Installation Manual

An Invensys company

Contents

1 2 3 4 5 6 7

Scope and safety warnings Cell identification Unpacking Storage Installation instructions Filling with acid General battery charging requirements Commissioning charge Boost charge or equalising charge

2 3 4 4 4 5

Batteries are often the last line of defence in providing electrical energy after failure of a mains supply. Hawker supplies two types of vented lead acid cells described in this publication, Plant and Pasted Plate, both of which meet the requirements of BSEN 60896-1 and BS6290:1999. This manual provides the user with information for optimising performance and life at minimal cost. Warranties are only valid if the product has been installed, operated and maintained in accordance with these instructions.

(5) Note operating instructions Observe instructions for use of the battery, and ensure the instructions are visibly prominent near the battery.

(6) Keep away from children (7) Danger Heavy weights! Take care in transporting, lifting and installing batteries. (8) Electrical Hazard Electrical Hazard! Batteries are always live.

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10 Adjustment of specific gravity 11 Battery discharge testing procedure 12 Float charge voltage 13 Service instructions 14 Torque settings 15 Isolation connectors for high voltage batteries 16 Diagnosis of battery condition 17 Specification of purified water 18 Specification for filling electrolyte Appendix I Appendix II

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10 11 11 12

1. Scope and safety warnings

Plant and Pasted Plate batteries are hazardous. Take note of the meanings of the following symbols and information. (1) No Smoking No smoking! No naked flames! No sparks! Risk of explosion. (2) Sulphuric Acid Electrolyte is highly corrosive.

(9) Chasing arrows/Pb Return to the manufacturer! Old batteries bearing this sign are re-cyclable. Batteries not returned for re-cycling must be disposed of as special waste in accordance with national regulations. The information contained in this manual must be read in conjunction with BS 6133, British standard code of practice for the safe operation of lead acid stationary cells and batteries latest issue. Reference should also be made to the companies secondary lead acid batteries, health & safety Information sheet, a copy of which is available upon request.

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Sulphuric acid! Flush any acid splashes from eyes and off skin with plenty of clean water. Seek medical aid immediately. Contaminated clothing should be washed in water with minimum delay. (3) Contains explosive gases Risk of explosion and fire! Avoid short circuits. Never place metal tools or other objects on batteries as they are always live. (4) Shield eyes Always wear safety glasses and protective clothing. Comply with accident prevention regulations and your national Health and Safety standard.

1.1 Risk analysis The immediate risks are electric energy, ignition of gases, sparks from short circuits chemical burns from the electrolyte and handling.

ELECTRIC ENERGY Electrical energy can be supplied from both batteries and charging equipment. Use acid resistant insulated tools and remove or insulate all metallic items worn about the person. Protect the eyes by wearing safety spectacles. Minimise the number of conductors exposed at any one time. Use temporary insulation if connectors are not insulated. On high voltage batteries break the battery down into sections of 60 cells or less, and never work alone.

ELECTROLYTE SPILLAGE Electrolyte spills should be contained and neutralised. sulphuric acid should not be allowed to enter the drains.

1.2 For the batteries health and safety A battery is normally the last line of defence against system failure and service schedules should reflect this. Ensure that the battery charging system is operating correctly. When topping up add only purified water, never add any kind of sulphuric acid. Keep the battery and the connectors clean, coated with nooxide grease, and to the correct tightness. Apply equalising charges to maintain the correct state of charge.

IGNITION OF GASES Prevent ignition of gases from the battery. Never permit smoking, sparks or any kind of flames near the battery. Isolate circuits before connection or disconnection of test loads or chargers. Ensure that ventilation prevents the concentration of hydrogen gas below an explosive threshold.

1.3 Electromagnetic compatibility Rechargeable cells or batteries are not sensitive to normal electromagetic disturbances and therefore no immunity tests shall be required.

