EnerSys SuperSafe OPzV Gel Battery Instruction Manual

EnerSys SuperSafe OPzV Gel Battery

Installation, operating and maintenance instructions

• No smoking, no naked flames, no sparks
• Shield eyes
• Note instructions
• Electrical hazard
• Electrolyte is corrosive, in case of broken containers/lids
• Danger
• Clean all acid splash in eyes or on skin with lot of clear water. Then visit a doctor.
• Acid on clothing is to be washed with water.
• Recycle scrap batteries. Contains lead
• Warning: Risk of fire, explosion, or burns. Do not disassemble, heat above 60ºC, or incinerate. Avoid any short circuit. Metallic parts under voltage on the battery, do not place tools or items on top of the battery

Handling
OPzV batteries are supplied in a fully charged state and must be unpacked carefully to avoid short-circuit between terminals of opposite polarity. The cells are heavy and must be lifted with appropriate equipment.

Keep flames away
In the case of an accidental overcharge, a flammable gas may be emitted from the safety valve. Discharge any possible static electricity from clothes by touching an earth-connected part.

Tools
Use tools with insulated handles. Do not place or drop metal objects onto the battery. Remove rings, wristwatch and metal articles of clothing that might come into contact with the battery terminals.

Warranty
Any of the following actions will invalidate the warrranty – Non-adherence to the Installation, Operating and Maintenance instructions. Repairs carried out with non-approved spare parts. Application of additives to the electrolyte. Unauthorised interference with the battery.

DELIVERY AND STORAGE

Inspect for signs of damage or missing components. Store the battery in a dry, clean and preferably cool and frost-free location. Do not expose the cells to direct sunlight as damage to the container and cover may occur. As the batteries are supplied charged, storage time is limited. In order to easily charge the batteries after prolonged storage, it is advised not to store it more than:

• 12 months at 20°C
• 6 months at 30°C
• 3 months at 40°C

A refreshing charge shall be performed after this time or if the open circuit voltage is below 2.07 Vpc. Failure to observe these conditions may result in greatly reduced capacity and service life. The refreshing charge shall be carried out according to clause a) of the commissioning charge paragraph below. Alternatively the cells can be float-charged at 2.25 Vpc during storage.

INSTALLATION

The electrical protective measures and the accommodation and ventilation of the battery installation must be in accordance with the applicable rules and regulations. Specifically IEC 62485-2 applies.
Do not use terminal posts to lift or handle cells. The battery should be installed in a clean, dry area. It will not emit corrosive gases in normal operation and can be installed together with other electrical equipment. Under normal conditions the gas release is negligible and natural ventilation is sufficient for cooling purposes and inadvertent overcharge, enabling OPzV batteries to be used safely in offices or within equipment. However care must be taken to ensure adequate ventilation when placed in cabinets. They must not be placed in sealed cabinets without ventilation openings at the top and bottom. Avoid placing the battery in a warm place or in direct sunlight. Approved battery racks are recommended for proper installation. Place the cells on the rack and arrange the positive and the negative terminals for connection according the wiring diagram.

Horizontal Installation

• Do not use terminal posts to lift or handle cells.
• Do not install the cells in such a way that the box-lid bond is resting on a runner. Always ensure that the arrow on the lid of each unit is pointing in vertical orientation.
• Do not invert cells (vents upside down) or allow the front of the cells to be positioned lower than the base of the cell as it might block the safety valve and damage pillars.
• Check that all contact surfaces are clean. If required clean with a brass brush. Tighten the terminal screws, taking care to use the correct torque loading (Tab. 1). To avoid damage to the plastic materials, do not use grease. Fit the covers supplied for protection against inadvertent contact.

Tab. 1: Torque loadings for terminal screws

Carefully follow the polarity sequence to avoid short circuiting cell groups. A loose connector can make adjusting the charger difficult, create erratic performance and possible damage to the battery and/or even personal injury. Finally, with the charger switched off, the battery fuses removed and the load disconnected, connect the battery to the D.C. power supply.
Ensure that the polarity is correct -positive terminal of the battery to the positive terminal of the charger. Switch on the charger and charge according to the commissioning charge paragraph below. The first charge must be monitored to ensure that the limits are not exceeded and that no unacceptable temperatures occur.

Cells or Monoblocs in Parallel Strings
OPzV cells monoblocs may be connected in parallel to give higher current capability. In the case of parallel connected strings, use batteries of the same capacity, design and age only with a maximum of 4 parallel strings. The resistance of the cables in each string must be the same, e.g. same cross- section, same length. Connect the battery strings in parallel at the charger terminals.

COMMISSIONING CHARGE

When commissioning a new battery (first charge), follow procedure a) or b). Procedure a) is recommended.

• IU method (boost charge):
  At a raised voltage of 2.33 – 2.40 Vpc.
  The charging time will be 12 to 24 hours depending on the initial charge condition. The current must be limited to 4 x I10. Boost charging must be switched off or switched over to float charging as soon as the fully charged state is reached.

• Float charge:
  With a voltage of 2.25 Vpc. Full capacity will be obtained after a longer period of 4 to 6 weeks depending on state of charge.

