EnerSys PowerSafe OPzS User manual

Filling and Charging

Moist Charged

Flooded Batteries

RESERVE

POWER

PowerSafe® OPzS

PowerSafe® TS

1. Definition of moist charged batteries 3

2. Delivery and storage 3

• Accessories and tools required

3. Battery installation 4

• Stand assembly

• Cell installation

4. Putting cells into service 5 - 7

• Filling cells

• Initial charge

5. Specific gravity reading 8

• Final specific gravity after charging

• Correction of specific gravity according to temperature

6. Safety 9

7. Appendices 10 - 12

8. Notes 13 - 15

Contents

Cells and accessories are dispatched in wooden boxes. Electrolyte is dispatched in plastic drums which are approved for

marine transportation.

2. Delivery and storage

A moist charged battery is a wet, fully charged battery that has had the electrolyte removed and has a special, air-tight

plug used during storage.

1. Definition of moist charged batteries

Do not remove the special air-tight plugs from the moist charged batteries until ready to activate.

Moist-charged batteries are active and electrically live at all times.

Do not short terminal posts.

Accessories and tools required

Please ensure that all accessories and tools are available before starting the installation of the battery.

Sulphuric acid in plastic drum

Manual filler pump

Thermometer Hydrometer

Funnel

Rigid connector + Caps Cable + Caps

Tool for air-tight plugs

Until ready for use, a moist-charged battery must be stored in a cool, dry and clean location, away from any source of heat

and protected from direct sunlight. In those conditions, moist charged cells can be stored for up to 2 years.

Before starting the assembly of the stand, please ensure that all stand components are available.

For a battery above 150V, insulators will be provided with the stand.

Assembly instructions

Please follow the instructions below in conjunction with the drawings below. To accomplish these operations only a 13mm

spanner is required.

1. Mount and fasten insulators with bolts (9), screws (14) and washers (15) under each support (1).

2. Insert bolts (6) into washers (7) into upper slots of support (1), then screw into anchor plates (3) and connections

plates (4). Do the same with the other support (see details A and B).

3. Join rails (10) and supports (1). Space rails to the correct width.

4. Tighten all bolts. Cells can now be installed.

5. Please ensure that the stand is levelled using a spirit level. If required, use the spacers provided (16).

3. Battery installation

Stand assembly

Cells should be connected in series.

Assemble the battery on the stand, ensuring that the positive terminal of one cell is connected to the negative

terminal of the adjacent cell and so on throughout the battery.

Do not lift cells by their terminal posts. Use appropriate equipment (such as a raising board and a sling band)

for handling standby cells.

Cells are supplied with special air-tight plugs which must be replaced with standard vent plugs (supplied

separately) once cells have been filled with electrolyte.

For 4-tier stands and above, we recommend the cells are filled before being placed on the stand.

Note: the maximum fill to charge time is 12 hours (see section 4).

Cell installation

Please follow the instructions below.

1. Position the first cell on the stand, starting with the

least accessible row. Check the alignment of the cells.

2. Install the other cells with the appropriate spacing between

cells in mind.

Filling cells

1. Remove the air-tight plugs with the special tool.

3. Raising the electrolyte drum to a

level above the cell will significantly

reduce the filling time.

4. Putting cells into service

Before removing the air-tight plugs for filling the cells, please ensure that the battery charger is ready for use.

Cells should be stored as received and should only be activated (i.e. filled with electrolyte and charged) when

installed.

2. Fit the manual filler pump to the acid drum.

Please ensure that the pump is screwed

tightly into the plastic drum. The specific

gravity of the filling acid (at 20ºC) is 1.280.

4. Let the cells rest for 2 to 4 hours after filling.

7. Unscrew the terminal protectors.

Avoid all short circuits between

terminals of opposite polarities.

6. Place the standard vent plugs on the cells.

Do not tighten them at this stage to avoid

over-pressuring cells during the charge.

Check the polarity with a voltmeter.

At this point, the specific gravity will have

reduced.

Electrolyte Temperature

30°C (86°F)

35°C (95°F)

40°C (104°F)

9. After two to four hours, start the charge (see ‘‘Initial

charge’’ section) providing the maximum temperature

of the electrolyte is as per the table below.

10. When the charge is complete, tighten the standard vent

plugs properly. The final specific gravity after charging

must be 1.235 - 1.240 at 20ºC (maximum level).

8. Fit inter-cell connectors.

Torque them to 25Nm.

