DEKA UNIGY II INTERLOCK A75 (01) PDF Document

Work performed on the DEKA UNIGY II INTERLOCK A75 should be supervised by personnel familiar with batteries and battery safety precautions. Always wear safety glasses or a face shield when working on or near these batteries.

The following procedures should be followed during installation:

1. These cells are sealed and contain no free electrolyte. Under normal operating conditions, they do not present any acid danger. However, if the cell jar or cover is damaged, sulfuric acid could be present, which 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.

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 cells. Do not store un-insulated tools in pockets or a tool belt while working in the vicinity of the battery.

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

5. Provide adequate ventilation and follow recommended charging voltages.

6. Never remove or tamper with the pressure relief valves, except for cell replacement. The warranty is void if the vent valve is removed.

7. Inspect flooring and lifting equipment for functional adequacy.

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

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

10. Refer to relevant IEEE Standards for additional information.

WARNING: Risk of fire, explosion, or burns. Do not disassemble, heat above 40°C, or incinerate.

Per IEEE 1188 recommendations, the following minimum set of equipment for safe handling of the cells 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.

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 the receipt date, inspection data, and notify the carrier of any damage.

Unpacking:

1. Always wear eye protection.

2. Check all cells 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 immediately.

4. Never lift cells by the terminal posts.

NOTE: Do not place cells in an upright position during installation, storage, or transporting.

5. When lifting cells and modules, the proper equipment is needed, such as a forklift or a portable crane. Always check the lifting capacities of the equipment being used and never lift more than one module and or cell at a time.

1. Cells should be stored indoors in a clean, level, dry, cool location. Recommended storage temperature is 0°F to 90°F (-18°C to 32°C).

2. Stored lead-acid cells self-discharge and must be given a boost charge to prevent permanent performance degradation.

0°F to 77°F (-18°C to 25°C) storage: Batteries should be recharged six months from the date of manufacture.

>77°F (25°C) storage: Use the recharge interval chart for recharge intervals. Voltage readings should be taken on a monthly basis. Cells that reach 2.10V per cell or less should be recharged regardless of the scheduled interval. Record dates and conditions for all charges during storage.

3. If a boost charge is required, the recommended charge is 24 hours at a constant voltage equal to 2.40V per cell.

4. Do not store beyond 12 months.

5. Store in a horizontal position only.

Assemble the battery string per the following details. All parts should be verified against the packaging list. Report any missing parts.

1. Remove the floor-mounting base support from the top of the modules. The base(s) are wire-tied to the module assembly.

2. Position the base(s). Consult the included battery string layout diagram for the required base layout.

3. Bases are required to be level prior to installing modules.

4. Anchor holes can be marked and drilled with bases in place. All anchor holes in the base are required to be used to meet seismic requirements. Consult local building codes for anchor bolt requirements (anchor bolts not included).

5. Remove hardware holding modules together and holding modules to the skid. Hardware removed from modules will be reused to attach modules to bases and to each other. Hardware holding modules to the skid can be discarded.

6. When leveling Interlock battery strings using a 1-piece base support, note that the back channel is 3/16″ shorter than the front channel. If a level is placed across the front and rear channels, a 3/16″ shim should be placed on top of the rear channel to level properly.

7. Ensure the floor is level and capable of supporting the battery string’s weight. If floors are not level, shim material can be placed under each of the base supports within a battery string until they are level. All base supports within a string must be level with each other.

8. Install modules onto bases using the supplied lifting straps. Two straps are required to lift each module. CAUTION: Never lift more than one module at a time with the supplied lifting slings.

9. Slide the module into cutouts in the back of the base. Lower the first module onto the base with the module slightly forward. Slide the module towards the back of the base until it is locked into slots.

10. Connect the module to the base with a maximum of six 3/8-16 x 1.25″ bolts & dragon tooth washers in the front only. Consult “Hardware Torque Requirements” for proper torque values.

11. Connect the modules to each other with a maximum of six 3/8-16 x 1.25″ bolts & dragon tooth washers installed in the front of the modules. Repeat until all modules are installed. Consult “Hardware Torque Requirements” for proper torque values.

12. The module layout should be compared to the battery string layout diagram, and all hardware should be checked for proper torque before proceeding.

1. Safety shield brackets are to be installed at the outside corners of every 2 modules, starting from the bottom and working towards the top. This is repeated for each stack in the battery system. For stacks containing an odd number of modules, an additional set of safety shield brackets will be required at the top of the module. Use 3/8-16 x 2.50″ hardware to install brackets. The bracket should be flush with the side of the module to ensure correct safety shield alignment. Tighten the hardware, but do not torque it.

