,

C&D Technologies, Inc.

Dynasty Division

900 East Keefe Avenue

Milwaukee, WI53212

Phone: 800-396-2789

Fax: 414-961-6506

Form 41-7525 (Rev.6100) Printed in U.S.A.

Page

333

Fig. 1

Fig.2

DYNASTY VRLA Battery System DescriptionSeries Connected Batteries 00000..0..0.0 0000Two strings of Batteries Connected in Parallel

4444

VRLA Battery Safety Hazards

Electrical Disposal Fire, explosion and Heat .

Installation Tools and Equipment 5

Preparation for System Installation 5

Receiving Instructions 5

Fig.3

Fig.4Fig.5

677

Storage Instructions and Task Flow Chart Cabling -(1 each) Three-tier Rack -30 each 12 VDC batteries for 360 VDC

Cabling -(2 each) Three-tier Racks -40 each 12 VDC batteries for 480 VDC

Locating the Batteries on the Rack 8

8Battery Terminal Preparation

Numbering the Batteries 8

Inter-unit Connections Fig.6 8

9

10

10

11

14

15

15

16

17

Table 1

Table 2

Fig.6

Fig.7Table 3Table 4

Fig.8

Fig.9

Inter-tier, Inter-row and Inter-rack Connections Inter-Unit Cables, Part No's., Hardware Kits and Terminal Insulating Covers

Inter- Tier Cables, Part No's. and Cable Lengths Inter-Unit Cable Configurations Inter- Tier Cable Configurations Inter-Row Cables, Part No's. and Cable Lengths Inter-Rack Cables, Part No's. and Cable Lengths Inter-Row Cable Configurations Inter-Rack Cable Configurations

Battery Connection to the Load/Charger 18

Parallel Connection of individual Battery Strings 18

Battery System Pre-Operational Checks 18

Initial Freshening Charge 18

Initial "Float" Charging 18

Optional Battery Tests and Checks 19

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DYNASTY VRLA BATTERY SYSTEM

OPEN RACK INSTALLATION ANDSYSTEM CHECKOUT GUIDE

General Information

relief vent to relieve any excess pressure generatedduring overcharge and the battery is otherwiseessentially sealed.

The typical Dynasty battery system is a group of the 6or 12 VDC individual batteries connected in series toprovide a higher voltage and power to a critical loadduring commercial power outages. Typical systemvoltages are in the range of 12 through 480 VDCdepending on the application. For example 12, 24 and48 VDC might be used for communications equipmentstandby power while from 72 to 480 VDC might beused for data center UPS systems.

The lead acid battery has a nominal voltage of 2 VDCper cell. A 6 volt battery has 3 cells. Just as thevoltage of a battery system is increased by connectingthe individual multicell blocks in series, the ampere-hours and kilowatt capacity of the systems can beincreased by connecting strings of series connectedbatteries, in parallel. Refer to Figures 1 and 2 forexamples of series and parallel connected batteries.

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This pamphlet provides a guide for use duringreceiving, installation and checkout of the DYNASTYVRLA batteries of 25 through 200 ampere-hourscapacity on open rack systems.

This guide may not be complete within itself andshould be used in conjunction with the following:

1. Rack Installation Guide

2. Specification Sheet for individual battery

3. Self Discharge and Inventory Control pamphlet# 41-7272

4. Integrity Testing pamphlet # 41-7264

5. Operational Qualification and WarrantyRegistration Checklist pamphlet # 41-7471

Other related C&D Technologies pamphlets which maybe of interest include:

1. Impedance and Conductance Testing pamphlet# 41-7271

2. Acceptance and Capacity Testing pamphlet# 41-7135

Figure 1-Series Connected Batteries

3. UPS Applications and VRLA Battery Sizing

pamphlet # 41-7334

4. Communications Applications and VRLA

Battery Sizing pamphlet # 41-7361

C&D Technologies DYNASTY VRLA Battery

System General Description

The DYNASTY valve regulated lead acid (VRLA)

battery is a lead acid battery which facilitates the

recombination of internally generated gasses. As a

result the battery vents minimal gas during normal

conditions and does not require the addition of water

to the electrolyte. The electrolyte is either in a gelled

form or is absorbed in the blotter type of separator

thus eliminating any free liquid electrolyte. Each cell

within the battery contains a self resealing pressure

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Figure 2-Two Strings of Batteries Connected in Parallel

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harmful to the skin and eyes; is electricallyconductive; and is corrosive.

VRLA Battery Safety Concerns

Installation and servicing of the DYNASTY VRLAbattery should only be performed and supervised bypersonnel knowledgeable of lead acid batteries andrequired personal and equipment safety precautions.Keep unauthorized personnel away from the batteriesand installation activity.