Room Temperature

20°C (68°F)

30°C (86°F)

35°C (95°F)

40°C (104°F)

5. Once plates and separators have absorbed the electrolyte, re-adjust, if necessary, the filling level back to maximum.

The charge must be started within 12 hours of the initial fill.

Methods of charging

Charging time

The charge must be

stopped

When can the charge

start again?

Note

End of charge

Very important

Note

Cell voltage and

specific gravity

imbalance

Constant current

I = 0.053 C10

Example for a battery of 500Ah

500 x 0.053 = 26.5A

Constant voltage

Voltage per cell: 2.35

Initial current limited to 0.1 C10

Example for a battery of 500Ah

500 x 0.1 = 50A

Typically 6 to 15 hours, depending upon storage conditions.

Long or poor storage will increase the charge time.

If the temperature of the electrolyte reaches:

- temperate climate: 40°C (104°F)

- tropical climate: 50°C (122°F)

55°C (131°F) (maximum case)

When the temperature of the electrolyte is below:

- temperate climate: 30°C (86°F)

- tropical climate: 40°C (104°F)

If charging is stopped more than 3 times because of cell temperature rise, please

reduce the constant current value. This will simply increase the charge time.

Until all cell voltages and electrolyte specific gravities (corrected to 20°C) cease to

rise for three consecutive hourly readings.

Long or poor storage will increase the time to charge. Constant current charging is

preferable to ensure electrolyte consistency across the cells and a reasonable charge time.

If the temperature of the electrolyte is below 40°C, it is better to overcharge the

battery rather than to keep the battery undercharged.

Imbalances are possible after long or poor storage.

Example: charging at constant voltage a battery which has been stored in poor conditions,

24 cells in which only 6 cells have been kept in good storage conditions.

- charge at constant voltage 2.35 Volts per cell

- maxi voltage supplied by the charger 2.35 x 24 = 56.4 Volts

- the voltage of the best 6 cells rises quickly to 2.60 x 6 = 15.6 Volts

- 18 cells will be in average at 2.26 Volts per cell

when the battery voltage reaches 56.4 Volts 2.26 x 18 = 40.8 Volts

56.4 Volts

- at 56.4 Volts, the current falls off to a very small value. With this very low float current, the

charging time will be longer for the 18 cells at 2.26 Volts. Continue charging until the specific

gravity of the electrolyte for all cells rise to the nominal specific gravity at maximum level.

Initial charge

The initial charge is very important as it can affect the life and performance of the battery.

Cells must be fully charged before the battery is put into service. Charging must be continued until the specific

gravity of every cell reaches between 1.235 and 1.240 at 20°C (maximum level) - see section 5.

Details of charge at constant voltage

The voltage is maintained at a constant fixed value per cell.

If the voltage is limited to 2.30Vpc the battery will not reach the gassing point. Ensuring that the specific gravity of the

electrolyte within a cell is consistent will take longer.

Details of charge at constant current (see appendix)

The current is constant troughout the charging period.

The voltage of the battery rises during the charging period, reaching a maximum value when the charge is complete.

This value depends on:

- The charging current

- Temperature: voltage must be corrected by +0.005 Volt per degree above 20°C

and -0.005 Volt per degree below 20°C

Example:

Read voltage at 27°C = 2.73 Volts

Corrected voltage at 20°C = 2.73 + (7 x 0.005) = 2.765 Volts

What happens at the end of charge?

- The temperature may rise quickly and excessive gassing maybe produced (which homogenises the electrolyte).

- V ariation of the voltage at the end of charge of a cell according to temperature and charging rate.

Charging rate

C10 capacity

0.05 C10 or C10/20

0.033 C10 or C10/30

0.022 C10 or C10/45

0.017 C10 or C10/60

2.75V

2.70V

2.67V

2.64V

2.70V

2.65V

2.62V

2.59V

2.65V

2.60V

2.57V

2.54V

2.60V

2.55V

2.52V

2.49V

Minimum voltage in volts per cell for

15°C 25°C 35°C 45°C

Time to equalise the specific gravity

Example:

If the room temperature is about 20°C and the initial charge is carried out at 2.35V, it will take 13 to 30 hours to fully

charge the cell.

The table above applies if the specific gravity variance after filling and the rest period is below 0.010.

If the variance is higher than 0.010, the recharge at constant voltage will take longer.

In such case, it is better to recharge the battery at constant current.

