DEKA UNIGY II INTERLOCK AVR45 (01) PDF Document

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.

Although the DEKA UNIGY II INTERLOCK AVR45 cells are valve-regulated with immobilized electrolyte, electrical hazards still exist. All work should be supervised by personnel familiar with batteries and battery safety precautions. The following safety procedures must be followed during installation:

1. Always wear safety glasses or face shield when working on or near batteries.

2. These cells are sealed and contain no free electrolyte. Under normal operating conditions, they do not present an 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 and first aid measures.

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

4. 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.

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

6. Provide adequate ventilation (per IEEE standard 1187 and/or local codes) and follow recommended charging voltages.

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

8. Inspect flooring and lifting equipment for functional adequacy.

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

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

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.

5. When lifting cells and modules, use proper equipment like a forklift or a portable crane. Always check the lifting capacities of the equipment and never lift more than one module and/or cell at a time.

Storage:

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. For 0°F to 77°F (-18°C to 25°C) storage, batteries should be recharged six months from the date of manufacture. For storage >77°F (25°C), use the recharge interval chart. Take monthly voltage readings and recharge any cells that reach 2.10V per cell or less, regardless of the scheduled interval. Record all charge dates and conditions.

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. Do not place cells in an upright position during installation, storage, or transport.

The specified hardware torque requirements for the DEKA UNIGY II INTERLOCK AVR45 are as follows:

The recharge interval for the DEKA UNIGY II INTERLOCK AVR45 depends on the storage temperature. The higher the temperature, the more frequently the battery needs to be recharged.

Recharge Interval Chart:

• At 77°F, recharge every 6 months.
• At 81°F, recharge every 5 months.
• At 85°F, recharge every 4 months.
• At 89°F, recharge every 3.5 months.
• At 95°F, recharge every 3 months.

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.

Assemble the battery string per the following details, verifying all parts against the packaging list.

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) according to the included battery string layout diagram. Ensure bases are level before installing modules.

3. Before installation, ensure the floor is level and can support the battery string’s weight. If the floor is not level, use shim material under the base supports to level them. All base supports within a string must be level with each other.

4. When leveling a 1-piece base support, note that the back channel is 3/16″ shorter than the front. Place a 3/16″ shim on the rear channel to level it with the front channel.

5. Anchor the bases to the floor. All anchor holes in the base are required for seismic requirements. Consult local building codes for anchor bolt requirements (anchor bolts are not included).

6. Remove hardware holding modules together and to the skid. Reuse the hardware connecting modules to attach them to the bases and each other.

7. Install modules onto the bases using the supplied lifting straps. Two straps are required to lift each module. Never lift more than one module at a time. The module slides into cutouts in the back of the base. Lower the module slightly forward, then slide it towards the back until it’s locked into the slots.

8. 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. Consult the hardware torque requirements for proper values.

9. Connect modules to each other with a maximum of six 3/8-16 x 1.25″ bolts and dragon tooth washers installed in the front of the modules. Repeat until all modules are installed, torquing hardware as you go.

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

11. For seismic applications, two 3/8-16 x 1.00″ bolts are required to be installed between modules.

12. Compare the final module layout to the battery string layout diagram and check all hardware for proper torque.

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

2. For stacks with an odd number of modules, an additional set of safety shield brackets will be required at the top of the 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 to ensure correct alignment. Tighten the hardware, but do not torque it.

4. For systems with multiple stacks, install joining plates at the front of the modules at the top of the stacks. Use one joining plate at the junction of two modules, using the 3/8-16 x 2.50″ hardware that connects the safety shield bracket.

Connector Assembly:

1. The contact surfaces of each post have been 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. Use the tables below to ensure you have the correct package.

CONNECTOR PACKAGES

BOLT PACKAGE

3. Typically, a 1CU package is used, requiring one connector per post.

4. For high-rate applications, multiple connectors are needed. A 2CU package requires 2 connectors per connection (1 per side), a 4CU package requires 4 connectors (2 per side), and a 6CU package requires 6 connectors (3 per side).