If electrolyte contacts the skin, wash immediately andthoroughly. If electrolyte enters the eyes, washthoroughly for 10 minutes with clean water or aspecial neutralizing eye wash solution and seekimmediate medical attention.

Neutralize any spilled electrolyte with the specialsolutions contained in a "spill kit" or with a solution of1 Ib. bicarbonate of soda to 1 gallon of water.Electrical Hazards

Battery systems present a risk of electrical shock andhigh short circuit currents. The following precautionsshould be observed when installing and maintainingVRLA batteries:

Fire, Explosion and Heat Hazards

Lead acid batteries can contain an explosive mixtureof hydrogen gas which can vent under overchargingconditions.

1 .Remove all personal metal objects (watches

and rings).

---Do not smoke or introduce sparks in the vicinity of the

battery.

2. Use insulated tools.

Wear full eye protection and rubber gloves.Do not install and charge batteries in a sealed

container.4. Observe circuit polarities,

Do not make or break live circuits. Mount the individual batteries with 0.5 inches of spacebetween the batteries to allow for convection cooling.If contained, assure the container or cabinet and roomhave adequate ventilation to prevent an accumulationof potentially vented gas.

6. Prior to handling batteries on a metal rack,assure the battery is not inadvertentlygrounded by measuring the voltage betweenthe battery and the rack. It should be zero. Ifnot, determine the cause and correct prior to

proceeding.Refer to the current issue of the National ElectricCode.

Disposal Caution

Lead acid batteries are to be recycled. Batteriescontain lead and dilute sulfuric acid. Dispose of inaccordance with Federal, State and local regulations.Do not dispose of in a landfill, lake or otherunauthorized location.

Do not attempt to remove the vents (valves) from theDYNASTY VRLA battery or add water. This presents asafety hazard and voids the warranty.

Caution

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The individual batteries may weigh from 25 to 100pounds depending on part number. Exercise carewhen handling and moving batteries. Assure the useof appropriate handling equipment.

Chemical Hazards

Any gelled or liquid emissions from a VRLA battery iselectrolyte which contains dilute sulfuric acid which is

4

Obviously the racks must be assembled and installedprior to installation of the batteries. Instructions for therack assembly are contained in a separate pamphletreceived with the racks.

The batteries are rated at 77° F (25° C). Operation atcooler temperatures will decrease the operating time.Operation at elevated temperatures will decrease theoverall life of the battery. There is a 50% life reductionfor each 15° F above 77° F.

Required Installation Tools & Equipment

Preparation for System Installation

The installation of the battery system involves a series

of activities from planning and initial receipt through

final checkout and warranty registration. The sequence

of these tasks are presented in Figure 3 and should

be thoroughly studied and understood before

proceeding.

Receiving Instructions

Upon receipt the shipment should be thoroughlyinspected for any physical damage to the packagingand to assure the proper quantities of items arereceived. The packages should then be opened andthe batteries inspected to assure there is no hiddendamage. Special attention should be given to thecontainers and terminals of the received batteries.

Refer to the bill of material and determine that theitems received are complete and as described on thebill of material.

If any damage is noted, or the number of packages isdifferent from the shipping papers, the carrier shouldbe contacted and a claim should be filed with thecarrier within 10 days.

The content of the shipment should be inspected andcounted to assure the proper instructions, drawingsand number of batteries, hardware kits, cables andaccessories as identified on the bill of material arereceived. Should the count be incorrect or thecomponents be of the wrong type, contact C&DTechnologies Dynasty Division Customer Service as

soon as possible.

The batteries are shipped fully charged, howeversome self-discharge will occur during transit and thedegree is a function of the transit time andtemperature. The fully charged open circuit voltage is2.12 to 2.14 volts per cell (6.36 to 6.42 and 12.72 to12.84 VDC for 6 and 12 volt batteries respectively).Upon receipt the batteries should be a minimum of2.07 volts per cell or 6.2 and 12.4 volts for 6 and 12volt batteries respectively. If at these minimumvoltages the batteries should be recharged as soon aspossible. If at or below 2 volts per cell (6 and 12 volts)the batteries should not be used and the vendorshould be contacted immediately.

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As part of this preparation activity the installer shoulddevelop a system schematic diagram which identifieshow the individual batteries are to be placed on therack, interconnected and numbered. Figure 4 is a

schematic for a typical system of 30 each 12 voltbatteries on a single 3 tier rack while Figure 5 is aschematic for a typical string of 40 each 12 voltbatteries on two each 3 tier racks. The cablingreceived with the system presumes a specific rackand installation configuration.