CHEMICAL BURNS Before starting work ensure that a supply of water, eye wash stations, and a first aid kit is available. The eyes and face should be protected. For general inspection and maintenance, boiler suit, eye protection, and rubber gloves should be worn. When filling the cell with electrolyte, in addition to the above, an apron and boots should be worn. In case of electrolyte burns, wash affected areas with lots of cold water. If electrolyte gets into eyes, rinse with eyewash. In all cases, take rapid medical advice.

2. Cell identification
To identify the cell the following information is ink-jet printed onto the lid. Cell type Cells nominal voltage: Vnom Recommended float voltage: Vflo Rated temperature: T Rated 3 hour capacity at T: C3 (Note for AU cells the watts per cell rating at 15 minutes is indicated) End voltage of the rated discharge: Vf Fully charged electrolyte density at T: d

HANDLING Cells can be very heavy and awkward to handle. The terminal pillars should not be used to handle cells. Lifting devices should be not be designed in such a way that they may cause short circuits across the terminals.

Date of manufacture and serial number: YYWWNNNN where Y= year, W= week, N= 4 figure serial number

3. Unpacking
Carefully examine the consignment for any obvious signs of transit damage and that it agrees with the consignment note. If any damage or shortages are evident, advise the carriers immediately in writing and send a copy of the letter to our company. If the product has been supplied in a filled and charged condition it is normal that the electrolyte level will be a little below the maximum level. This occurs because gas bubbles created during factory charging are not always dispersed before dispatch but are dispersed in transit. If on opening the package there is obvious indication of acid spillage, the affected cells should be topped up with dilute acid to the recommended electrolyte level, the cells should be inspected for transit damage, and the fault reported to the company. Product supplied filled and nominally charged will have an electrolyte specific gravity below that for fully charged cells because of self discharge occurring after factory charging.

The above storage times are applicable to a relative humidity of 50%. The storage time is progressively reduced to half that given above at a relative humidity of 100%.

4.2 Filled and charged cells 4.2.1 Storage times for cells supplied filled and nominally charged Storage time for filled and charged cells are dependant upon cell voltage. Cells will need to be recharged when the following voltages are observed: Plant AS, AM, AL - 2.02Vpc Plant AU - 2.04Vpc Pasted Plate FP - 2.08Vpc If the storage times and/or temperature limits are exceeded, permanent damage and loss of capacity may result. If the battery is to be stored prior to commissioning for a period greater than stated for the relevant average temperature, it must undergo a charge as detailed in section 7. It should receive further charges as appropriate for storage temperature until such time as it is commissioned.

4. Storage
If the battery is not to be used immediately, certain criteria must be observed for it to remain in good condition. The maximum period for which the product can be stored depends on the condition in which it is supplied.

5. Installation instructions
5.1 Installation of battery stands Assemble the battery stand in accordance with the instructions provided with the stand.

4.1 Dry charged cells They must be stored in dry and clean condition. Product must not be placed in direct sunlight. If the storage times and/or temperature limits are exceeded, the product may lose its dry charged characteristics and is then described as time expired dry charged. An extended commissioning charge will be required which may be up to twice as long as that required for product stored for the times given above. Further details are given in section 8.1. dry charged, time expired cells have an indefinite storage time.

Ensure that the stand is level and stable. Standard steel stands are provided with adjustable plastic feet. Special stands have alternative methods for levelling eg. shims. Where two or more stands are supplied, ensure that the runners of adjacent stands are adjusted to the same height. Fit stand to wall or floor fixings as required. Ensure that all nuts and bolts are tight.

5.2 Installation of cells 4.1.1 Storage times for cell supplied dry charged 12 months up to 20C 6 months up to 30C 3 months up to 40C The cells must be carefully handled and must not be lifted by the terminals. Suitable lifting equipment should be used. If the battery has been supplied dry, it may be better to fill the cells with acid before fitting them to the stand. However, it must be remembered that filled cells present a greater hazard, and there is a maximum stand time of 18 hours between filling cells and charging.

