C&D Technologies UPS12-100MR Manuale utente

Valve Regulated Lead Acid Battery

20 to 200 ampere-hours capacity

10 Year VRLA

Battery Periodic

Maintenance

Instructions

41-7546

TECHNICAL BULLETIN

41-7546/0213/CD www.cdtechno.com

General Information

Battery ystem General Description

Series string .......................................................................................................................3

Parallel string ......................................................................................................................3

VRLA Battery afety Concerns

Electrical Hazards ...............................................................................................................4

Disposal ..............................................................................................................................4

Chemical Hazards ...............................................................................................................4

Fire, Explosion and Heat Hazards.......................................................................................4

Handling Hazards ...............................................................................................................5

Preparation for VRLA Battery Periodic Maintenance ...............................................................5

Required Maintenance Tools and Equipment .....................................................................5

Periodic Maintenance Tasks and chedule ..............................................................................5

Quarterly Checks ................................................................................................................6

Semi-Annual Checks ..........................................................................................................6

Annual Checks ....................................................................................................................6

Bi-Annual Checks ...............................................................................................................6

Data Analysis and Corrective Actions .......................................................................................6

Ambiant and Battery Temperature.......................................................................................7

Battery Visual nspection ....................................................................................................7

System Float Voltage ..........................................................................................................8

Ground Fault Check ............................................................................................................8

Float Charging Current .......................................................................................................9

ndividual Battery Float Voltage ..........................................................................................9

High Rate Momentary Load Test ........................................................................................10

Battery mpedance ..............................................................................................................10

Connection Resistance .......................................................................................................10

Performance Testing ...........................................................................................................11

Tables

Table 1-Battery System Symptoms and Solutions...............................................................12

Table 2-Battery Parameters by Model Number ...................................................................19

Figures

Figure 1-Series String of VRLA Batteries ............................................................................3

Figure 2-Parallel Strings of VRLA Batteries ........................................................................3

Figure 3-Float Current VS. Float Voltage ............................................................................9

Figure 4-VRLA Battery mpedance VS. Capacity ...............................................................10

Appendices

Appendix 1-VRLA Battery Periodic Maintenance Data Recording Form ............................20

Table of Contents

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C&D VRLA BATTERY Y TEM

PERIODIC MAINTENANCE AND

TROUBLE HOOTING GUIDE

General Information

This document provides a guide for use during

periodic maintenance and troubleshooting of the

10 Year VRLA batteries of 20 through 200

ampere hours capacity.

Other instructional documents which can be used

in conjunction with this guide include:

For example, as shown in Figure 2, two of each

48 volt 90 ampere hour capacity strings can be

connected in parallel to provide a nominal 48

volts at 180 ampere hours.

10 Year VRLA

Battery ystem General Description

n general the battery system is a group of 2, 4,

6, or 12 volt batteries connected in a series string

to provide a total system of higher voltage. For

example, as shown in Figure 1, four of the nominal

12 volt batteries may be connected in series to

provide a 24 cell system with a nominal voltage

of 48 volts.

Multiple strings of the series connected batteries

may be connected in parallel to provide a total

system with a capacity of the sum of the capacities

of the individual strings.

The 10 Year VRLA battery is a lead acid

battery which facilitates an oxygen recombination

cycle. The net result is that under normal

conditions there is minimal gas emission and loss

of water from the electrolyte. The electrolyte is

immobilized by absorbing within an absorbent

separator between the plates. Consequently, the

battery is maintenance free in terms of electrolyte

maintenance-that is, there is no requirement nor

capacity to add water to the cells or to measure

the electrolyte specific gravity.

VRLA Battery afety Concerns

Maintenance and servicing of the C&D VRLA

battery should only be performed and

supervised by personnel knowledgeable of lead

acid batteries and required personal safety and

equipment safety precautions. Keep unauthorized

personnel away from the batteries and

maintenance activities.

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1. ntegrity Testing 41-7264

2. mpedance and Conductance Testing 41-7271

3. Acceptance and Capacity Testing 41-7135

Figure 2-Parallel Strings of Batteries

Figure 1-Series Connected String of Batteries

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41-7546/0213/CD 3 www.cdtechno.com

Electrical Hazards

Battery systems present a risk of electrical shock

and high short circuit currents. The following

precautions should be observed when maintaining

VRLA batteries:

1. Remove all personal metal objects

(watches, rings, etc.).

2. Use insulated tools.

3. Wear full eye protection and rubber

gloves.

