Transcript
9/2004
SUPPLIMENTAL INSTALLATION AND OPERATING INSTRUCTIONS HOPPECKE STANDBY BATTERIES FNC-A (Advanced Series, nickel cadmium batteries)
WARNING SHOCK HAZARD – DO NOT TOUCH UNINSULATED BATTERY, CONNECTORS OR TERMINALS. BE SURE TO DISCHARGE STATIC ELECTRICITY FROM TOOLS AND TECHNICIAN BY TOUCHING A GROUNDED SURFACE IN THE VICINITY OF THE BATTERIES, BUT AWAY FROM CELLS AND FLAME ARRESTORS.
GAS PRODUCED BY THIS BATTERY CAN BE EXPLOSIVE. PROTECT EYES WHEN WORKING AROUND BATTERY. PROVIDE ADEQUATE VENTILATION SO HYDROGEN GAS ACCUMULATION IN THE BATTERY AREA DOES NOT EXCEED 2%. DO NOT SMOKE, USE OPEN FLAME OR CREATE SPARKS NEAR THE BATTERY.
THIS BATTERY CONTAINS POTASSIUM HYDROXIDE, WHICH CAN CAUSE SEVERE BURNS. IN CASE OF SKIN CONTACT WITH ELECTROLYTE, REMOVE CONTAMINATED CLOTHING AND FLUSH AFFECTED AREAS THOROUGHLY WITH WATER. IF EYE CONTACT OCCURS, FLUSH FOR A MINIMUM OF 15 MINUTES WITH COPIOUS AMOUNTS OF WATER AND SEEK IMMEDIATE MEDICAL ATTENTION.
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RECEIVING: Upon receipt, immediately check for physical damage and check shipment against bill of lading. In case of physical damage, note damage on bill of lading and file a claim with carrier. Check the number of crates and skids against the bill of lading and verify the components against the packing list. Keep a copy of the verified list for your installation records. Verify the accessory package is present and the component quantity is correct. DAMAGE AND SHORTAGE SITUATIONS: Hoppecke ships FOB our plant (ownership passes at our dock). If shipments are damaged or if a crate or skid is missing, a claim must be filed with the freight carrier. Place an immediate order for replacement with Hoppecke. If individual component items are missing, a shortage report should be filed immediately with Hoppecke. Mail or fax a copy of the component packing list to verify the missing items as well as the items checked off by your receiver. Contact:
Hoppecke Batteries Inc. 1960 Old Cuthbert Road, Suite 130 Cherry Hill, NJ 08034 Phone: 856-616-0032 Fax: 856-616-0132
INSTALLATION: Racks: Racks must be in a safe location for maintenance and away from ambient heat sources. Before batteries are installed, racks must be level and cross braces in place. All bolts must be tightened before installing batteries. For seismic racks, place rear retaining rails and tighten. Front and end retaining rails are installed after the cells have been placed on the rack. Anchor bolts for the racks are not provided. Installing Battery: Before working on the battery, be sure to discharge static electricity that can build up on tools or the technician by touching a grounded surface in the vicinity of the battery, but
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far enough from the cells and flame arrestors. Avoid creating sparks or exposing cells to open flames that could ignite gasses produced by a charging battery. Make sure shipping plugs are removed and install flame arrestor vents before installing battery. The following equipment and tools are required: 1. Safety Equipment: Eye protection, Safety shoes, Rubber apron and gloves 2. Insulated torque wrench and box wrench 3. 5% sodium borate solution or Vinegar, Water, a bucket and clean rags, Do Not Use Solvents of any kind. 4. Soft bristle brush Always lift cells from the bottom ONLY. Do Not Lift by the Terminals. Cells should be loaded by placing them directly in front of the designated location on the rack and carefully installing them into the final position. Arrange them so that the positive terminal of one cell can be connected to the negative terminal of the next cell. Required cell – to – cell spacing is 0.50” (10mm). For seismic racks, place spacers between cells. Install flame arrestor vents when provided separately. Affix cell numbers, beginning with number one (1) at the positive terminal, following the electrical circuit. Also affix other labels in the kit at this time. DO NOT add water to cells until after they have been on charge. After a minimum of 2 hours after the completion of the first charge, check the electrolyte levels and add deionized water as needed to bring the levels to the max. level line. NOTE: During charging gas is produced between the plates, due to the normal recombination effect of the cells. This will cause the electrolyte level to rise. Adding water prior to charging, may cause excessively high electrolyte levels in the cells. In some cases depending on the charge voltage, the electrolyte level may rise up to 5mm above the max. level line. This is normal and will not affect the operation of the battery. CAUTION: High voltage may be present; observe precautions and become familiar with local, state, federal and professional safety codes. Check polarity of the battery before energizing. CONNECTIONS: NOTE: CONNECTIONS ARE THE RESPONSIBILITY OF THE USER.
