DEKA UNIGY II INTERLOCK AVR95 (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.

The DEKA UNIGY II INTERLOCK AVR95 contains Lead, Sulfuric Acid (Electrolyte), and Lead Compounds. Key dangers include:

Health Hazards:

– 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 cancer if ingested or inhaled.

– Causes damage to the central nervous system, blood, and kidneys through prolonged or repeated exposure.

Physical Hazards:

– May form an explosive air/gas mixture during charging.

– Extremely flammable gas (hydrogen) is produced, posing 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. Do not remove the vent valve.

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.

The following safety procedures should be followed during installation:

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

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. Do not store un-insulated tools in pockets or 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 (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. 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.

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 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, use proper equipment like a forklift or portable crane. Always check the lifting capacities of the equipment 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 monthly. 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 horizontal position only.

When grounding the battery string, proper techniques should be applied per electrical standards, such as NEC and/or local codes. Two 0.201 diameter x 0.750 center holes are provided in the back of each module to accept a #6 x 0.750 center compression grounding lug. The holes must be tapped for a 1/4-20UNC thread and paint must be removed for a proper grounding pad location.

Note: Battery string and/or stack to stack grounding, if required, is the installer’s responsibility.

Assemble the battery string per the following details. All parts should be verified 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). 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 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.

6. When leveling, it is critical to note that the back channel of the base support 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. For module/base shimming, ensure the floor is level. If not, use standard steel shim stock under the base supports until they are level. All base supports within a battery 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. Module slides 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 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 torque requirements.

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.

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

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.

2. For stacks containing 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 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.

4. For multiple stack systems, 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. Use the 3/8-16 x 2.50″ hardware to connect the safety shield bracket together. Note: Stack to stack grounding electrical conductivity is the responsibility of the installer.

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

2. The battery is supplied with a connector package appropriate for the load. Review the “Connector Packages” chart to ensure the correct package has been supplied.

3. Install cell post hardware as specified. The direction is important.

4. Unigy II battery strings are typically supplied with a 1CU connector package, requiring one connector per post.

5. High-rate applications require multiple connectors per post (e.g., 2CU, 4CU, 6CU packages). Tighten and torque all bolts after all connectors are installed per the “Hardware Torque Requirements”.

6. For installations requiring a vertical “C” connector (limited to 2CU package), follow the specific instructions for your cell type (plate size).

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 assembly. 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.

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.

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

Top terminal plates are designed for up to a 0.50″ dia. bolt and a maximum 1.75″ center, 2-hole lug. Lugs can be positioned on both sides of the plate. Lug and 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 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 in the location where bolts were removed. Use 3/8-16 x 2.50″ bolts, installed loosely. Replace the safety shield bracket at the same location from the previous step.

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, installed loosely.

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

6. After all parts are installed and aligned, tighten the safety shield bracket hardware (do not torque). Torque all remaining hardware to 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.

Side terminal plates are designed for up to a 0.50″ dia. bolt and a maximum 1.75″ center, 2-hole lug, capable of handling 4 runs of cable. Lugs can be positioned on both sides. Lug and 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, 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 the individual cells to assure 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 measured voltage 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. 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. 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 to avoid reducing reserve time and power.

1. Ensure all safety shield brackets are already installed.

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. At the same time, align 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 with 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.

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. 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 done, reset the charging equipment to the proper float voltage.

Operating temperature affects battery capacity and 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.

Failure to comply with these requirements can void the warranty.

Frequency:

– Ripple with a frequency greater than 667Hz (duration less than 1.5ms) is acceptable, unless it causes additional cell heating.

– Ripple with a frequency less than 667Hz (duration greater than 1.5ms), must meet the voltage specification below.

Voltage:

– Ripple voltage shall be less than 0.5% peak to peak (.177% rms) of the manufacturer’s recommended battery string voltage.

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 using the Battery Maintenance Report:

1. Conduct a visual inspection of each cell.

2. Battery string voltage at battery terminals while 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 values, cells must be fully charged, at the same temperature, and probes placed at the same location each time. 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. 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 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.

1. Before removing a cell, review 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:

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

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

7. Remove one cell at a time.

8. Thread a non-metallic rope through two battery terminals and knot it. Pull the cell from the module onto the lifting device. Be careful that the lifting device does not contact the cell posts.

1. Batteries develop internal pressure. Relieving this pressure from the cell will make it easier to install. 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 on the replacement cell.

**Data subject to change.