Between 4 and 10 days

Room temperature

20°C 35°C

Charge voltage per cell

2.25V 2.35V 2.25V 2.35V

Between 13 and 30 hours Between 8 and 18 hours

Between 3 and 7 days

The minimum voltage at end of charge should be as follows:

2.45

2.50

2.55

2.60

2.65

2.70

2.75

2.80

0 0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 0.055

Voltage (Vpc)

Charging rate C10

End of charge : Voltage vs charging rate and temperature

15°C

25°C

35°C

45°C

15°C 20°C 25°C 35°C 45°C

1.147 1.144 1.142 1.138 1.131

1.167 1.164 1.162 1.157 1.149

1.186 1.183 1.180 1.176 1.168

1.206 1.203 1.200 1.194 1.187

1.217 1.213 1.210 1.204 1.197

1.227 1.223 1.220 1.214 1.207

1.237 1.233 1.230 1.224 1.216

1.244 1.240 1.237 1.231 1.223

1.248 1.244 1.241 1.234 1.226

1.254 1.250 1.247 1.240 1.232

1.259 1.255 1.252 1.245 1.236

1.270 1.266 1.263 1.256 1.247

Specific gravity

Measure the specific gravity with a hydrometer.

After reading, squirt the solution back into the cell from which it was drawn.

The nominal specific gravity at the end of the charge at the specified level is for a temperature of 20°C.

If the temperature is above or below 20°C, the specific gravity reading must be adjusted using the table below.

Temperature correction

The specific gravity (20ºC) of each cell at the end of the charge should be between 1.235 and 1.240 (maximum level).

5. Specific gravity reading

Final specific gravity after charging

Example:

If at the end of charge, the specific gravity of the electrolyte reads 1.231 at 35ºC, this is equivalent to a specific gravity of

1.240 at 20ºC. This means that the cell is fully charged.

The battery room should be well ventilated in order to remove gases produced during charging. The gases (a mixture of

oxygen and hydrogen) liberated by the cells when on charge may cause an explosion, and therefore, care must be taken

not to produce sparks. Naked lights and smoking are not allowed.

The following precautions must also be taken:

During maintenance operations, do not wear clothing likely to create static electricity (for example nylon).

Do not use portable apparatus linked to an electric plug.

All installation practices and ventilation requirements must comply with EN 50272-2 and IEC 62485-2 standards and

national regulations.

6. Safety

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 must be observed.

Note operating

instructions.

When working on

batteries, wear safety

glasses and

protective clothing.

No smoking. Do not

allow naked flames, hot

objects or sparks near

the battery, due to the

risk of explosion or fire.

Danger. Cells are heavy.

Make sure they are

safely installed. Only use

suitable transport and

lifting equipment.

Electrical hazard.

Electrolyte is highly

corrosive.

Risk of explosion and fire.

Avoid short circuits.

Wash all acid splash in

eyes or on skin with

plenty of clean water and

seek immediate medical

assistance.

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

moist 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.

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.

7. Appendices

Electrolyte specification

H2SO4 dilute sulfuric acid, specific gravity = 1.280

Specific gravity at 20°C 1.280 +/-0.005

Visual aspect Clear

Freezing point -66°C

Maximum impurities (mg/l)

Antimony Sb 0.4

Arsenic As 0.1

Copper Cu 6.2

Sulphur S 0

Selenium Se 0.4

Iron Fe 10.6

Zinc Zn 2.8

Nickel Ni 0.4

Cobalt Co 0.4

Manganese Mn 0.4

Platinum Pt 0

Chloride Cl- 6.2

Nitrate NO3 4.5

Ammonia NH3 2.8

Anhydride sulphur SO2 4.5

Materials oxydisable to KMnO4 - 25.4

Visual Aspect Clear

Resistivity >60 000 Ω

Maximum Impurities (ppm)

Iron Fe 5

Copper Cu 5

Arsenic As 1

Antimony Sb 1

Manganese Mn 0.1

Nickel Ni 0.1

Chloride Cl- 5

Nitrate NO3- 5

Lead Pb 0

Zinc Zn 0

Platinum Pt 0

Potassium K 0

Iodine I 0

Bromide Br 0

Phosphate PO42- 0

Sulphate SO42- 0

Ammonia NH4 8

pH - 4 to 7

Dry residue at 110°C (a) 350ppm

Dry residue at 500°C (b) 250ppm

Organic matter (a) – (b) 100ppm

Total hardness: total hardness expressed

as calcium carbonate (calcium + magnesium) 1°F = 10ppm

Distilled or de-ionised water specification

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