2. Safety shield brackets are to be installed at the top of the module in the same manner. Tighten, do not torque hardware.

3. For multiple stack systems, joining plates are to be installed at the front of the modules at the top of the stacks. One joining plate is used at the junction of two modules. Use the 3/8-16 x 2.50″ hardware used to connect the safety shield bracket together. Stack to stack grounding electrical conductivity is the responsibility of the installer.

1. The contact surfaces of each individual post on every cell have been cleaned and coated with a thin film of No-Ox-ID “A” grease at the factory. Ensure the contact surfaces are free of dust or dirt prior to assembly.

2. The battery string is supplied with a connector package appropriate for the required load. Review the chart below to ensure the correct package has been supplied.

CONNECTOR PACKAGES

BOLT PACKAGE

3. The installation and direction of cell post hardware are important. Typically, one connector per post (1CU) is required.

4. High-rate applications will require multiple connectors per cell post. A 2CU package requires 2 connectors per connection (1 per side). A 4CU package requires 4 connectors per connection (2 per side). A 6CU package requires 6 connectors per connection (3 per side). Tighten and torque all bolts after all connectors are installed. Consult “Hardware Torque Requirements” for proper values.

5. Some installations require a vertical “C” connector (limited to a 2CU package). Consult installation diagrams for your specific cell type.

Consult the battery string layout diagram for the termination location.

1. Remove the module bolt directly behind the terminal plate location. If the location contained a safety shield bracket assembly, install the cap washer in front of the dragon tooth washer and re-install the safety shield bracket assembly. Install the plastic cap after the bolts are torqued. Consult “Hardware Torque Requirements” for proper values.

2. Slip the clip onto the back of the channel through the cutout. Install the terminal plate bracket to the top of the module using 3/8-16 x 1.25″ hardware. Install loosely for future alignment.

3. Install the terminal plate to battery posts using 1/4-20 hardware (consult the battery string layout diagram and parts kit for specific length).

4. Attach the terminal plate to the terminal plate bracket. The terminal plate bracket may need to be moved to be flush with the terminal plate.

5. After confirming alignment, the safety shield bracket hardware should be tightened, but not torqued. All remaining hardware should be torqued. Consult “Hardware Torque Requirements” for proper values.

6. Assemble the four parts of the top terminal safety shield.

The top terminal plates are designed to accept up to a 0.50″ dia. bolt and use a maximum 1.75″ center, 2-hole lug. Lugs can be positioned on both sides of the terminal plate. Lug and lug hardware are not included.

Consult the battery string layout diagram for the termination location.

1. Remove module bolts (3/8-16 x 1.25″) from the module where side termination is to be installed. If a safety shield bracket is at one of these locations, retain it for later use.

2. Install the plastic side terminal bracket in the location where bolts were removed. Use 3/8-16 x 2.50″ bolts, installed loosely for future adjustments. Replace the safety shield bracket at the same location from the previous step.

3. Install side terminal connectors to battery posts using 1/4-20 bolts. Bolts should be installed loosely for future adjustments.

4. Install the side terminal plate to the terminal plate bracket using 1/4-20 x 1.00″ hardware. Bolts should be installed loosely.

5. Connect the side terminal plate to the side terminal plate connectors. Bolt length is dependent on the connector package.

6. After all parts are installed and alignment is confirmed, the safety shield bracket hardware should be tightened, but not torqued. All remaining hardware should be torqued. Consult “Hardware Torque Requirements” for proper values.

7. Install the side terminal shield to the side terminal plate bracket using 1/4-20 x 0.625″ screws. Tighten but do not torque the hardware.

The side terminal plate is designed to use up to a 0.50″ dia. bolt and a maximum 1.75″ centers, 2-hole lug. The plate is capable of handling 4 runs of cable. Lugs can be positioned on both sides of the terminal plate. Lug and lug hardware are not included.

NOTE: The following steps are to be followed with the battery disconnected from any load or charge source.

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

2. Read and record the voltages of the individual cells to assure that they are connected properly. The total battery string voltage should be approximately equal to the number of cells connected in series, multiplied by the measured voltage of one cell. If the measured value is less, recheck the connections for proper polarity. Verify that all cell connections have been properly torqued.

3. Measure and record the intercell connection resistance using a micro-ohms meter. This helps determine the adequacy of the initial connection installation and can be used as a reference for future maintenance. Review the records of each connection and detail resistance measurements. Clean, remake, and re-measure any connection that has a resistance measurement greater than 10% of the average of all the same type connections (i.e. intercell, intermodule, etc.).