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At a minimum, the following tools and equipment arerequired to install the DYNASTY VRLA battery.

1 .Digital voltmeter.

2. Socket wrench, insulated.

3. Torque wrench calibrated in inch-pounds.

4. Box end wrench, insulated.

5. Battery lifting equipment (handles) and fork liftto lift pallets of batteries.

6. Rubber gloves.

7. Full face shield.

8. Plastic apron.

9. Potable eyewash.

10. Spill kit.

11. Fire extinguisher (class C).

The following equipment is optional depending on thetype of checkout to be performed.

1. Micro-ohm meter.

2. Battery resistance, impediance or conductancetest set.

3. 100 amp momentary load test set.

4. System load bank (DC if to be performed atthe battery and AC if to be performed byloading a UPS output).

Batteries in storage should be given a fresheningcharge at 2.4 volts per cell for 24 hours each 6months or when the open circuit voltage declines to2.07 volts per cell (6.2 and 12.4 volts for 6 and 12 voltbatteries respectively).

Additional details concerning storage and inventorycontrol are contained in the pamphlet "Self Dischargeand Inventory Control", form #41-7272.

Storage Instructions

Store batteries in a clean, dry cool area away from

radiant heat sources. Elevated storage temperatures

increase the self-discharge rate of the batteries and

reduces the storage time between required freshening

charges. Fully charged batteries with an electrolytespecific gravity of 1.280 or higher can be safely stored

at temperatures at low as -60 degrees F.

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~Figure 3-DYNASTY VRLA Battery System Installation Task Flow Chart

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r(.) FOS/ (JJTPUTInterunit Connector ~

.,I'"'

~I

TIER 3

D9 8 7 6 5 310 2

r-

fi IntertierConnectioJ

UI TIER 2

01

12 13 IS 16 17II 18 19

0

1nTIER

26 2529 --

~(-)NEGOUTPUT

28 27 23 22 21

Ir"'

Connection Hardware

Figure 4-0ne Three- Tier Rack with 30 each 12 VDC Dynasty Batteries for 360 VDC

Interrack Connection..,.,

-

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Figure 5-Two Three Tier Racks with 40 each 12 VDC Dynasty Batteries for 480 VDC

7

Interunit Connections

The various batteries may be of different dimensions

and with different terminal configurations. This and the

anticipated load determine the wire size, lugs and

length of the cable to be used for the interunit

connectors. Refer to Table 1 and Figure 6 for the

typical connection configuration and cable to be used

for each part number of DYNASTY VRLA battery.

Locating the Batteries on the Rack

The individual batteries should be placed on the racktier/shelf with 1/2" (1.27 cm) spacing between theunits. This is important to assure the inter-unitconnecting cables properly align with the adjacentbattery terminals and to allow air space for propercooling of the batteries.

When the batteries are being placed side to side, allthe batteries should be placed with the terminals ofthe same polarity (pas. or NEG.) to the front of thetier/shelf. Refer to Figures 4 and 5.

For stability reasons, the batteries should be placedon the lowest tiers/shelves first.

CAUTION: Do not lubricate the rack rails or batterycontainers with grease or other lubricatingcompounds. Certain lubricating compounds will causedeterioration of the battery plastic container and/or therack plastic components.

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Battery Terminal Preparation

To minimize contact resistance, it is important that the

lead terminals of the batteries be cleaned of any

oxidation that may have occurred during transportation

and storage. It is most convenient to clean them prior

to placing them on the rack. Figure 6-Typicallnter-Unit Connections(See Page 11 For Specific Battery Models)

Lightly brush the terminal contact surface areas with abrass bristle brush, or the equivalent, and then applya light coating or the special antioxidant grease, suchas NO-OX-ID or NCP-2, to the surfaces to protect thelead terminal from further oxidation.

Numbering the Batteries

Once the batteries are placed on the racks, they

should be numbered for future identification during

maintenance, etc.

Refer to the system wiring schematic and starting at

the battery that is to be the positive output of the

system, label it as #1. Then label the batteries in

ascending sequential order as they would be

connected in series. The battery at the negative output

of the system should be the highest number battery.

If individual strings are to be connected in parallel,

each string should be uniquely identified (e.g. A, B

and C).

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In general, the wire size to be used is:

1. AWG #6 for loads of up to 109 amperes or 190watts per cell.

2. AWG #2 for loads of up to 190 amperes or 330watts per cell.

3. AWG #2/0 for loads of up to 298 amperes or515 watts per cell.

4. AWG #4/0 for loads of up to 400 amperes or693 watts per cell.

5. 2 each AWG #2/0 for loads of up to 595amperes or 1032 watts per cell.