4. Observe circuit polarities.

5. Do not make or break live circuits.

6. Prior to handling batteries on a metal

rack, assure the battery is not

inadvertently grounded by observing the

ground fault detector indicator. n its

absence, measure the voltage between

the battery and the rack. t should be zero.

f not, determine the cause and correct

prior to proceeding.

7. Do not lay metal tools and hardware on

top of the batteries.

8. As appropriate, use an insulating

blanket to cover exposed portions of the

battery system when performing extended

maintenance that could result in personal

or equipment contact with the energized

conductors.

Certain types of rectifier circuits used in charging

the VRLA battery may not include a line isolating

transformer. n these cases extreme caution

should be exercised when maintaining and

collecting data on the battery system.

The VRLA battery is sometimes enclosed in

cabinets with very limited access. Again, extreme

caution must be exercised when maintaining and

collecting data on the battery system.

Disposal

Lead acid batteries are to be recycled. Batteries

contain lead and dilute sulfuric acid. Dispose of

in accordance with Federal, State and local

regulations. Do not dispose of in a landfill, lake or

other unauthorized location.

Chemical Hazards

Any liquid leaking from a VRLA battery is electrolyte

which contains dilute sulfuric acid which is harmful

to the skin and eyes; is electrically conductive;

and is corrosive.

f electrolyte contacts the skin, wash immediately

and thoroughly with water. f electrolyte enters the

eyes, wash thoroughly for 10 minutes with clean

water or a special neutralizing eye wash solution

and seek immediate medical attention.

Neutralize any spilled electrolyte with the special

solutions contained in a spill kit or with a solution

of 1 lb. bicarbonate of soda to 1 gallon of water.

Fire, Explosion and Heat Hazards

Lead acid batteries can contain an explosive

mixture of hydrogen gas which can vent under

overcharging conditions.

Do not smoke or introduce sparks in the vicinity

of the battery.

Prior to handling the batteries, touch a grounded

metal object, such as the rack, to dissipate any

static charge that may have developed on

your body.

Do not charge batteries in a sealed container.

The individual batteries should have 0.5 inches

of space between the batteries to allow for

convection cooling. f contained, assure the

container or cabinet and room have adequate

ventilation to prevent an accumulation of

potentially vented gas.

41-7546/0213/CD 4 www.cdtechno.com

Caution

Do not attempt to remove the vents (valves) from

the 10 YEAR VRLA battery or add water. This

presents a safety hazard and voids the warranty.

Handling Hazards

The individual batteries may weigh from 25 to

150 pounds depending on part number.

Exercise care when handling and moving

batteries. Assure the use of appropriate

handling equipment.

Preparation for VRLA Battery

Periodic Maintenance

There is little difference between the periodic

maintenance associated with a VRLA battery

and a vented (wet) cell battery with the exception

of that related to the liquid electrolyte. Naturally,

it is not required to measure electrolyte specific

gravity or add water to the VRLA cells.

For optimum reliability, it is recommended that

the battery system be monitored quarterly. f the

battery system incorporates an automatic

monitoring system to gather the electrical and

environmental data, the quarterly checks are

limited to the evaluation of the recorded data and

a visual check of the battery.

n general the types of checks to be made during

the periodic maintenance include:

1. System charging voltage

2. Ambient temperature

3. Battery pilot unit temperatures

4. nterunit connection hardware resistance

5. ndividual battery float voltage

6. Momentary high rate load test

7. Battery system capacity test

A test of the individual unit resistance, impedance

or conductance, while optional, is also recommended

on a periodic basis. This data and its trend can be

a valuable aid in troubleshooting the system and

predicting the need for a system capacity test.

Prior to starting the periodic maintenance activity

assure that all required maintenance tools and

equipment and safety equipment is available

and functional. Notify anyone who will be affected

by the intended maintenance or troubleshooting

activity.

Also, all units in the battery should be numbered

so as to facilitate the recording and analysis of

data unique to each unit.

Required Maintenance Tools

and Equipment

At a minimum, the following tools and equipment

are required to maintain and troubleshoot the

10 Year VRLA battery.

1. digital voltmeter

2. socket wrenches, insulated

3. box end wrenches, insulated

4. torque wrench calibrated in inch-lbs.

5. rubber gloves

6. full face shield

7. plastic apron

8. potable eyewash

9. spill kit

10. fire extinguisher (class C)

The following equipment is optional depending on

the type of maintenance to be performed.

1. micro-ohm meter

2. battery resistance, impedance or

conductance test set

3. 100 amp momentary load test set

4. system load bank (DC if to be performed

at the battery or AC if to be performed

by loading a UPS output)

41-7546/0213/CD 5 www.cdtechno.com

Quarterly Maintenance

The following checks should be completed

quarterly.