5. Tighten and torque all bolts after all connectors are installed, referring to the “Hardware Torque Requirements”.

Consult the battery string layout diagram for the termination location.

1. Remove the module bolt directly behind the terminal plate location. If a safety shield bracket was there, install a cap washer in front of the dragon tooth washer and re-install the bracket. 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 loosely for future alignment.

3. Install the terminal plate to the battery posts using 1/4-20 hardware of the specific length required by 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 terminal plate.

5. After confirming alignment, the safety shield bracket hardware should be tightened, but not torqued. All other hardware should be torqued to the proper values.

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

Top terminal plates are designed for up to a 0.50″ diameter bolt and a maximum 1.75″ center, 2-hole lug. Lugs and lug hardware are not included. Lugs can be positioned on both sides of the terminal plate.

Consult the battery string layout diagram for the termination location and review the connector package chart.

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 at one of these locations, 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, installed loosely. Replace the safety shield bracket at the same location if one was removed.

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

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

5. Connect the side terminal plate to the side terminal plate connectors. The required bolt length depends on the connector package (1CU/2CU requires 1/4-20 x 1.00″ hardware; 4CU/6CU requires 1/4-20 x 1.25″ hardware).

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 to the specified 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 this hardware.

Follow these steps 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 they are connected properly. The total battery string voltage should be approximately equal to the number of cells in series multiplied by the voltage of one cell. If the total 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. This helps determine the adequacy of the installation and serves as a reference for future maintenance. Review the records and clean, remake, and re-measure any connection with a resistance greater than 10% of the average of all same-type connections (e.g., intercell, intermodule).

4. Select cable size based on current carrying capability and voltage drop to ensure maximum system performance. The cable size should not cause a greater voltage drop than specified by the customer, as excessive drop reduces reserve time and power.

1. Ensure all safety shield brackets are installed according to the “Interlock Module Installation” section.

2. The safety shields use a “keyhole” type attachment. One shield covers two modules.

3. 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.

4. The next shield will overlap the previously installed shield. 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 it.

6. For side terminal assemblies, attach the top protective cover to the highest front shield.

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

Battery string operating temperature affects both 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 battery string 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. The individual cells in a string must not vary by more than 5°F (2.8°C) between the lowest and highest individual cell temperature.

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: Should not exceed the recommended minimum and maximum requirements as 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 maximum and minimum 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 that this higher voltage will not adversely affect any other connected equipment. If performed, reset the charging equipment 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. Ripple with a frequency greater than 667Hz is acceptable unless it causes cell heating. Ripple with a frequency less than 667Hz must meet the voltage specification.

Always wear eye protection and keep sparks/flames away from batteries. These readings should be taken only after the battery string has been on a continuous, uninterrupted float charge for at least one month. Record the following values on the Battery Maintenance Report:

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 should be taken at the negative post.

7. Individual cell ohmic readings. To get accurate values, cells must be fully charged, at the same temperature, with probes placed at the same location each time. On a 4-post cell, measure from left positive to left negative, or right positive to right negative. For 6-post cells, measure from center positive to center negative. 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 the contact surfaces and recheck.

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

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. Use clean water to remove the baking soda residue. Never use solvents to clean the battery.

Cell Removal Procedure:

1. Before starting, review all 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. Relieving this pressure will make it easier to remove the cell. To do this:

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 to release pressure.

d. Immediately tighten the valve and torque to 12-14 in-lb with the 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. Be careful that the lifting device does not contact the cell posts.

Cell Replacement Procedure:

1. Relieve the internal pressure from the new cell to make installation easier by following step 5 from the removal procedure.

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.

The recommended float voltage per cell varies with temperature. Use the following chart for temperature compensation (2mV per °C).

The following tables show the maximum and minimum charge currents for different models. Using the minimum charge current will extend recharge time and increase the risk of the battery being undercharged.

AVR45 Series

AVR75 Series

AVR95 Series

AVR125 Series

The charging parameters for cyclic applications are as follows:

The maximum charge currents for cyclic applications are listed in the following tables:

AVR45 Series

AVR75 Series

AVR95 Series

AVR125 Series