity removed from the battery system be replaced after each discharge. This additional Ah is to compensate for any efficiency losses between the battery charger and the battery system.

Charging Parameters Charge Voltage

Bulk Charge:
Currently limited to 30% of C20 or 6 times I20.

Absorption Charge: 12.10V to 14.40V per 12V battery

Float Charge:
13.44V to 13.56V per 12V battery

Equalize:
14.40V to 14.60V per 12V battery

NOTE: Divide values in half for a 6-volt battery.

Temperature Compensation
Battery voltage should be adjusted for ambient temperature variations.

• 3mV per °C (1.8°F) per cell
• 18mV per 12V battery
• 9mV per 6V battery

For temperatures above 77°F (25°C) subtract and for temperatures below 77°F (25°C) add. Consult the Voltage Compensation Chart in Appendix D for temperature compensation voltage maximum and minimum limits. The average battery operating temperature should not exceed 95°F (35°C) and should never exceed 105°F (40.5°C) for more than eight hours. Operating at temperatures greater than 77°F (25°C) will reduce the operating life of the battery. 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.

SYSTEM OPERATION continued

Charge Current
To properly determine the amount of charge current required the following variables are to be considered:

• DoD (Depth of Discharge)
• Temperature
• Size & efficiency of the charger
• Age and condition of battery(ies)

Maximum charge current should be limited to 30% of the C20 Ah rate for the battery(ies) being used in the system.

Example: 8G24 C20 rate – 73.6Ah Max. recharge rate: 73.6Ah x 0.3 = 22.1A Consult the Charging Current vs Charging Time chart in Appendix E as a guideline to determine recharge time from 0% to 90% state of charge at an initial charge current.

Discharge Voltage Curve
To estimate battery voltage during a constant current discharge at various DoD (Depth of Discharge) consult the chart Discharge Voltage Curve in Appendix E.

NOTE: Battery voltage can vary depending on temperature, age, and condition of battery.

State of Charge
Battery state of charge can be determined by measuring the open circuit voltage. Consult the below table. State of Charge vs. Open Circuit Voltage*

NOTE: Divide values in half for 6-volt battery(ies) *The “true” O.C.V. of a battery can only be determined after the battery has been removed from the load (charge/discharge) for 24 hours.

RECORD KEEPING
Voltages, Temperatures & Ohmic Readings Consult User Manual of specific applications for additional Safety & Operating requirements. Record keeping is an important part of battery maintenance and warranty coverage. This information will help in establishing a life history of the battery and inform the user if and when corrective action needs to be taken. (Refer to Appendix B, Battery Maintenance Report).

After installation and the batteries are in a fully charged condition, the following data should be recorded: Depending on application, some of the following recommendations may not apply.

• Battery and/or string terminal voltage
• Charger voltage
• Individual battery float/charge voltages
• Individual battery ohmic readings**
• Ambient temperatures
• Terminal connections should be checked to verify all connections are properly torques. 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 connections. If the reading remains high, clean contact surfaces according to the installation portion of this manual.

Note: To provide accurate consistent values, battery systems must be fully charged, at the same temperature, and probes placed at the same location each time readings are taken.

MAINTENANCE

Always wear eye protection when working on or near batteries. Keep sparks and open flames away from batteries at all times. Consult the User Manual of specific applications for additional Safety & Operating requirements.

Acceptance Testing
Each battery should be at 100% State of Charge before 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 (7.20V for 6V battery) for 24 hours. Temperature-compensated charging parameters shall be applied as detailed in the “Voltage Compensation Chart” in Appendix A of this manual. To ensure the batteries are fully charged within 24 hours; the charger used for this charge must have a current equal to the maximum charge current for the given battery type (model). If these requirements cannot be met, contact East Penn Reserve Power’s Product Support group for alternate instructions. Upon completion, the charge voltage should be lowered to the float voltage of 13.50 volts per battery (6.75V for 6V 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 (6.75V for 6V 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 East Penn Reserve Power’s Product Support group before performing additional equalizing charges on batteries that have successfully passed their initial acceptance test.