1. Assure the battery room is clean, free of

debris and well lighted.

2. Assure that all facility safety equipment is

available and functional.

3. Measure and record the air temperature

within the battery room.

4. Visually inspect the battery for:

a. cleanliness.

b. terminal damage or evidence of

heating.

c. container or cover damage.

d. evidence of overheating

5. Measure and record the battery system

DC float charging voltage at the battery.

Optionally measure and record the AC

ripple voltage at this time also.

6. Measure the DC voltage from each

polarity of the battery to ground to detect

any ground faults.

7. f possible, measure and record the battery

system DC and AC float charging current.

8. Measure and record the temperature of

the battery pilot unit. Measure the

temperature on the side of the unit in the

center or at the negative terminal of

the unit.

9. Measure and record the individual unit

DC float charging voltage.

10. Measure and record the System

Equalization Voltage.

emi-Annual Maintenance

1 Repeat the quarterly checks,

2. Optionally perform the 10 sec. high rate

(e.g. 100 amp) load test to assure the

individual batteries are functional.

3. Optionally perform the 10 sec. high rate

(e.g. 100 amp) load test to assure the

individual batteries are functional.

4. Optionally measure and record the

resistance/impedance/conductance of

the individual units to trend the condition of

the individual units over time and to detect

dramatic differences between individual

units and the norm.

Annual Maintenance

1. Repeat the semi-annual checks.

2. Retorque all the interunit connecting

hardware to the values noted in tables

listed in the Table of Contents.

This can be omitted if the connection

resistance is measured and found to have

not increased more than 20% from the

value at installation.

Bi-Annual Maintenance

The battery should be capacity tested every two

years at the service load or at the battery rating

related to the service requirements. deally, this

will be the same rate at which it was acceptance

tested when originally installed. Once the battery

is found to be at 85% of rating, it should be

capacity tested annually. Capacity testing instructions

are found in the bulletin "Acceptance and

Capacity Testing" #41-7135.

Data Analysis and Corrective Actions

The data accumulated during the periodic

maintenance activities should be recorded on a

form such as shown in Appendix One. Following is an

explanation of how the data would be interpreted

and the correction action to be taken. However, it

must be recognized that this explanation is not all

inclusive and the analysis and corrective action

decision must be made by personnel familiar with 10

Year VRLA batteries and their operation and

failure modes.

41-7546/0213/CD 6 www.cdtechno.com

Environment Ambient and

Battery Temperature

While the VRLA battery will function at extremes

of temperature, it is rated at 77°F (25°C) and the

ideal operating temperature range for the 10

Year VRLA battery is 70°F (21°C) to 80°F (27°C).

Operation at cooler temperatures will reduce the

anticipated standby operating time while

operation at warmer temperatures will detract

from the battery life and will increase the

potential of a thermal runaway condition.

The battery will experience a 50% reduction of

life for each 18°F (10°C) above 77°F (25°C).

High ambient room temperature should be corrected

through the use of appropriate ventilation and air

conditioning.

The VRLA battery should not be charged at

temperatures exceeding 122°F (50°C). A thermal

runaway condition could result.

The individual batteries within the string should

not exceed the ambient temperature by more

than 18°F (10°C). f the entire battery or individual

units temperatures are excessively high, the

respective units may be experiencing thermal

runaway. n this situation the charging current

should be terminated by disconnecting the

Charger/Rectifier and the cause of the situation

should be determined and corrected.

f thermal runaway has occurred, the battery

system should be capacity tested and replaced

if necessary.

Battery Visual Inspection

Container Cleanliness

t is important that the individual batteries be

clean and properly spaced. An accumulation

of dirt or dust and moisture on the covers can

produce a conductive path between the

terminals or to ground which could result in

short circuits or ground faults.

When batteries are cleaned, they should be on

open circuit. For cleaning, use a cloth moistened

in a solution of bicarbonate of soda and water.

Do not use cleaners of unknown solutions such

as window or glass cleaners and solvents. Use of

certain petroleum based cleaners will damage the

battery plastic containers and could cause them

to crack and craze.

Container and Cover Damage

Should a crack or other penetration of the

container or cover of a battery be noted, it should

be replaced. A crack in the container could allow

conductive electrolyte to wick from the battery and

create a ground fault. A ground fault could lead to

melting and burning of the container.

A hole in the cover, even without wicking of the

electrolyte, can also be a serious situation.

The hole will allow drying of the electrolyte in the

subject cell resulting in an eventual high resistance

and heating of the subject cell.

