NorthStar Battery (NSB) Telecom Installation and Operation Guide

Transcription

1 15DOC0020 NorthStar Battery (NSB) Telecom Installation and Operation Guide Contents 0 Definitions Battery Safety Old Batteries Handling Receiving the shipment Do Don t Storage Storage conditions Shelf Life Commissioning Unpacking the Batteries Checking the Voltage Spread Putting the Batteries in Place Connecting the Batteries Application of Grease After Tightening Electrical Connections Discharge Rate Maintenance Cleaning, Pesticides, and Chemicals Silver Star Technology Self Discharge During Storage Putting the Battery In Service Charging Voltage... 8 Date: ECO DCN: SES Page 1 of 14

2 7 Blue Star Technology Self Discharge During Storage Charging the batteries prior to operation Boost Charging Float Charging Voltage Blue Self Discharge During Storage Putting the Battery In Service Boost Charging Float Charging Voltage Red Star Technology Self Discharge During Storage Putting the Battery In Service Charging Voltage Contact To help us better serve you, please visit our web site at and complete our Customer Survey. We value and appreciate your input. Date: ECO DCN: SES Page 2 of 14

3 0 Definitions The definition for each of the following terms or abbreviations describes the context employed throughout this document. Monobloc* Battery* A discrete unit of one (1) or more 2-V cells A unit or module consisting of one (1) or more monoblocs VPC Volts per cell Electrolyte Sulfuric acid diluted with deionized water and mixed with sodium sulfate * Terms may be used interchangeably given the circumstance. 1 Battery Safety For full information please read the Material Safety Data Sheet (MSDS). The MSDS document may be downloaded from the Internet at: When dealing with Valve Regulated Lead Acid Batteries (VRLA) some additional safety information is required. Please read and observe the installation and operation instructions. 1.1 Old Batteries Batteries are heavy objects. Use proper handling equipment safety gear during installation. Inappropriate lead acid battery disposal can result in environmental contamination. Please dispose of batteries according to local regulations. Battery may be returned, shipping pre-paid, to the manufacturer or any distributor for recycling. Batteries contain electrolyte (diluted sulfuric acid in deionized water). Any fluid found outside the batteries should be regarded as electrolyte. Monoblocs which have reached their End of Life (EOL) should be removed from the application they are in and disposed of in accordance with federal, state, and local laws concerning the handling of hazardous materials and the environment. EOL is an industry defined term for VRLA batteries which indicates that the monobloc has only 80% of its original capacity left. When working on batteries wear appropriate Personal Protective Equipment (PPE). Refer to battery MSDS for complete list. Do not expose the battery to an open flame or other ignition source. During operation an explosive mixture of hydrogen gas may accumulate. Battery terminals are always energized and, if short-circuited, cause electrical arcing. Always use insulated tools. Date: ECO DCN: SES Page 3 of 14

4 2.2 Do Figure 1 Location of manufacturing labels on NSB batteries Manufacturing codes are limited to 12 alphanumeric digits: 1. The first two digits specify the model of the monobloc. 2. The remaining ten digits are a random, non-sequential serial number which is unique to this particular monobloc and will not be duplicated. Always use the handles on the monoblocs when lifting or carrying them. Always have a straight back and lift using your legs when lifting or carrying monoblocs. Always have appropriate safety gear (see safety section) available when handling monoblocs. Always perform an Open Circuit Voltage (OCV) check on a monobloc PRIOR to installation. Verify that the OCV is appropriate for the monoblocs application. Always perform a visual inspection of the monobloc prior to handling. If any damage or electrolyte leakage is detected during this inspection do not install the monoblocs. Isolate and remove spilled electrolyte using proper cleaning process. Always use the packing from new monoblocs for transporting old monoblocs for proper disposal. If unavailable, place batteries on a pallet and strap them down secure for shipping. Having the monoblocs loose during transportation can lead to either an inadvertent discharge of the monoblocs, or damage to the monoblocs and electrolyte leakage. Always dispose of monoblocs in accordance with local and national requirements. Always follow the instructions provided with the monoblocs when installing them. Always use insulated tools when handling monoblocs. Failure to do so can lead to electric shock. 2.3 Don t 2 Handling 2.1 Receiving the shipment In addition to safety requirements (see section 1) special care should be taken when handling monoblocs. The following are some DOs and DON Ts. Don t drag a monobloc along the floor. Doing so could cause damage to the monobloc case leading to a possible leakage of electrolyte. Don t install a monobloc into any application that has been dropped. A dropped monobloc could have damage to either its internal or external casing leading to a possible leakage of electrolyte and damage to equipment. Date: ECO DCN: SES Page 4 of 14