STANDBY OPERATION / FLOAT CHARGE

Float Voltage
The recommended float / charge voltage is 2.25 V per cell at 20°C (tolerance 2.23 –2.25 Vpc). The charger voltage amounts to 2.25 Vpc x no. of cells. If the average ambient temperature deviates more than± 10°C from the reference temperature of 20°C, it is recommended to adjust the float voltage to the following temperature compensation curve:

In case that the average temperature deviates less than ±5°C, no temperature compensation has to be applied.
The recommended float charge voltage is 2.25 volts per cell at 20°C. Following a commission charge and after 6 months continuous charge at the recommended float voltage, individual cell voltages will stabilise within ±4.5% of the mean applied voltage.
However, immediately following commis-sioning and for the initial 6 months of continuous float charge, individual cell voltage values outside the above tolerance may be observed without adverse efect. There is no relationship between a cell’s float voltage and its discharge capacity. Cells are prefectly capable of giving their discharge capacity even when outside the ±4.5% range. After 6 months service, should any individual cell show a continuing reduction or increase in voltage outside the above limits over
3 successive monthly periods, our sales department should be contacted for advice.

Charging Current
Limitation of the charging current is not required under float charge condition at 2.25 Vpc. At higher charge voltages the charge current shall be limited to 4 x I10.

Boost Charge
To reduce the recharge time the battery may be recharged at 2.33 – 2.40 V per cell with a current limited to 4 x I10. Fast charging must be switched over to float charging when the fully charged state is reached.

Ripple Current
In the standby operation mode the effective value of the A.C. ripple current must not exceed 5 A/100Ah C10, otherwise reduced operational life must be expected.

TEMPERATURE

The recommended operating temperature range is -10°C to +45°C. The battery will give best performance and service life when working in the temperature range of +10°C to +30°C. Higher temperatures reduce the operational life. Lower temperatures reduce the available capacity. Temporary peak temperatures shall not exceed –30°C and +55°C. Consideration must be given to depth of discharge (low temperatures) and ventilation (high temperatures). All technical data relates to the rated temperature of
+20°C. Do not expose cells to direct sunlight.

DISCHARGING

End of Discharge Voltage
The battery must not be discharged more than the capacity specified in the performance tables. Deeper discharges may damage the battery and shorten its operational life. As a general rule the end of discharge voltage shall be limited to the values listed below:

Individual cell voltages may fall below UE by not more than 0.2 Vpc. A low voltage disconnect is recommended to prevent deep discharge. Special attention should be given to small loads that are not automatically disconnected at the end of discharge.

Discharged Cells and Monoblocs
OPzV batteries must not be left in a discharged condition after supplying the load but must be immediately returned to recharge mode. Failure to observe these conditions may result in greatly reduced service life and unreliability.

Accidental Deep Discharge
Following accidental deep discharge, the battery must be recharged at 2.25 Vpc followed by an equalizing charge. As the internal resistance is high at first, the initial charge current is low.

Important Notice
Each deep discharge is abusive and could affect the life expectancy of the battery.

TESTING

Capacity tests are to be carried out in accordance with IEC 60896-21/22. Check that the battery is fully charged. Before testing new batteries it must be ensured that a sufficient commissioning charge has been applied.

Temperature Correction Factor
The temperature has an effect on the battery capacity. The following table shows the correction factors for temperatures other than the reference temperature of 20°C.

RECHARGE

After a discharge the battery can be recharged at the operating voltage (float charge voltage). Depending on the depth
of discharge this may take up to 3 days. To reduce the charging time the recharging can be carried out with a boost charge voltage of 2.33 to 2.40 Vpc (fast charge).
The recharging times are dependent on the depth of discharge and on the charging current available. Generally, 10 to 20 hours duration can be expected at charging currents between 5A and 40A per 100Ah C10 . Fast charging must be switched over to float charging when the fully charged state is reached.

Equalising Charge
Under exceptional circumstances only, e.g. after deep discharges or after repeated inadequate recharging, an equalising charge shall be carried out according to clause a) of the commissioning charge paragraph or with the following IUI characteristic:
Charge at increased voltage of 2.33 – 2.40 Vpc, then continue with a constant current of 1.5 A per 100 Ah C10 during which individual cell voltages can be allowed to rise to 2.60 – 2.65 Vpc maximum. The charging must be monitored. The charging time at constant current shall be 5 to 10 hours.

MAINTENANCE/CHECKS

OPzV batteries are maintenance free, sealed, lead acid batteries and do not have to be topped up with water or electrolyte. The containers and lids should be kept dry and free from dust. Cleaning must be undertaken with a damp cotton cloth without man-made fibres or addition of cleaning agents. Avoid static discharges generated during cleaning.
Every 6 months, check the total voltage at the battery terminals, the cell voltages of pilot cells and the temperature. Once a year, in addition to the above, take readings of individual cell voltages. Keep a logbook in which the measured values can be noted as well as power cuts, discharge tests, etc. Do not attempt to open the safety valve. Opening could cause lasting damage to the battery and is prohibited.

SPECIAL APPLICATIONS

Whenever OPzV batteries are to be used for special applications such as repeated cycling or under extreme ambient conditions please contact your sales representative.
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