DEKA UNIGY II INTERLOCK AVR125AH (01) PDF Document

The DEKA UNIGY II INTERLOCK AVR125AH is a lead-acid battery system containing lead, sulfuric acid (electrolyte), and lead compounds. It is crucial to follow all safety precautions.

DANGER:

• Harmful if swallowed, inhaled, or in contact with skin. Acid causes severe skin burns and eye damage.

• May damage fertility or the unborn child if ingested or inhaled. May cause harm to breast-fed children.

• May cause cancer if ingested or inhaled. Causes damage to the central nervous system, blood, and kidneys through prolonged or repeated exposure.

• May form an explosive air/gas mixture during charging. It produces extremely flammable hydrogen gas, creating an explosive, fire, blast, or projection hazard.

WARNING:

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

• High Voltage: Risk of shock. Do not touch uninsulated terminals or connectors.

• 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.

Always obtain special instructions before use and do not handle until all safety precautions have been read and understood.

Per IEEE 1188 recommendations, the following minimum set of equipment for safe handling of the cells and protection of personnel shall be available when working on the DEKA UNIGY II INTERLOCK AVR125AH:

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.

The following safety procedures must be followed during the installation of the DEKA UNIGY II INTERLOCK AVR125AH:

1. Always wear safety glasses or a face shield when working on or near batteries. Although cells are sealed, if a jar or cover is damaged, sulfuric acid could be present, which is harmful to the skin and eyes. Flush any affected area with water immediately and consult a physician if splashed in the eyes.

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

3. Do not wear metallic objects like jewelry. Do not store un-insulated tools in pockets or a tool belt while working near the battery.

4. Keep the top of the battery string dry and clear of tools and other 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, except for cell replacement. The warranty is void if a 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.

Receiving Inspection:

Upon receipt, visually inspect each package for any possible damage or electrolyte leakage. If any is found, conduct a more detailed inspection of the entire shipment and note it on the bill of lading. Record the receipt date and inspection data, and notify the carrier of any damage.

Unpacking:

1. Always wear eye protection.

2. Check all cells for visible defects like cracked containers or loose terminal posts. Defective cells must be replaced.

3. Check package contents against the packing list and report any missing parts or damage immediately.

4. Never lift cells by their terminal posts.

5. Use proper lifting equipment (e.g., forklift, portable crane) for cells and modules. Check lifting capacities and never lift more than one module or cell at a time.

Storage:

1. Store cells indoors in a clean, level, dry, cool location. The 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 performance degradation.

• For 0°F to 77°F (-18°C to 25°C) storage: Recharge batteries six months from the date of manufacture.

• For >77°F (25°C) storage: Use the recharge interval chart. Take monthly voltage readings. Recharge cells that reach 2.10V per cell or less, regardless of the scheduled interval.

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

4. Do not store beyond 12 months.

5. Store in a horizontal position only. Do not place cells in an upright position during installation, storage, or transporting.

Hardware Torque Requirements:

Recharge Interval:

The required recharge interval for stored DEKA UNIGY II INTERLOCK AVR125AH batteries decreases as the storage temperature increases. The chart below shows the recommended time in months to recharge based on temperature.

• At 77°F, recharge every 6 months.
• At 85°F, recharge every 4.5 months.
• At 95°F, recharge every 3 months.

Voltage readings should be taken monthly, and any cell at or below 2.10V should be recharged immediately.

Follow these steps to install the modules. All parts should be verified against the packaging list.

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

2. Position the base(s) according to the included battery string layout diagram.

3. Ensure bases are level before installing modules. If the floor is not level, use shims under the base supports until they are level. All base supports in a string must be level with each other.

4. Mark and drill anchor holes. All anchor holes in the base are required to meet seismic requirements. Consult local building codes for anchor bolt requirements.

5. Remove hardware holding modules together and to the skid. The hardware from the modules will be reused.

6. When leveling, note that the back channel of the base is 3/16″ shorter than the front. A 3/16″ shim should be placed on top of the rear channel to level properly.