5 Don t make the final connection to an application until all batteries in the string have had their interconnections finished. The batteries contain a large amount of stored energy, and can cause damage from an energy discharge. Don t dispose of batteries in unapproved sites. The batteries contain electrolyte and compounds of lead that are harmful to nature and can contaminate the environment if not disposed of properly. Don t drill, or in any other way attempt to breach the monoblocs case. Doing so could lead to a possible leakage of electrolyte. Don t force a monobloc into equipment. Forcing the monobloc into equipment can lead to a breach in the monoblocs internal or external casing causing a possible leakage or electrolyte or electrical short circuit. Don t move the monoblocs using the terminals. The terminals are not designed to support the weight of the monobloc, and damage to internal components could result. 3 Storage 3.1 Storage conditions Below is a list of equipment that is recommended to be on hand in the area where monoblocs are stored. 1. DC volt meter 2. Battery chargers (a normal car battery charger, purchased locally, is sufficient) 3. Mechanical lifting device (such as a fork lift etc.) 4. Appropriate Personal Protective Equipment (PPE), which is listed in the battery MSDS at: It is strongly recommended to store the monoblocs in a cool dry environment. For more information see Self Discharge During Storage. The monoblocs should be stored in the original containers. The packaging serves to protect the monoblocs from harsh environmental conditions and accidental damage. If they must be removed, palletize them, and utilize as much of the original packaging as possible. Different ways to correctly store monoblocs 3.2 Shelf Life NorthStar batteries have a two year shelf life at +25 C (+77 F). 4 Commissioning Always use the installation instructions provided with the monoblocs and follow all outlines for safety and handling mentioned earlier in this document. 4.1 Unpacking the Batteries When received, a visual check should be made on the monoblocs. If the monoblocs show transportation damage, physical damage to the case, leaking electrolyte etc., they should not be installed, and a claim should be initiated immediately. Make sure all the accessories are present in the delivery. Please observe the cardboard material around the monoblocs has no bottom! The cardboard should be removed prior to lifting the monoblocs. Please keep all packing material for future use if possible. If the monoblocs cannot be put into place directly in the end application and need to be put Date: ECO DCN: SES Page 5 of 14

6 on the floor/ground, put some of the cardboard material under them in order to protect the monobloc from hard surfaces. An alternative material is to use the top of the crate that the monoblocs were shipped in. 4.2 Checking the Voltage Spread insulation covers should be put back after all connections have been completed. See the figures below: Insulation Cover Before connecting the monoblocs in series, the voltage variation must be checked. If the voltage varies more than 0.15 V of the maximum monobloc reference, the monoblocs should be charged individually before being connected in series. Refer to the recharge table(s) in this manual for the particular monobloc type used. Alternatively the monoblocs may be matched in each string so that all the monoblocs with voltage spread less than 0.15V. 4.3 Putting the Batteries in Place Make sure the monoblocs are all evenly spaced, aligned and rest on a flat surface. Resting the monoblocs on an acid resistant, electrically insulating surface is strongly recommended. Monoblocs can be installed in any orientation, but inverted is not recommended. 4.4 Connecting the Batteries The monoblocs shall be connected into series using the cable and connectors designed for the particular layout of your delivery. Refer to the particular layout of the system. Please observe the risk for arcing and high currents when connecting the monobloc string to the system. Preferably the last connection should be made at distance from the monobloc string. If the system comprises a monobloc circuit breaker or any other means of disconnection this shall be in an off condition when connecting the monobloc to the system. Before connecting cables, clean contact surface and apply a light coating of antioxidizing grease to contact surfaces. A torque wrench must be used for tightening the bolts on the battery. Recommended torque will vary depending on the size of the battery. Refer to the product label applied directly to the battery for recommended torque values. The covers shall be put back after all connections have been completed. Please observe that when heavy cables are used, these need to be supported in order not to stress the monoblocs terminals. The 4.5 Application of Grease After Tightening Electrical Connections Electrical grade conductive grease is applied directly to the battery terminals as a corrosion preventative measure during manufacturing. In typical indoor installations no additional grease is required to protect the terminals and other electrical connections after installation. This is because NSB batteries have the electrolyte stored within an absorbent glass mat (AGM) separator which means the risk of electrolyte leakage is very low even if the integrity of the container is compromised. In addition NSB batteries also feature a multi-stage terminal seal that is extremely effective against electrolyte leakage. Finally the bus bars and other hardware provided with the batteries are plated to protect from corrosion. 4.6 Discharge Rate In this document, the charge and discharge rates (amps) are expressed as multiples of 10, where 10 is the current for a 10-hour discharge to 100% depth-of-discharge (DOD). These values serve to normalize data across a range of monobloc sizes. Consider the following example: 10-h discharge capacity NSB 100FT = 100 Ah (EODV = C). 1 x 10 = 1 x (10-h discharge current) 1 x 10(NSB 100FT) = 1 x 10A = 10 A 2 x 10(NSB 100FT) = 2 x 10A = 20 A Date: ECO DCN: SES Page 6 of 14