Lightly brush and coat with the protective grease thecontact surface area of the battery terminal andinterunit cable lug and assemble the interunitconnection per the relevant connection diagram ofTable 1. Torque the connection hardware to thatspecified in Table 1.

As all the batteries are interconnected on each

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tier/shelf the total open circuit voltage (OCV) of thebatteries on the tier/shelf should be verified as:

OCV per Tier = number of batteries per tier X voltage

per battery

If the measured voltage is not as expected, determinethe cause and correct before proceeding.

If a battery is installed with reverse polarity, themeasured voltage for the tier of batteries will bereduced from the expected value by twice the opencircuit voltage of the individual battery.

Refer to the battery system schematic diagram andthe battery numbers to determine the location of thevarious cables interconnecting the tiers of batteries.

Refer to Tables 2, 3 and 4 for the specific cable to beused to interconnect the tiers and rows of batteriesand Figures 7, 8 and 9 for the typical connection

techniques.

Prepare, assemble and secure the intertier cabledconnections in the same manner as the interunitcabled connections.

Intertier, Interrow and InterrackConnections

Measure the open circuit voltage of the completelyinterconnected system. The expected voltageshould be:

System OCV = number batteries X battery OCV

Cables used to interconnect tiers, rows and racksof batteries should be of at least the same size as theinterunit connecting cables.

If the measure voltage is not the expected voltage,determine the cause and correct before proceeding,

r-- Cables supplied as a system meet specificdimensions required for racks designed by Dynasty.This includes consideration for spacing, maximum loadand cable configuration.

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FIGURE 6-(Continued) INTERUNIT CABLE CONFIGURATIONS

CABLE ASSEMBLY PART NO.32668 410 FLEX CABLE150-1777132631 #2 FLEX CABLE150-1655032394 210 FLEX CABLE150-19485

CABLE ASSEMBLY PART NO32551 #2 FLEX CABLE150-16536

eolU

Figure 6-6-UPS12-475, TEL12-90, TEL12-125 Figure 6-7- TEL 12-30

~DUAL CABLEASSEMBLY PART NO.32665 2/0 FLEX CABLE150-16574

CABLE ASSI

32664#2 Fl

150-16567

32665 210 F

150-16574

Figure 6-8-UPS2-370, MPS12-100

Figure 6-10-UPS12-100 Figure 6-11-TEL6-180

12

EMBLY PART NO.

EX CABLE

LEX CABLE

1"'"'""'

Figure 6-16-TEL12-70 Figure 6-17-TEL12-80

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TABLE 4

Inter-Rack Cables Placed End to End)r.-.,

Connection

CapabilityAmps &

Watts/Cell

Inter-row Cable Use With Battery PINRef.

Diag. Cable

Length(Inches )

MPS TEL UPS

TEL 12-30

TEL 12-45

TEL 12-105F

TEL 12-150F

TEL6-180

STOCK NO.

(Use Prefix:)"CABASY"

32407 (#2)

32484 (#2/0)

32705 (#4/0)

2ea. 32484 (#2/0)

32484 (#2/0)

20"

16"

15"

190A 330 w/c

9-1 298A 515 w/c All exceptUPS12-100400A 693 w/c

9-2 2ea. @ 16" 596A 1030 w/c

TEL 12- 70

TEL 12-80

TEL 12-90

TEL 12-125

16" 298A 515 w/c9-3

32705(#4/0)

32723 (#6)

400A 693 w/c15"

9-4 20" 109A 190 wlc . I UPS12-100 ~

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FIGURE 8 -INTERROW CABLE CONFIGURATIONSBETWEEN RACKS INSTALLED BACK TO BACK

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]1

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Figure S-2-Typical Dual Cable Interrow Connection forBatteries With .'Flag" Terminals

Figure 8-1-Typical Single Cable Interrow Connection forBatteries With "~' Terminals

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~Figure 8-3-Typical Single Cable Interrow Conection for

Batteries With Flag Terminals

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FIGURE 9 -INTERRACK CABLE CONFIGURATIONSBETWEEN RACKS PLACED END TO END WITH 4" SPACING

Figure 9-2- Typical Dual Cable Interrack Connection forBatteries With "L:' Terminals

Figure 9-1-Typical Single Cable Interrack Connection forBatteries With .'L" Terminals

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Figure 9-3-Typical Single Cable Interrack Connection forBatteries With Threaded Insert Terminals

Figure 9-4-Typical Single Cable Interrack Connection forBatteries With Small "Flag" Terminals

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Initial Freshening ChargeBattery Connection to the Load I Charger

Select the proper size and type of cable per the NECor other applicable code which can handle the chargeand discharge current related to the battery. The cablesize selected should also consider the cableresistance per foot and the voltage drop allowedbetween the battery output terminals and the load.