Before filling or installation, all cells must have their terminals cleaned to remove any deposits of oxide formed during storage, and all exposed metal parts must be coated with the no-oxide grease supplied. This also applies to both plated and non-plated accessories, taking care not to remove any plating. Extra care must be taken when cleaning the terminals of filled and charged cells to avoid shorting out. Clean each cell with a soft clean cloth. Do not use solvents, paraffin or other similar cleaning agents. Coat all exposed metal parts of terminal pillars and connectors with the no-oxide grease provided. Carefully position each cell on the stand or in the cabinet avoiding unnecessary shock loadings. Lifting or manoeuvring by the terminals will damage the pillar seal and/or lid to container seal and will lead to premature failure. Ensure that the cells sit firm and square on the stand runner or shelf. Determine the positive and negative battery take off position and commence assembly from either of these positions. For normal series connection commencing from the positive end, cell number 1, ensures that the negative terminal of one cell is connected to the positive terminal of the adjacent cell and so on through the battery. It is good practice to omit initially the occasional inter-cell connector and thus limit the battery voltage to safe levels whilst it is being worked on. Section 16 details the recommended positions and section 5.5 gives special instructions for these batteries. These connections should only be fitted with the load isolated and when the rest of the installation is completed and checked. Using an insulated torque spanner, tighten all bolts or nuts to the value stated in section 15. Exceeding the stated torque values may damage or break the screw threads, leading to an unsafe installation. Re-check all cells to ensure that they sit firm and square on the runner or shelf. The resistance between each connector or battery take off and cell pillar, when measured using a micro-ohm meter, must be less than 25 micro-ohms.

5.4 Insulation covers When the terminal assembly is secure and liberally coated with no-oxide grease, fit the insulated terminal covers.

5.5 Installation of high voltage batteries A battery consisting of 60 or more cells connected in series presents additional hazards and the following notes on installation should be employed. 1. Limit the battery voltage by omitting inter-cell connectors to give a maximum section voltage of 120V or 60 cells. 2. Section 16 gives details of the recommended isolation connector position. The connection should be chosen to be in an accessible position. These connectors should only be fitted with the load and charger isolated and when the rest of the installation is complete and checked. 3. Never work alone on high voltage batteries. 4. Always use insulated tools and wear approved high voltage insulating gloves. 5. When supplied, fit the high voltage battery warning labels in a prominent position.

6. Filling with acid

Where cells have been supplied dry, first clean and grease the pillars. This will protect the pillar if acid is spilled during the filling process. Then fill with pure, cool, dilute sulphuric acid of accumulator quality complying with BS 3031:1996 or equivalent. It is important that cells are filled and allowed to stand for a minimum of 4 hours and a maximum of 18 hours before commencing the commissioning charge. Failure to observe this procedure can cause a permanent loss of capacity or reduced battery life. Therefore, do not fill any cells without first ensuring that the charging equipment is functioning correctly and can be charged as a complete battery. If the battery has to be split into sections for commission charging, only fill cells that can be fully commissioned at one time.

5.3 Battery take-off connections To prevent damage to the cell pillar seal, large unsupported cables must not be terminated directly onto the pillars. Terminal take off plates and transition boxes to suit all applications are available.

Table 6.1 Initial Filling Electrolyte Specific Gravity for Dry Charged Product CELL TYPE RANGE AS, AM & AL FPA, FPB & FPC AU S.G. AT 20C 1.197 1.257 1.227 S.G. AT 20C 1.193

Before the battery can be put into service it must receive a commissioning charge as detailed in section 8. Failure to carry out this procedure can cause permanent damage or a reduction in service life. During the commissioning charge, Record full details of the charge.

1.253 1.223 Stop the charge should the temperature reach 45C and resume when the electrolyte temperature is 35C. Continue charging until the specific gravities have stabilised for 3 consecutive hourly readings.

Carefully fill each cell to the maximum level. Any spillage should be dealt with immediately. If the cells have not been positioned on the stand or in the cabinet, now is the time to do so. During the 4 to 18 hours stand period the electrolyte level will fall slightly. This is normal and the level must be restored to within 5 mm of the maximum before commencing the charge. Use acid of the same specific gravity as initial filling for this topping up procedure.