7 5 Maintenance 5.1 Cleaning, Pesticides, and Chemicals Do not spray insecticides directly on the monoblocs. The plastic monobloc containers are not compatible with many commercially available chemicals including cleaning products and insecticides. These chemicals can damage the monobloc case and cause leakage of electrolyte. If the monobloc needs to be cleaned, use water. 6 Silver Star Technology 6.1 Self Discharge During Storage During storage, lead acid batteries will gradually self discharge. It is recommended to maintain State of Charge (SOC) above 50% by routinely recharging the monoblocs. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals. 6.2 Putting the Battery In Service Depending on the voltage of the monoblocs at the time of installation charge at elevated voltage may be needed. In order to maximize life it is recommended that the monobloc be fully recharged prior to initial startup. Measure the voltage across the terminals of the monoblocs and consult Self Discharge During Storage to determine % SOC. Date: ECO DCN: SES Page 7 of 14

8 The following table shows approximate charge times based on monobloc OCV, and assuming the power avaliable for recharge is relatively low. If the charging system is properly sized, a fast charging regime may reduce the charge time. For further details consult the Telecom Application Manual. OCV Recharge Time >12.80 V 3 day 2.27 VPC V 3 day 2.27 VPC V 1 day 2.41 VPC V 1 day 2.41 VPC 6.3 Charging Voltage In order to achieve the design life, the recommended float charging voltage must be employed. The recommended float voltage is 2.27 ± 0.02 VPC 25 C. This equates to ± 0.12 V per monobloc provided that the temperature will be close to 25 C. For other temperatures, refer to our Table 2 below. For UPS equipment multiply the voltage with the number of monoblocs. Table 2 T C / F V (float) 24 V 48 V 20 / ± 0.12V ± 0.24V ± 0.48V 25 / ± 0.12V ± 0.24V ± 0.48V 30 / ± 0.12V ± 0.24V ± 0.48V 35 / ± 0.12V ± 0.24V ± 0.48V Date: ECO DCN: SES Page 8 of 14

9 7 Blue Star Technology 7.1 Self Discharge During Storage During storage, lead acid batteries will gradually self discharge. It is recommended to maintain State of Charge (SOC) above 50% by routinely recharging the batteries. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals. 7.2 Charging the batteries prior to operation Blue Star Technology batteries must be fully charged prior to operation. The following table gives the charging time required to reach full SOC. Recharge Time Current Limit (A) VPC 1*I10 2*I0 4*I10 10*I V 2 Days 1 Day 1 Day 1 Day 2.35 V 12 hrs 12 hrs 6 hrs 6 hrs 2.45 V 12 hrs 6 hrs 6 hrs 6 hrs 7.3 Boost Charging A boost charge allows for the fastest recharge following a deep discharge, or after long storage time. The boost charging voltage shall be 2.35 VPC provided that the temperature is nominal Date: ECO DCN: SES Page 9 of 14