7. Install modules onto bases using the supplied lifting straps (two straps per module). CAUTION: Never lift more than one module at a time.

8. Slide the module into the cutouts in the back of the base. Lower the first module onto the base slightly forward, then slide it toward the back until it is locked into the slots.

9. Connect the module to the base with a maximum of six 3/8-16 x 1.25″ bolts and dragon tooth washers in the front only. The curve of the dragon tooth washer must face away from the bolt head. Torque to 25 ft-lb.

10. Connect the modules to each other with a maximum of six 3/8-16 x 1.25″ bolts and dragon tooth washers in the front of the modules. Repeat until all modules are installed. Torque to 25 ft-lb.

11. For seismic applications, two 3/8-16 x 1.00″ bolts are required to be installed as shown in the manual diagrams.

12. Once all modules are installed and aligned, install the joining plates at the top of every stack to ensure levelness.

1. Install safety shield brackets at the outside corners of every two modules, starting from the bottom and working up. Repeat for each stack.

2. For stacks with an odd number of modules, an additional set of safety shield brackets will be required for the top module.

3. Use 3/8-16 x 2.50″ hardware to install the brackets. The bracket should be flush with the side of the module for correct alignment. Tighten the hardware, but do not torque it.

4. For multiple stack systems, install joining plates at the front of the modules at the top of the stacks, using one plate at the junction of two modules. Use the 3/8-16 x 2.50″ hardware from the safety shield bracket to connect them. Stack-to-stack grounding is the installer’s responsibility.

1. The contact surfaces of each post are factory-cleaned and coated with No-Ox-ID “A” grease. Ensure these surfaces are free of dust or dirt before assembly.

2. The battery is supplied with a connector package appropriate for the load. Review the chart below to ensure you have the correct package.

CONNECTOR PACKAGES

BOLT PACKAGE

3. Install cell post hardware as shown in the manual diagrams. The typical Unigy II battery string is supplied with a 1CU package (one connector per post).

4. High-rate applications require multiple connectors. A 2CU package requires 2 connectors per connection, 4CU requires 4, and 6CU requires 6. Tighten and torque all bolts after all connectors are installed. Torque 1/4-20 bolts to 125 in-lb.

Consult the battery string layout diagram for the correct termination location.

1. Remove the module bolt directly behind the terminal plate location. If a safety shield bracket was there, reinstall it with a cap washer in front of the dragon tooth washer. Install the plastic cap after bolts are torqued.

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 it loosely for future alignment.

3. Install the terminal plate to the battery posts using the 1/4-20 hardware specified in your parts kit.

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

5. After confirming alignment, tighten the safety shield bracket hardware (do not torque). Torque all remaining hardware to the specified values (3/8-16 to 25 ft-lb, 1/4-20 to 125 in-lb).

6. Assemble the four parts of the top terminal safety shield as detailed in the manual.

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 and lug hardware are not included.

Consult the battery string layout diagram for the correct termination location.

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

2. Install the plastic side terminal bracket where the bolts were removed. Use 3/8-16 x 2.50″ bolts, installing them loosely. Replace the safety shield bracket if it was removed.

3. Install side terminal connectors to the battery posts using 1/4-20 bolts, installing them loosely.

4. Install the side terminal plate to the terminal plate bracket using 1/4-20 x 1.00″ hardware, installing loosely.

5. Connect the side terminal plate to the side terminal plate connectors. The bolt length depends on the connector package (1.00″ for 1CU/2CU, 1.25″ for 4CU/6CU).

6. After all parts are installed and alignment is confirmed, tighten the safety shield bracket hardware (do not torque). Torque all remaining hardware to the specified values (3/8-16 to 25 ft-lb, 1/4-20 to 125 in-lb).

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 this hardware.

Side terminal plates are designed for up to a 0.50″ dia. bolt and a maximum 1.75″ centers, 2-hole lug, and can handle 4 runs of cable. Lugs and lug hardware are not included.