Fig 7A
No 1 No 52 No 153 No 204

CHARGER

7. General battery charging requirements

Float charging of the battery is carried out with cell voltage of 2.25Vpc, and battery voltage set to 2.25Vpc times the number of cells. The charging system must be capable of providing a steady voltage within 1%V. The current available to the battery must be not less than the value given in table 7.1 below. The maximum output from the charger need not be limited providing the cell maximum voltage does not exceed 2.25V. For economic reasons, the maximum charging current is generally specified as 8% of the 3 hour capacity. Charger output or load induced current ripple can cause permanent damage and a reduction in battery life. The RMS limit is 7% in amperes of the 3 hour capacity over the frequency range 100 to 360Hz. For details at other frequencies, contact our company. The 3 hour capacity is given in the following table 7.1. Fig 7B
No 1 No 52 No 153 No 204

CHARGER

Fig 7C
2.8 2.7 2.6 CELL VOLTS 2.5 2.4 2.3 2.2 2.1 2.0 TIME

Table 7.1 Recommended charge rates, nominal capacities & electrolyte quantity HIGH PERFORMANCE PLANT Cell type Charge rate (ampere) below 32C 1.3 2.7 4.0 5.4 6.0 8.0 10 12 14 16 18 20 22 24 26 28 30 32 34 36 39 47 55 62 70 78 86 94 101 109 117 125 133 140 148 156 164 172 7.8 9.1 12 13 16 17 20 21 23 25 29 31 33 Charge rate (ampere) above 32C 1.0 2.1 3.1 4.2 4.6 6.2 7.7 9.2 11 12 14 15 17 19 20 22 23 25 26 28 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 126 132 6 7 9 10 12 13 15 16 18 19 22 24 25 Capacity (AH) 15.2 30.4 45.6 60.8 63 84 105 126 147 168 189 210 231 252 273 294 315 336 357 378 416 499 582 665 748 831 914 997 1080 1163 1247 1330 1413 1496 1579 1662 1745 1828 102 119 153 10 204 221 255 272 306 323 374 408 425 Electrolyte (litres) 0.93 1.45 2.75 2.50 3.60 3.30 4.80 4.50 6.00 5.70 7.20 7.00 8.40 8.00 11.5 11.1 10.7 10.5 10.4 10.0 29 28 35 34 33 40 38 45 43 42 52 50 49 64 62 60 59 58 3.4 3.2 4.6 4.4 5.9 5.6 6.0 5.8 7.6 7.4 10. 58. 98.7
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AS15 AS 30 AS 45 AS 60 AM75 AM100 AM125 AM150 AM175 AM200 AM225 AM250 AM275 AM300 AM325 AM350 AM375 AM 400 AM 425 AM450 AL500 AL600 AL700 AL800 AL900 AL1000 AL1100 AL1200 AL1300 AL1400 AL1500 AL1600 AL1700 AL1800 AL1900 AL2000 AL2100 AL2200 AU420 AU490 AU630 AU700 AU840 AU910 AU1050 AU1120 AU1260 AU1330 AU1540 AU1680 AU1750