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Align cells so the intercell connectors match up with the holes of the terminal posts. Make the connections using the terminal bolts provided (positive to negative). Tighten the connections to the specified torque values. Specified Torque:
M8 bolts sizes: M10 bolt sizes:
16 Nm +/- 1 Nm (12 ft-lbs) 20 Nm +/- 1 Nm (15 ft-lbs)
Make intertier or interstep connections, then tighten to specified torque values. Check battery voltage to confirm correctness of series connections. After checking battery polarity, make connections from the rectifier to the battery, positive to positive; negative to negative. Provide an initial charge as indicated in the instruction manual. For standby parallel operation the voltages should be set as follows: Float voltage:
Voltages should be set at 1.37 to 1.38 vpc x number of cells connected in series, when measured at the battery terminal.
Boost voltage:
2 options are available for this voltage setting (Section 4.3.1) Option #1: Voltages should be set at 1.50 to 1.55 vpc x number of cells connected in series. When the pre-set voltage is reached (end of constant current phase), the charge current tapers. Charge at the pre-set voltage for 0.25 hr (15 minutes) and then automatically switch the charger to the float voltage. Option #2: Voltages should be set at 1.45 vpc x number of cells connected in series. When the pre-set voltage is reached (end of constant current phase), the charge current tapers. Charge at the pre-set voltage for 2 – 3 hours and then automatically switch the charger to the float voltage.
STORAGE: If cells are put into service within 2 – 4 months after delivery, a boost charge per section 4.3.1 of the Operating Instructions should be performed before putting the battery in service. If cells are to be stored for a period of 6 months or longer the following procedure should be followed: 1. Discharge the cells at the nominal 5 hour discharge rate (e.g., for a 100Ah battery the 5 hour discharge current would be 100Ah / 5hrs = 20 Amps). Discharge the cells to an end voltage below 1.00volts per cell or approximately 0.5 volts per cell. Any cells that are discharged to Zero (0.0) volts or reversed should be
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removed from the battery (or jump out these cells) and continue the discharge until all cell voltages are below 1.00vpc. 2. The cells can then either be stored with the electrolyte in the cells or the electrolyte can be emptied out of the cells. 3. In either case, the standard vent plug (flip top vent) must be removed and replaced with a transport plug which completely seals the air from the cell. NOTE: IF THE ELECTROYTE IS EMPTIED OUT OF THE CELL, IT IS CRITICAL THAT THE TRANSPORT PLUG SEAL BE SECURE. ANY ELECTRODE ELEMENTS THAT ARE EXPOSED TO AIR MAY BE DAMAGED DUE TO OXIDATION. 4. Cells stored in this condition can be stored indefinitely. 5. When the cells are put into service, an initial conditioning charge must be carried out as described below. INITIAL CONDITIONING CHARGE: After the storage period, to put the cells into service follow the procedure below 1. Replace the transport plugs used for storage with standard vent plugs (flip top vents). 2. If the cells have been emptied of electrolyte, replace the electrolyte before charging. a. If electrolyte is added to the cells, fill to the max level line. After a period of 12 hours adjust the level again if necessary. b. For cells that were stored discharged and filled with electrolyte, no adjustment is necessary. 3. Connect the cells with the supplied inter cell connectors using the torque values specified. Make sure there is at least 10mm spacing between all cells before proceeding. 4. The initial conditioning charge is carried out using the batteries nominal charging current (e.g., for a 100Ah battery the nominal charging current is 100Ah / 5 = 20 Amps). This charge is carried out under constant current conditions for a period of 7 hours. If a constant current charger is not available and only a constant voltage charger can be used divide the battery bank into 2 halves and charge each half separately for 7 hours using the standard boost setting for the charger.
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5. During this initial conditioning charge the cell voltages will rise up to 1.8 volts per cell. These high voltages are normal. Disconnect any loads from the battery to prevent damage to the loads. 6. During charging, a great deal of water will be consumed and converted to hydrogen and oxygen gas. Provide adequate ventilation and exercise caution, keep sparks and flames away from the battery and keep the vent caps closed to prevent propagation of any external spark or flame into the cells which could result in an explosion. 7. A minimum of 2 hours after completing the charge, the cell electrolyte should be topped up to the max. level line with deionized water. 8. Clean the cells with warm water and put the battery in service.
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