The output circuit of the battery should contain a DCrated fuse or circuit breaker to protect the wiring andwhere appropriate a disconnect to facilitate service tothe battery in an open circuit condition.

When the batteries have been in storage or transit foran extended period or the battery system is intendedfor use at the minimum float charging voltage or whenthe number of cells in series is greater than 24, it isrecommended the battery system be given afreshening charge at 2.4 volts average per cell for 24hours. This will assure higher initial performance andwill reduce the time period required for the cells toachieve proper voltage balance between the individualunits.

Document the progress of the freshening charge inSection V of the pamphlet "Operational Qualificationand Warranty Checklist", Form 41-7471.

With the load/charger fuse, circuit breaker ordisconnect in the "open" condition, connect thebattery output cables to the load/charger circuit.

To apply a freshening charge:

Parallel Connection of Individual

Battery Strings~

When individual strings of batteries are to beconnected in parallel, each of the individual batterystrings should be cabled separately to a commonjunction point or box. They should not be .'daisychained" in parallel.

1. Confirm the freshening (equalization) voltagefrom the charger/rectifier is set to a valueequal to 2.4 volts per cell X number of cellsconnected in series (7.2 and 14.4 voltsrespectively for 6 volt and 12 volt batteries).

2. Close the circuit from the charger I rectifier tothe battery system and note that the batteryaccepts current.

Each of the individual battery strings output circuitsshould contain a fuse, circuit breaker or disconnectprior to the common connection at the junction pointto protect the wiring and facilitate battery maintenance.

When the separate strings of batteries are to beinitially connected in parallel their open circuitvoltages should be within 1 VDC of each other prior tomaking the paralleling connection.

3. Monitor the battery periodically and note thatthe operation is proceeding normally and thatthe current acceptance is declining, thebatteries are not overheating (within :t5 F ofeach other and the ambient) and that theindividual battery voltages on equalizationcharge are 7.2:tO.25 and 14.4:tO.50 volts for 6and 12 volt batteries respectively.

Battery System Pre-Operational Checks 4. Terminate the freshening charge in the event ofany extraordinary situations or after 24 hours.

Prior to application of any freshening charge or loadto the battery system the following checks should beperformed as defined in the pamphlet "OperationalQualification and Warranty Registration Checklist",Form #41-7471.

Initial "Float" Charging

Battery Room and General Equipment Checks.

Following the "freshening" charge the battery systemshould be placed on "float" charge at an averagevoltage of 2.25 to 2.30 volts per cell (6.75 to 6.90 and13.5 to 13.9 volts for 6 and 12 volt batteries

respectively).2. Battery Charger I Rectifier Checks.

3. Battery Rack/Enclosure Checks.Prior to placing on .'float" charge, assure thecharger / rectifier is set to the proper output voltage.4. Battery Open Circuit Checks.

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Optional Battery Tests and Checks

While not a requirement of the warranty registrationthe following checks are recommended to assuremaximum reliability of the battery system over time.

After the battery system has been on "float" forapproximately 24 hours, the float current acceptanceshould be approximately to .005 amperes or less perrated ampere hour capacity of the battery string butgreater than zero.

The individual battery float charging voltages shouldbe within the following range:

1. "High rate momentary load" test as describedin the pamphlet "Integrity Testing" Form #41- 7264,While this test does not indicate the actualcapacity of the battery it does indicate it isfunctional.

12 volt batteries 13.3 min. to 14.5 max.

10 volt batteries 11.10 min. to 12.1 max

6 volt batteries 6.65 min. to 7.25 max.

4 volt batteries 4.43 min. to 4.85 max.2. Individual battery measurements of resistance/

conductance/impedance as described in thepamphlet "Impedance and ConductanceTesting" Form #41- 7271. Again, while this test doesnot indicate the actual capacity of the batteryit does provide base line data from whichchanges can be trended over time as thebattery normally deteriorates. This can be veryuseful in trouble analysis during the periodicmaintenance activities.

Document the results of these measurement activitiesin Section VI, Float Charging Checks, of the"Operational Qualification and Warranty RegistrationChecklist", Form #41-7471.

If any special battery monitoring equipment is to beutilized, it should be installed and calibrated at thistime.rThe DYNASTY battery system installation is nowcomplete and the system is available for acceptancetesting and operational service.

3. Battery performance test as described in thepamphlet "Acceptance and Performance Testing'Form #41-7135.

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