PowerSafe 1017 Flooded Stationary Lead Acid Battery Instruction Manual
- June 3, 2024
- PowerSafe
Table of Contents
PowerSafe 1017 Flooded Stationary Lead Acid Battery Instruction Manual
VENTED LEAD ACID STANDBY BATTERIES
Installation, operating and maintenance instructions
Safety precautions
Batteries give off explosive gasses. They are filled with dilute sulphuric
acid which is very corrosive. When working with sulphuric acid, always wear
protective clothing and glasses. Exposed metal parts of the battery always
carry a voltage and are electrically live (risk of short circuits). Avoid
electrostatic charge. The protective measures according to EN 50272-2 and IEC
62485-2 must be observed.
Recycling and disposal of used batteries
♻ Used batteries contain valuable recyclable materials. They must not be
disposed of with the Domestic waste but as special waste. Modes of return and
recycling shall conform to the prevailing regulations in operation at the site
where the battery is located.
Warranty
Any of the following actions will invalidate the warranty: 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.
Handling
Vented lead acid 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
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
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
3 months at 20°C 2 months at 30°C 1 month at 40°C
A refreshing charge shall be performed after this time. 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, cells can be float
charged at the recommended float voltage (see table 5) during storage.
If the batteries are supplied moist charged, the storage time shall not exceed
2 years. For filling, see special instructions on filling and commissioning of
moist charged batteries.
Storage of a battery after use
Never store a battery discharged but ensure it is perfectly charged before
storage. Storage times quoted above (before use) also apply after use.
INSTALLATION
The electrical protective measures, the accommodation and ventilation of the battery installation must be in accordance with the applicable rules and regulations. Specifically EN 50272-2 and IEC 62485-2 apply.
The battery should be installed in a clean, dry area. Avoid placing the
battery in a warm place or in direct sunlight.
The layout of the charging room must allow easy access to the batteries.
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 to the wiring diagram. Battery cells are usually installed in series.
Cells in parallel strings
Vented cells 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 end terminals.
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. Make sure
that all caps are closed.
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.
The electrolyte level on delivery can vary. The final electrolyte level will
be achieved after the commissioning charge. Small quantities (up to 3 mm) can
be topped up with distilled water.
COMMISSIONING CHARGE
When commissioning a new battery supplied filled and charged (first charge),
follow procedure a) b) or c).
Procedures a) or b) are recommended.
a) IU method (boost charge):
At a raised voltage of 2.33 2.40V/cell. The charging time will be 12 to 36
hours depending on the initial charge conditions. The current must be limited
to 4 x I10.
b) I method (boost charge):
With a constant current of 2.5-5 A/100 Ah with a final charging voltage of
2.50-2.75 V/cell. The charging must be monitored. The charging time can be 6
to 24 hours. If the maximum temperature of +45°C is exceeded, charging must be
terminated, continued at a reduced current, or temporarily switched to float
charging.
Boost charging must be immediately switched off or switched to float charging
when the fully charged state is reached.
c) Float charge:
With the recommended float voltage according to table 5. Full capacity will be
obtained after a longer period of 4 to 6 weeks depending on the state of
charge.
The fully charged condition has been achieved when, for a period of 2 hours,
the cell voltages do not continue to increase and the charging current does
not continue to decrease. The nominal specific gravity shall be achieved at
the end of charge (tolerance: ± 0.01).
For minimum end of charge voltages using the constant current characteristic
see table 2.
For the commissioning charge of moist charged cells, please refer to the specific moist charged instructions.
STANDBY OPERATION/FLOAT CHARGE
Float Voltage The recommended float / charge voltage is 2.23 V/cell or 2.25
V/cell per cell at 20°C depending on the specific type (see table 5). The
charger voltage amounts to Uflo per cell x no. of cells (tolerance ± 1 %).
If the average battery temperature exceeds the recommended operating
temperature range of +10°C to +30°C, the float charge voltage shall be reduced
by (Tcell – 30) x 0.003V/ cell when the temperature exceeds +30°C (but not
less than 2.18V/c) and shall be increased by (10 Tcell) x 0.003V/cell when
the temperature is less +10°C.
Deviations of individual cell voltages of 0.05 to +0.10 V/c may be observed. However the total voltage of the battery shall be within the limits stated above.
Charging Current
Limitation of the charging current is not required under float charge
condition.
At higher charge voltages up to 2.40 V/c the charge current shall be limited
to 4 x I10.
After reaching the gassing voltage of 2.40 V/c a current limit of 2.5 to 5 A/100 Ah is recommended (see Table 3).
Boost Charge
To reduce the recharge time the battery may be recharged at 2.33 2.40 V/cell
with a current limited to 4 x I10 . Boost charging must be switched 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 per 100 Ah C10, otherwise reduced
operational life must be expected.
TEMPERATURE
The permissible operating temperature range is -10°C to +45°C.
The recommended operating temperature range is +10°C to +30°C. All technical
data relates to the rated temperature of +20°C.
Higher temperatures reduce the operational life. Lower temperatures reduce the
available capacity.