Annual Inspection
Depending on the application, some of the following recommendations may not apply.

1. Conduct a visual inspection of the battery(ies).
2. Record battery and /or string voltage. The accuracy of the DMM (Digital Multimeter) must be 0.05% (on a dc scale) or better. The DMM must be calibrated to NIST traceable standards. Because voltage readings are affected by discharge and recharge, for cyclic applications, the battery(ies) must be in a fully charged condition before taking readings. Batteries should be within ± 0.30 volts (+ 0.15 volts for 6V) of the average battery float voltage.
3. Record charger voltage.
4. Record the ambient temperature.
5. Record individual battery ohmic readings.***
6. Record all interunit and terminal connection resistances.

Micro-ohm readings should be taken during this inspection. If any reading is greater than 20% from initial readings, retorque the connection. Recheck the micro-ohm reading. If the reading remains high, clean the contact surface according to the installation portion of this manual.

NOTE: To provide accurate/consistent values, battery(ies) must be fully charged, at the same temperature, and probes placed at the same location each time readings are taken.

Rectifier Ripple Voltage FREQUENCY
Ripple that has a frequency greater than 667Hz (duration less than 1.5ms) is acceptable unless it is causing additional battery heating. Ripple that has a frequency less than 667Hz (duration greater than 1.5ms), must meet the following voltage specification to be acceptable.

VOLTAGE
Ripple voltage shall be less than .5% peak to peak of the manufacturer’s recommended string voltage.

Battery Cleaning
Batteries, cabinets, racks, and modules should be cleaned with clean water. If neutralizing is required, use a mixture of baking soda and water. Use clean water to remove baking soda residue. Never use solvents to clean the battery(ies).

Capacity Testing
Capacity tests should not be run unless the battery’s operation is questionable. Do not discharge the battery(ies) beyond the specified final voltage. When discharging at higher rates, extra connectors may be required to prevent excessive voltage drop. When performing capacity testing and recording data use applicable standards and/or User Manual. Should it be determined any individual battery(ies) or cell(s) need to be replaced, contact your nearest East Penn agent or East Penn Mfg. Co. To determine if a battery can deliver its rated capacity, a test discharge, or capacity test, can be performed. This test helps determine the “health” of a battery and whether or not it should be replaced. Only experienced battery technicians should be allowed to prepare a battery for discharge testing and to conduct the actual discharge test. The test is conducted by discharging a fully charged battery at a specific rate until the battery voltage drops to a predetermined volts per battery, times the number of batteries in the battery system. By noting the time elapsed between when the battery was put on discharge and when the final voltage was reached, you can determine whether the battery is delivering its rated capacity:

1. Give the battery an equalizing charge until the current has stabilized. Start the test and record the starting time.
2. Record individual battery voltages and overall battery system voltages during the first hour at 10 minutes, 30 minutes, and then 60 minutes. After the first hour, take hourly readings until the first battery voltage reaches 10.80 volts per battery. From this point on, record the voltage of the batteries every 5 minutes. Monitor the voltage of the low batteries and as the voltage of each battery drops below the predetermined final voltage, record the time.
3. When the majority of the batteries reach termination value, stop the test. Don’t let any battery go into reversal. For example, if the test was run at the 360-minute rate and was terminated after 336 minutes; the capacity percentage would be 93%
4. If the battery system delivers 50% or more of its rated capacity, it can be returned to service. If the test indicates less than 50% of the battery’s rated capacity is being delivered, the battery system should be either repaired or replaced, depending on its age and overall condition. For more detailed information on capacity testing, contact East Penn Manufacturing Company or your local authorized East Penn Representative.

GLOSSARY

• AGM – Absorbed Glass Mat – A class of VRLA (Valve Regulated Lead-Acid) battery in which the electrolyte is absorbed into a glass mat.

• Ambient Temperature – The average temperature of the battery room. Temperatures below 77°F (25°C) will reduce battery capacity. Temperatures above 77°F (25°C) will reduce battery service life.