PASTED PLATE Cell type Charge rate (ampere) below 32C 1.2 2.4 3.7 4.9 6.1 7.3 9.8 11 13 15 16 18 20 21 23 25 26 28 29 31 33 34 36 38 39 41 42 44 46 47 49 51 32 36 41 45 50 54 59 63 68 72 77 81 86 90 95 99 104 108 113 117 123 127 132 135 Charge rate (ampere) above 32C 0.9 1.8 2.8 3.8 4.7 5.6 7.5 9 10 11 13 14 15 16 18 19 20 21 23 24 25 26 28 29 30 31 33 34 35 36 38 39 24 28 31 35 38 42 45 49 52 55 59 62 66 69 73 76 80 83 87 90 94 98 101 104 Capacity* (AH) 14 28 41 55 69 83 110 127 145 163 181 200 218 236 254 272 290 309 327 345 363 381 400 417 436 454 472 490 508 526 545 563 715 817 919 1022 1124 1226 1328 1430 1532 1635 1737 1839 1941 2043 2145 2248 2350 2452 2554 2656 2758 2861 2963 3065 Electrolyte (litres) 1.0 0.9 1.6 1.4 2.9 2.7 2.2 3.7 3.6 3.5 5.0 4.9 4.8 4.7 6.4 6.0 5.7 8.0 7.8 7.7 7.6 9.1 8.9 8.7 8.5 11.8 11.6 11.4 11.2 11 10.8 10.6 30 29 28 27 26 36 35 34 42 41 40 48 47 46 59 58 57 56 64 63 62 61 60 59

FPA20 FPA40 FPA60 FPA80 FPA100 FPA120 FPA160 FPB175 FPB200 FPB225 FPB250 FPB275 FPB300 FPB325 FPB350 FPB375 FPB400 FPB425 FPB450 FPB475 FPB500 FPB525 FPB550 FPB575 FPB600 FPB625 FPB650 FPB675 FPB700 FPB725 FPB750 FPB775 FPC1050 FPC1200 FPC1350 FPC1500 FPC1650 FPC1800 FPC1950 FPC2100 FPC2250 FPC2400 FPC2550 FPC2700 FPC2850 FPC3000 FPC3150 FPC3300 FPC3450 FPC3600 FPC3750 FPC3900 FPC4050 FPC4200 FPC4350 FPC4500

* The capacity given is in ampere hours at the 3 hour rate at 20C to 1 80Vpc and for high gravity acid for FPA, FPB and FPC types.

8. Commissioning charge
8.1 Dry charged batteries Refer to general requirements in section 7. After filling the cells, they must be stood for a minimum of 4 hours and a maximum of 18 hours before commencing the commissioning charge. The actual commissioning charge time for dry charged batteries depends on the storage time, temperature, humidity, the charge current used and cell type. Table 9.1 gives a guide to the minimum times required. The standard vent or optional flame retardant vent must be securely fitted before charging.

The pilot cell should be chosen to indicate the maximum temperature of a group of not more than 20 cells,e.g. for a 60 cell battery, 3 pilot cells are required. During charging, the individual cell voltages will be seen to rise slowly up to about 2.30Vpc where a more rapid increase up to about 2.70Vpc will be recorded. This higher cell voltage indicates that the cells are approaching a fully charged state. At the end of the commissioning charge, the specific gravity and voltage of ALL cells must be recorded along with the temperature of the electrolyte of the pilot cells. These recordings must be taken at hourly intervals over a 2 or 3 hour period, i.e. 3 or 4 sets of readings. Irrespective of the time involved, the charge is not complete until constant values are observed. The precise time to complete the commissioning or boost charge depends on many factors including storage conditions, storage time, and charge current used. Upon completion, the battery can be put into service or tested as required. Throughout the commissioning charge the electrolyte level must be maintained between the maximum and minimum lines by adding purified water. However, during charging the electrolyte level may increase up to 5mm over the maximum line permitted when the cells are gassing freely at top of charge. Note: Under extreme conditions, the commissioning charge may be carried out at a current down to half that given in table 7.1. This low current may be used if the charging source is restrictive or if high temperatures are experienced. It must be noted that the commissioning charge time will be extended, e.g. at half current the time will be at least double.