Do not expose cells to direct sunlight.
Effect of temperature on capacity
If the battery operating temperature is different from 20°C, a correcting
factor is to be applied to capacity value taking into account discharge time.
Example: A battery with a capacity of 200 Ah at 20°C for a 5 hour discharge will have a capacity of 182 Ah when discharged at 10°C (200 x 0.91).
ELECTROLYTE
The electrolyte is diluted sulphuric acid.
The nominal S.G. of the electrolyte at 20°C is as follows to table 5.
NOMINAL LEVEL
Correction of S.G. according to temperature Electrolyte S.G. varies with
temperature. If temperature is above or below 20°C, specific gravity readings
must be corrected.
The temperature correction factor for S.G. is 0.0007 per °C.
Example: S.G. of 1.230 kg/l at +35°C
corresponds to a S.G. of 1.240 kg/l at +20°C.
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 V/c. 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
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.
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 EN 60896-11. Check that the battery is fully charged. Before testing new batteries it must be ensured that a sufficient commissioning charge has been applied, the S.G. is relating to the nominal value (± 0.01 kg/l) and the battery is fully charged. Lower S.G. results in lower capacity.
RECHARGE
After a discharge the battery can be recharged at the operating voltage (float
charge voltage).
To reduce the charging time the recharging can be carried out with the boost
charge voltage of 2.33 to 2.40 V/c. The recharging times depend on the
charging procedure and on the charging current available. Generally 10 to 20
hours duration can be expected at charging currents between 5 A and 40 A per
100 Ah nominal capacity. Recharge 1.2 times the discharged capacity.
During recharging up to 2.40 V/cell the effective value of the A.C. ripple
current can reach a temporary maximum 10 A per 100 Ah nominal capacity.
Equalising Charge
After a deep discharge or after inadequate recharging, an equalising charge is
necessary. This can be carried out as follows:
a) at constant boost charge voltage of
2.33 2.40 V/cell for a maximum of 72 hours.
b) with I charge method according to the commissioning charge paragraph above,
clause b).
If the maximum temperature of 45°C is exceeded, charging must be terminated or
continued at a reduced current or temporarily switched to float charging. The
end of equalising charge is reached when the S.G. of the electrolyte and the
cell voltages have not risen for a period of 2 hours.
Because the permissible system voltage level may be exceeded when charging at
increased voltages, suitable measures should be taken to protect the load
circuits, e.g. charging «off line».
MAINTENANCE/CHECKS
Water topping Top up the electrolyte level to the nominal level, but without
exceeding the « Max » mark. Only demineralised or distilled water (purity
grade: max. conductivity 10 µS/cm) shall be used.
After topping-up an equalising charge can be applied to reduce the time for
homogenisation of the electrolyte density.
Cleaning
Keep containers and lids dry and free from dust. Cleaning must be
undertaken with a damp cotton man-made fibres.
WARNING – Do NOT use any type of oil, solvent, detergent, petroleum-based
solvent or ammonia solution to clean the battery containers or lids. These
materials will cause permanent damage to the battery container and lid and
will invalidate the warranty.
If the battery, cell, lid or container is damp with or shows signs of spilled electrolyte, wipe with a cloth dampened with a solution of sodium bicarbonate and cold water, mixed in the proportions of 1.0 lb/1.0 gal (0.5 kg/5.0 litter) of water. Follow this by wiping with a cloth dampened in clear water.
Avoid static discharges generated during cleaning.
Plugs
Leak-resistant plugs with a frit or flame arrestor plugs with a ceramic funnel
must not be cleaned with water or positioned up side down. Should the frit be
moistened with electrolyte, the plug must be replaced during regular
maintenance. Standard plugs without frit can be cleaned with purified water if
necessary. Dry them thoroughly before fitting them back onto the battery.
Readings Log book
Every 6 months, check the total voltage at the battery terminals. Also check
the voltage, S.G., and the temperature of pilot cells and record the room
temperature.
Once a year, in addition to the above, take readings of individual voltages
and S.G. of the electrolyte. Measure the S.G. either before topping up water
or after boost charge.
Keep a logbook in which the measured values can be noted as well as power
cuts, discharge tests, equalising charges, topping up dates, storage times and
conditions, etc.
SPECIAL APPLICATIONS
Whenever the battery cells or monoblocs are to be used for special
applications such as repeated cycling or under extreme ambient conditions
please contact your SALES OFFICE.
For further information please visit our website:
www.enersys.com
NOTES
EnerSys World Headquarters 2366 Bernville Road Reading, PA 19605
USA Tel: +1 610 208 1991
+1 800 538 3627
Fax: +1 610 372 8613
EnerSys EMEA EH Europe GmbH Baarerstrasse 18 6300 Zug Switzerland
EnerSys Asia 152 Beach Road Gateway East Building Level 11 189721 Singapore Tel: +65 6508 1780
© 2017 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted.
Publication No. EN-Flooded-IOM-007 DCS1002M October 2017 – Subject to revisions without prior notice. E.&O.E.