• Amp Hour (Ah ) – Amps times Hours

• Battery Efficiency – The amount of Ah return required to achieve full SOC vs. the amount of Ah removed during discharge. Require 110% to 115% Ah return

• Capacity – The capacity of a battery is specified as the number of Amp-Hrs that the battery will deliver at a specific discharge rate and temperature. The capacity of a battery is not a constant value and is seen to decrease with increasing discharge rate.

• C20 – Battery capacity measured in Ah (amp hour) at the 20-hour rate.

• End Voltage – The minimum voltage at which a DC system will operate.

• Flooded – A battery in which the products of electrolysis and evaporation are allowed to escape to the atmosphere as they are generated. The electrolyte is free-flowing throughout the battery.

• Gel – A class of VRLA (Valve Regulated Leda-Acid) battery in which the electrolyte is immobilized in a gel form (sulfuric acid mixed with silica)

• Parallel – A circuit that provides more than one path for the flow of current. A parallel arrangement of batteries (usually of voltages and capacities) has all positive terminals connected to a conductor and all negative terminals connected to another conductor. If two 12-volt batteries of 50 ampere-hour capacity each are connected in parallel, the circuit voltage is 12 volts, and the ampere-hour capacity of the combination is 100 ampere-hours.

• Series – A circuit that has only one path for the flow of current. Batteries arranged in series are connected with the negative of the first to the positive of the second, the negative of the second to the positive of the third, etc. If two 12-volt batteries of 50 aampere-hourscapacity each are connected in series, the circuit voltage is equal to the sum of the two battery voltages, or 24 volts, and the ampere-hour capacity of the combination is 50 ampere-hours.

• SOC (State of Charge) – The amount of deliverable
  low-rate electrical energy stored in a battery at a given time expressed as a percentage of the energy when fully charged and measured under the same discharge conditions. If the battery is fully charged the “SOC” is said to be 100%.

• Temperature Correction – A factor used to compensate for battery capacity and/or adjust battery voltage at ambient temperatures greater than or less than 77°F (25°C).

• Undercharge (Deficit charge) – Charging a battery with fewer ampere-hours (Ah) than is required to return the battery to its initial state of charge. This results in a reduction in the battery state of charge.

• VPC – Volts per Cell

• VRLA – Valve Regulated Lead Acid – a lead-acid cell/battery that is sealed except for a valve that opens to the atmosphere when the internal gas pressure exceeds atmospheric pressure by a pre-selected amount. VRLA batteries provide a means for the recombination of internally generated oxygen and the suppression of hydrogen gas evolution to limit water consumption.

| REFRESH RECORD FORM| ****

Rev. 0

---|---|---

Order **Number***

| Pallet ID Number| Individual Performing Test (Full Name)| Date of Refresh| Refresh Duration
 |  |  |  |
Model Number| ****

Information Prior to Refresh

| ****

Information within 1 hour of Refresh Completion

| ****

Notes & Comments

 | ****

Date Code

| Battery Serial Number| ****

Open Circuit Voltage

| Battery Voltage Reading| ****

Charging Current

| ****

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 BATTERY NUMBER ABOVE MUST BE COMPLETED ORDER NUMBER WILL APPEAR ON THE SHIPPING LABEL ON THE COVERING OF EACH PALLET OF BATTERIES

APPENDIX B

Completing all parameters ensures accurate battery sizing. Worksheet to be submitted to sales representative for battery recommendation.

APPENDIX C
Example of typical 3 stage charger

APPENDIX D
Depth of Discharge vs. Freezing Point

APPENDIX E
Capacity vs. Operating Temperature

APPENDIX F

Voltage Compensation Chart

NOTE: 1. Above values based on 12-volt battery 2. Divide the above values in half for a 6-volt battery.

Maximum Charge Current

APPENDIX G
Charging Current vs Charging Time chart

Discharge Voltage Curve

APPENDIX H Battery Maintenance Report

• www.dekabatteries.com
• An East Penn Manufacturing Co. Subsidiary 1-800-372-9253. www.mkbattery.com e-mail: sales@mkbattery.com
• E.P.M. Form No. 2478. 11/23 © 2023 by EPM Printed in U.S.A.

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