Table 8.1 Minimum commissioning charge times for dry charged batteries Cell Type Plant Types AS, AM, AL and AU Pasted Plate Types FPA and FPB Pasted Plate types FPC New 20 20 40 Time Expire 40 40 80

Time expired dry charged product, as referred to in section 4.1, Storage will need an extended charge period which may be up to 2 times longer than normal. Continue with the charge until three consecutive hourly readings of all cell specific gravities and cell voltages have been recorded. If in doubt about this extended charge, contact our company for advice. The commissioning charge must be carried out at a CONSTANT CURRENT without voltage limit. The current used must be as given in table 7.1 above, for the battery type being charged, with a tolerance of not more than 10%. As the cells approach a fully charged condition the charging current should stabilise. (If this is not possible then contact the company for advice. Cells will not be fully commissioned if they are not constant current charged). Throughout the charge, the electrolyte temperature, as measured at the pilot cells, must not be allowed to exceed 45C. If this temperature is reached, the charge must be terminated, the battery allowed to cool until the electrolyte temperature reduces to 35C, before continuing the charge. Failure to observe the maximum temperature can cause permanent damage and/or a reduction in battery life. The specific gravity and electrolyte temperature of the pilot cells should be recorded at hourly intervals throughout the charge.

8.1 Commissioning charge for filled and charged batteries Refer to general requirements in section 7. The commissioning charge for batteries, supplied filled and nominally charged, involves charging at the required current (as detailed in table 7.1) until specific gravities (corrected for temperature) and cell voltages (recorded over three consecutive readings taken at hourly intervals, with gravity adjusted to the correct value at the maximum level) remain constant. Ideally, the boost voltage should be set to 2.70Vpc, but practical constraints may limit the maximum boost voltage to 2.33Vpc to 2.50Vpc. These systems are acceptable but recharge times may be up to 72 hours.
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9. Boost charge or equalising charge

Refer to general requirements in section 7. Batteries that have been in service for some time may require a boost (equalising) charge if the electrolyte specific gravity, corrected for temperature and electrolyte level, is more than 10 points (0.010) below the fully charged level, The procedure detailed in section 8.1 should be followed.

It is unlikely that the finished SG will be low. However, if it is and you are sure the cell is fully charged, strong acid must be added. Using the same principle as above, for every 6ml of 1.400 SG acid added, per litre of electrolyte in the cell, the final gravity will be one point (0.001) higher. Further adjustment may be required after a short mixing charge at the standard charge rate as given in table 10.1, for 15 to 45 minutes.

10. Adjustment of specific gravity

At the end of the commissioning charge, and with the electrolyte at the maximum level, the specific gravity of electrolyte of all cells must be adjusted to the value given in table 10.2. As the specific gravity of the electrolyte varies with temperature, it must be corrected to a reference temperature of 20C. For each 1.5C above 20C add 1 point (0.001) to the specific gravity as read, and for each 1.5C below, subtract 1 point (0.001). Generally, if any adjustment is needed, it will be because the gravity is high. As a guide, first remove some electrolyte from the cell and add purified water. For every 5ml of water added, per litre of electrolyte in the cell, the final gravity will be one point (0.001) lower, e.g. if an AM175 cell has an SG of 1.222 at 20C it must be reduced by 10 to 20 points to obtain 1.202 to1.212 as given in table 11.2. The AM175 has an electrolyte volume of 6 litres, from table 7.1. Therefore, first remove 5ml x 6 x 15 = 450ml, then add 450 ml of purified water. Note we use 15 because it is between 10 and 20 points. Further adjustment may be required after a short mixing charge at the standard charge rate as given in table 7.1, for 15 to 45 minutes.

Table 10.1 Specific gravity of electrolyte in fully charged cells Cell type Specific gravity At 20C Plant types AS, AM AND AL Pasted Plate types FPA, FPB & FPC high gravity Plant type AU 1.202 to 1.212 1.262 to 1272 1.232 to 1.242 At 25C 1.198 to 1.208 1.258 to .12688 1.228 to 1.238

11. Battery discharge testing procedure

Before any discharge test, the battery shall be fully charged, by charging as detailed in section 7. A capacity test must be completed no longer than 24 hours after completion of charge. Before the test, measure and record individual cell specific gravities and electrolyte temperature, cell float voltages, overall battery voltage and charging current. Check all connections are clean and check all torque values. The test should be carried out in general accordance with BS EN 60896-1. It should be noted that the battery temperature will affect its discharge performance. The variations are given in table 11.1 below:

Table 11.1 Variation in discharge time with temperature for high performance Plant cells & Pasted Plate cells Length of Discharge 1 second to 59 mins 1 hour to 24 hours 0C 0.70 0.80 5C 0.775 0.85 10C 0.85 0.90 15C 0.925 0.95 20C 1 1 25C 1.075 1.05 30C 1.15 1.10 35C 1.225 1.15 40C 1.30 1.20

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12. Float charge voltage

The recommended float voltage for Hawker Plant and Pasted Plate vented lead acid batteries is 2.25Vpc which is applicable for all temperatures within the range 10C to 30C. For temperatures outside this range, please contact your local Hawker office or representative for advice. Operating the battery at an annual mean electrolyte temperature greater than 20C will cause a reduction in service life. Many companies operate at a float voltage lower than that recommended above which will reduce water loss due to electrolysis. Although the float voltage may be reduced, it is recommended that the minimum float voltage used is 2.15 Vpc. If a float voltage below 2.25Vpc is used, it will be necessary to boost charge (equalise charge) the battery as detailed in section 9 at regular intervals to keep it healthy. Failure to boost charge the battery at the prescribed intervals, in accordance with section 9, can lead to acid stratification and undercharging which may affect the performance and service life of the battery.

13.1 Initial records At the commissioning stage it is important to measure and record individual cell specific gravities, temperature and cell voltages. After completing the commissioning charge and ideally immediately after connecting to the normal float charge voltage, ensure that the battery charging voltage is within the recommended limits for the system and the float voltage is correct. Measure and record all cell voltages, pilot cell specific gravities and temperature, and charge current. A pilot cell is used to give an approximation for the battery as a whole and several pilot cells should be chosen.

13.2 Monthly inspection Ensure that the battery charging voltage is within the recommended limits for the system and the float charge voltage is correct.

13.3 Three month service Ensure that the battery charging voltage is within the recommended limits for the system and the float charge voltage is correct. With the battery in its normal mode of operation measure and record all cell voltages, specific gravities and temperatures, and charging current. Check electrolyte level and top up cells as required with purified water.

13. Service instructions

A standby battery is often the last line of defense in situations when the normal power supply is lost. Accordingly, service of the equipment must reflect the importance of having a back up battery. If, at any time, an abnormal condition is observed, make a note along with readings of voltage, specific gravity and temperature, then establish the cause of the abnormality and rectify it, without delay. When topping up cells it is imperative that only purified water is used. Also, it is recommended that cells be topped up before the level of electrolyte is allowed to fall to the minimum line, otherwise stratification may occur particularly when a low float voltage is used. In cases of low float voltage or if stratification is suspected, the battery should be given a boost charge, as detailed in section 9, after topping up until the electrolyte is thoroughly mixed. Unless the cell is actually being topped up, the service vent must be fitted at all times. Note: When cells are equipped with anti-explosion vents it is not necessary to remove the vents to measure temperature or specific gravity or to add water to the cell.

13.4 Six Monthly Service With the charging system connected and the battery in its normal mode of operation, measure and record all cell specific gravities and temperatures, cell voltages and charging current. Check battery and cell connections for correct torque tightness as detailed in section14. Check and top up all cells as required with purified water. Keep connectors and terminals clean and well coated with no-oxide grease to prevent corrosion. Carry out a thorough visual inspection of the battery and record any abnormalities. Establish the cause of the abnormality and correct.

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13.5 Extended period servicing When the monthly checks have shown that the battery and charging system are operating correctly, the interval between these checks can be extended to three months. However, this should not be done for the first six months. Similarly, the normal three monthly service may be extended to six months and the six month service to annual, providing the battery has been operating satisfactorily.