4. Battery string performance is based on the output at the cell terminals. Therefore, the shortest electrical connection between the battery string and the operating equipment results in maximum total system performance. Select cable size based on current carrying capability and voltage drop. The cable size should not provide a greater voltage drop between the battery string and operating equipment than the customer specified.

Safety Shield Assembly

1. All safety shield brackets should already be installed at this time.

2. Safety shields are designed with a “keyhole” type attachment.

3. One shield will cover two modules. Starting at the bottom of the stack, hang the first shield on the top brackets through the large part of the keyhole, while aligning the cutout at the bottom of the shield with the second set of brackets. The next shield will overlap the previously installed shield. For stacks containing an odd number of modules, a single module safety shield will be supplied. After all shields are in place, tighten the outer bolt, but do not torque.

Top Protection Shield Installation

For a side terminal assembly, attach the top protective cover to the highest front shield.

For a top terminal assembly, cut the protective cover to fit between the terminals and then attach it to the front shield.

Charger Voltage (per cell): 2.25V ± 0.01 @ 77°F (25°C). The charger must be able to maintain the battery string voltage within ± 0.5% of the desired level at all times.

Charge Current: Should not exceed the recommended minimum and maximum requirements as detailed in Appendix C.

Temperature Compensation: Battery voltage should be adjusted for ambient temperature variations. Use 2mV per °C (1.8°F) per 2v cell. Consult the Voltage Compensation Chart (Appendix C) for limits.

Cell Voltage: Individual cell voltages may vary by ± 0.05 volts of the average cell float voltage.

Equalizing: Upon installation, an optional charge of 2.40V per cell ± 0.01 @ 77°F (25°C) for up to 24 hours can be applied. NOTE: Verify that the higher cell voltage will not adversely affect any other connected equipment. If this is done, reset the charging equipment to the proper float voltage.

Operating Temperature: Temperatures greater than 77°F (25°C) will reduce the operating life of the battery. 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.

Rectifier Ripple Voltage: Ripple voltage shall be less than 0.5% peak to peak (.177% rms) of the manufacturer’s recommended battery string voltage. Failure to comply can void the warranty.

Always wear eye protection when working on or near batteries. Keep sparks and open flames away from batteries at all times. These readings should be taken only after the battery string has been on a continuous, uninterrupted float charge for at least one month.

The following values should be recorded:

1. Conduct a visual inspection of each cell.

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

3. Charger voltage at the charger panel.

4. Individual cell voltages. Cells should be within ± 0.05 volts of the average cell float voltage.

5. Ambient temperatures within the area of the battery string.

6. Average battery string temperature at a minimum of three different cells at varying locations. Temperatures shall be taken at the negative post.

7. Individual cell ohmic readings. To provide accurate/consistent values, cells must be fully charged, at the same temperature, and probes placed at the same location each time readings are taken. For a 4-post cell, place meter leads on the left positive & left negative posts or right positive & right negative posts. For 6-post cells, measure from center positive to center negative posts. Do not measure diagonally.

8. All intercell, interunit, and terminal connection resistances. Micro-ohm readings should be taken across every connection. If any reading differs by more than 20% from its initial installation value, re-torque the connection. If the reading remains high, clean contact surfaces and recheck.

Batteries, cabinets, racks, and modules should be cleaned with clean water. If neutralizing is required, use a mixture of 1 lb of baking soda to 1 gallon of water or a supplied battery cleaner. Use clean water to remove the baking soda residue.

Never use solvents to clean the battery.

Before removing a cell, review Safety Precautions.

1. Disconnect the Charger and the system ground connection.

2. Remove connectors from the cell being removed.

3. Remove the cell retainer bar(s) from the cell being removed.

4. Batteries develop internal pressure. Relieving this pressure from the cell will make it easier to remove the cell from the module.

a. Pry off the vent shroud using an insulated flat head screwdriver.

b. Remove the flame arrestor (round white disc).

c. Unscrew the valve 1/4 turn using a 17mm hex key (pressure will release).

d. Tighten the valve immediately and torque to 12-14 in-lb with a 17mm hex key.

5. The lifting device shall be rated to handle the weight of the cell.

6. Remove one cell at a time.

7. Thread non-metallic rope through two battery terminals and knot.

8. Pull the cell from the module onto the lifting device. Care should be taken so the lifting device does not come in contact with cell posts.

1. Batteries develop internal pressure. Relieving this pressure from the cell will make it easier to install the cell into the module. Follow the steps of the “Cell Removal Procedure” for relieving pressure.

2. Ensure cell polarity is correct prior to installing the cell.

3. Replace the cell retainer bar.

4. Refer to the “Electrical Connection” section for installing connectors of the replacement cell.

2mV per °C

AVR75 Series

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

3mV per °C

AVR75 Series