After assembly is complete, perform these checks with the battery disconnected from any load or charge source.

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

2. Read and record the voltages of individual cells to ensure proper connection. The total battery string voltage should be approximately the number of cells in series multiplied by the voltage of one cell. If it is less, recheck connections for proper polarity. Verify all connections are properly torqued.

3. Measure and record the intercell connection resistance using a micro-ohms meter. Clean, remake, and re-measure any connection that has a resistance measurement greater than 10% of the average of all the same type connections.

4. Ensure the shortest electrical connection is used between the battery string and the operating equipment for maximum performance. Select a cable size based on current carrying capability and voltage drop to avoid reducing reserve time and power.

Safety Shield Assembly:

1. Ensure all safety shield brackets are installed per the previous instructions.

2. The shields use a “keyhole” type attachment. One shield will cover two modules.

3. Start 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.

4. The next shield will overlap the previously installed one. For stacks with an odd number of modules, a single module safety shield will be supplied.

5. 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 maintain the battery string voltage within ± 0.5% of the desired level at all times.

Charge Current:

Charge current should not exceed the recommended minimum and maximum requirements detailed in Appendix C.

Temperature Compensation:

Adjust battery voltage for ambient temperature variations at a rate of 2mV per °C (1.8°F) per 2v cell. Consult the Voltage Compensation Chart in 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. Verify this higher voltage will not adversely affect connected equipment. If done, reset the charger to the proper float voltage afterward.

Rectifier Ripple Voltage:

Ripple voltage must be less than 0.5% peak to peak (.177% rms) of the recommended battery string voltage. Failure to comply can void the warranty.

Operating temperature significantly affects the battery’s capacity and operating life. Temperatures greater than 77°F (25°C) will reduce the operating life. For every 13°F (7°C) increase above 77°F (25°C), the warranty period is proportionally reduced by 50%.

The operating temperature should not exceed 95°F (35°C) and never exceed 105°F (40.5°C) for more than an eight-hour period. Discharging at temperatures less than 77°F (25°C) will reduce capacity and require longer charging time.

These readings should be taken only after the battery string has been on continuous, uninterrupted float charge for at least one month. The values should be recorded on the Battery Maintenance Report.

1. Conduct a visual inspection of each cell.

2. Record battery string voltage at battery terminals while on float.

3. Record charger voltage at the charger panel.

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

5. Record ambient temperatures within the battery string area.

6. Record the average battery string temperature at a minimum of three different cells at varying locations, taken at the negative post.

7. Record individual cell ohmic readings. For accurate readings, cells must be fully charged, at the same temperature, and probes must be placed at the same location each time. For a 4-post cell, measure between 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. Record all intercell, interunit, and terminal connection resistances. 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.

Failure to maintain proper records may result in voiding any applicable warranty.

Cell Removal Procedure:

1. Before starting, review the Safety Precautions.

2. Disconnect the Charger and the system ground connection.

3. Remove connectors from the cell being removed.

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

5. Batteries develop internal pressure. To make removal easier, relieve this pressure:

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

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

c. Unscrew the valve 1¼ turn using a 17mm hex key to release pressure.

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

6. Use a lifting device rated to handle the weight of the cell. Thread a non-metallic rope through two battery terminals and knot it.

7. Remove one cell at a time.

8. Pull the cell from the module onto the lifting device, being careful that the device does not contact the cell posts.

Cell Replacement Procedure:

1. Relieve the internal pressure from the new cell as described in step 5 of the removal procedure to make installation easier.

2. Ensure the cell polarity is correct before installing the cell.

3. Replace the cell retainer bar.

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

**Data subject to change.

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

AVR45 Series

AVR75 Series

AVR95 Series

AVR125 Series

Renewable Energy (Cyclic) Voltage Compensation

For temperatures not explicitly listed, refer to the full table in the manual.

AVR45 Series

AVR75 Series

AVR95 Series

AVR125 Series

For models not listed, refer to the full tables in the manual.