Table 15.1 Suggested position of isolating connectors for high voltage batteries made up of individual cells No of Cells 1-24 25-99 100-109 110-119 Sections 1 2 3 3 3 3 4 4 4 4 4 5 5 5 49-50 35-40 35-40 40-45 45-50 30-35 35-40 40-45 40-45 45-50 35-40 40-45 40-45 75-80 75-80 80-85 85-90 70-75 75-80 80-85 85-95 90-95 75-80 80-85 85-90 105-115 115-120 120-125 130-135 135-144 115-120 120-125 130-135 155-160 160-165 170-175 Section 1 Section 2 Section 3 Section 4

13.6 Cell cleanliness Ensure that the cells are at all times clean and dry. Any water or acid spillages should be cleared up immediately. Clean each cell with a soft cloth, do not use solvents, paraffin or other similar cleaning agents.

120-129 130-139 140-149 150-159 160-169 170-179 180-189 190-199 Recommended torque value 5 NM 16 NM 25 NM 200-209 210-220

14. Torque settings

Table 17.1 Cell type range AS and FPA AU, AM and FPB AL and FPC

16. Diagnosis of battery condition

The following notes enable an easy assessment of the state of charge and general condition of the cells. The following indicate a cell in a healthy charged condition: Specific gravities all within the limits indicated in table 10.1 Float voltage correct - see section 12 Positive plates - dark brown colour. Negative plates - metallic slate grey colour. Gassing from cells when switched to boost charge.

15. Isolation connectors for high voltage batteries

Section 5.5, Installation of high voltage batteries explains the additional hazard and appropriate precautions that must be employed when working on batteries greater than 120V or 60 cells. Before other work is performed it is essential that isolating connectors, as detailed in table 15.1 be removed to ensure the battery is broken into sections of less than 120V or 60 cells. Similarly, during installation these connectors should only be fitted after all other work on the battery has been completed. The exact position of each isolating connector is not critical but the maximum number of units in each section should not exceed 60 cells. When supplied, fit the isolation link labels and the high voltage battery warning labels in a prominent position.

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Fault diagnosis Characteristics of an undercharged battery Specific gravities low and irregular. Cell float voltages low or irregular. Positive plates are a light brown colour. Negative plates are a non-metallic dark grey colour. Boost charge voltage is low. No gassing when the system is switched to boost charge. Both positive and negative plates may be speckled. Characteristics of an overcharged battery Specific gravities high. Float voltages high or low. Excess gassing on float charge. Low electrolyte levels. Excessive deposits of sediment in the base of cell container. Shedding of positive plate active material. Spongy deposit on negative plates. Expansion and distortion of positive plates. Excessive water consumption An undercharged battery is caused by: (i) Charge voltages and/or currents too low. (ii) Insufficient freshening charges (current or duration). An overcharged battery results from: (i) Excessive periods of boost charge. (ii) Too high charging rate. (iii) Float voltage settings too high. If there is evidence of undercharging or overcharging, then adjust the charge rates according to the type and if necessary consult Hawker for further advice.

17. Specification of purified water

Only purified water complying with BS 4974:1975 Grade A, or equivalent national standard shall be used.

18. Specification for filling electrolyte

Only sulphuric acid complying with BS 3031:1996. or equivalent national standard shall be used.

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Appendix 1
Commissioning and boost charge record sheet (to be completed). This record sheet must be completed during commission and boost charging. W.O. no. Customer ref. No. of cells/s Installed at Charge current (see Table 7.1) Comments: A Type Date installed Battery title Date of charge

Engineer in charge

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Appendix 2
Service record sheet Time = Amps = Cell no. Volts V Specific Electrolyte gravity temp C Time = Amps = Volts V Specific Electrolyte gravity temp C Time = Amps = Volts V Specific Electrolyte gravity temp C Time = Amps = Volts V Specific Electrolyte gravity temp C

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Hawker Limited Rake Lane Clifton Junction Swinton Manchester M27 8LR UK Tel: +44 (0)161 794 4611 Fax: +44 (0)161 727 3809 e-mail: hawkerUK.sales@hawker.invensys.com www.hawker.invensys.com

Publication No. X6480150 January 2001 - Subject to revisions without prior notice