10 +25 C (+77 F). The following graph shows the recommended charging profile: NSB Boost Recharge Regime for Blue Star Technology : +25 C (+77 F). If the site cannot be climate controlled, float voltage must be adjusted according to the graph below: The table above shows the time needed to recharge following a 100% Depth of Discharge (DoD) cycle, depending on the maximum charge current available. 7.4 Float Charging Voltage The float charging voltage shall be 2.27 VPC provided that the temperature is a nominal Boost Float 8 Date: ECO DCN: SES Page 10 of 14

11 Blue+ 8.1 Self Discharge During Storage During storage, lead acid batteries will gradually self discharge. It is recommended to maintain State of Charge (SOC) above 50% by routinely recharging the batteries. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals. Depending on the voltage of the monoblocs at the time of installation charge at elevated voltage may be needed. In order to maximize life it is recommended that the monobloc be fully recharged prior to initial startup. Measure the voltage across the terminals of the monoblocs and consult Self Discharge During Storage to determine % SOC. The following table shows approximate charge times based on monobloc OCV, and assuming the power avaliable for recharge is relatively low. If the charging system is properly sized, a fast charging regime may reduce the charge time. For further details consult the Telecom Application Manual. OCV Recharge Time >12.80 V 3 day 2.27 VPC V 3 day 2.27 VPC V 1 day 2.41 VPC V 1 day 2.41 VPC 8.3 Boost Charging 8.2 Putting the Battery In Service Date: ECO DCN: SES Page 11 of 14

12 A boost charge allows for the fastest recharge. The boost charging voltage shall be VPC. The following graphs show the charge acceptance based on charging voltage. 8.4 Float Charging Voltage The float charging voltage shall be 2.27 VPC provided that the temperature is a nominal +25 C (+77 F). If the site cannot be climate controlled, float voltage must be adjusted according to the graph below: Date: ECO DCN: SES Page 12 of 14

13 9 Red Star Technology 9.1 Self Discharge During Storage During storage, lead acid batteries will gradually self discharge. It is recommended to maintain State of Charge (SOC) above 50% by routinely recharging the batteries. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals. voltage across the terminals of the monoblocs and consult Self Discharge During Storage to determine % SOC. The following table shows approximate charge times based on monobloc OCV, and assuming the power avaliable for recharge is relatively low. If the charging system is properly sized, a fast charging regime may reduce the charge time. For further details consult the Telecom Application Manual. OCV Recharge Time >12.80 V 3 day 2.27 VPC V 3 day 2.27 VPC V 1 day 2.41 VPC V 1 day 2.41 VPC 9.3 Charging Voltage 9.2 Putting the Battery In Service Depending on the voltage of the monoblocs at the time of installation charge at elevated voltage may be needed. In order to maximize life it is recommended that the monobloc be fully recharged prior to initial startup. Measure the In order to achieve the design life, the recommended float charging voltage must be employed. The recommended float voltage is 2.27 ± 0.02 VPC 25 C. This equates to ± 0.12 V per monobloc provided that the temperature will be close to 25 C. For other temperatures, refer to our Table 2 below. For UPS equipment multiply the voltage with the number of monoblocs. Date: ECO DCN: SES Page 13 of 14

14 Table 2 T C / F V (float) 24 V 48 V 20 / ± 0.12V ± 0.24V ± 0.48V 25 / ± 0.12V ± 0.24V ± 0.48V 30 / ± 0.12V ± 0.24V ± 0.48V 35 / ± 0.12V ± 0.24V ± 0.48V 10 Contact NorthStar in the Americas NorthStar Battery Company LLC 4000 Continental Way Springfield, MO, 65803, United States of America info@northstarbattery.com Tel: Fax: NorthStar in Europe, Middle East, Africa SiteTel Sweden AB Staffans Väg 6-8 Box 7039, SE Sollentuna, Stockholm, Sweden emea@northstarsitetel.com Tel: Fax: NorthStar in Asia-Pacific NS Asia Pacific Sdn. Bhd. B2-3A-13A, Solaris Dutamas No. 1, Jalan Dutamas 1, Kuala Lumpur, Malaysia asia@northstarsitetel.com Tel: Date: ECO DCN: SES Page 14 of 14