Containers which are severely swollen and

permanently deformed have been overheated and

experienced thermal runaway. Thermal runaway

will also cause the batteries to gas and dry out

and will damage the plates. n this case the entire

battery string should be replaced.

Terminals

Bent or otherwise damaged terminals can

produce high resistance connections or can

hide a fracture that could fuse open under load.

Batteries with damaged terminals should be

replaced.

f the protective grease at a termination has

melted and flowed onto the cover, it is an

indication that the connection has been hot and

this is, in all probability, the result of a loose or

high resistance connection. n this situation the

connection should be disassembled, inspected

for damage, cleaned and properly reassembled.

41-7546/0213/CD 7 www.cdtechno.com

Battery ystem Float

Charging Voltage

The recommended battery system float

charging voltage for the 10 Year VRLA

Batteries with a specific gravity of 1.280 to 1.300

is equal to the number of cells in the system

multiplied by the range of 2.25 to 2.30 volts per

cell at 77°F (25°C). For example, a string of 30

each 12 volt (6 cell) batteries should be float

charged within the range of 405 to 414 VDC

(180 cells x 2.25 v/c minimum and 180 cells x

2.30 v/c maximum) at 77°F (25°C).

When temperature extremes are encountered

the float charging voltage should be

temperature compensated. The temperature

compensation coefficient is -0.0028 v/c per

degree F (-0.005 v/c per degree C).

For example, if the battery normal temperature

is 90°F (13° above 77°F) the average float

charging voltage range should be reduced

0.036 v/c (13° x 0.0028 v/c per °F) to between

2.21 and 2.26 v/c. For a 180 cell battery this

would be 397.8 to 408.6 VDC. This will help

reduce the potential for thermal runaway at

elevated temperatures.

f the battery operates at cold temperatures,

for example 60°F (17° below 77°F), the charging

voltage can be increased to improve recharge time.

For example, the charging voltage range could

be increased by (17° x -0.0028 v/c per °F) or

0.048 v/c. The float voltage range would be

2.298 to 2.348 v/c. For the 180 cell string this

would be 413.6 to 422.6 VDC.

f the battery is undercharged for a period during

which there have been multiple discharges,

the battery will not fully recharge following each

discharge and it will provide progressively lower

capacity. This condition may be correctable with

an extended equalization charge (eg. 48 to 72

hours). However, if the situation has continued

for too long a time, irreversible sulfation of the

plates may have occurred and the battery may

have to be replaced.

Extended overcharging will cause excessive

float current, corrosion of the plate grids,

gassing and drying of the limited amount of electrolyte.

This constitutes premature aging of the battery

and loss of capacity.

Severe overcharging for extended periods can

induce a thermal runaway condition. This would

also necessitate replacement of the battery system.

While measuring the battery system DC float

charging voltage it may also be convenient to

measure the AC ripple voltage appearing across

the battery system. f the AC ripple voltage is a

sinusoidal waveform the maximum reading should

be less than 0.5% Vrms of the DC float voltage.

n the case of 180 cell string floating at 414 VDC,

this is 2.07 Vrms. When measuring the ripple with

an oscilloscope, the maximum p-p value should

be 1.5% of the float voltage or 6.2 Vp-p when

floating at 414 VDC.

Excessive AC ripple voltage across the battery

could cause gassing and heating of the battery

which would result in reduced life.

Battery ystem

Ground Fault Detection

f the rectifier used to charge the battery has a

ground fault detection capability, the indicator

should be observed to determine the safety of the

system. f a ground fault is indicated, it should be

isolated and corrected prior to further

maintenance on the battery system.

f the rectifier does not have a ground fault

detection circuit, use the digital voltmeter and

measure the voltage from each polarity of the

battery to ground (the grounded rack or cabinet).

A detected voltage would indicate a short or

leakage current from the battery to ground.

The approximate location of the cell with the

ground fault, from the battery system output terminal,

would be the measured voltage divided by the

average per cell charging voltage. For example,

if the measured voltage to ground was 135 VDC

and the charging voltage.

41-7546/0213/CD 8 www.cdtechno.com

was 2.25 v/c, the ground fault would be

approximately 60 cells (ten 12 volt units) from

the battery system output terminal.

Battery ystem

Float Charging Current

f the DC float current can be measured, it can

provide an indication of the proper current

acceptance of the battery system. Depending on

the charging voltage per string and the temperature,

the float current per string should be approximately

that shown in Figure 3. The float current will

approximately double for each 18°F (10°C)

above 77°F (25°C).

f the DC float current is zero there is an open

circuit in the battery string. f the float current is

higher than anticipated, it may be due to elevated

temperature of the battery or shorted cells within

the string. n either case the cause should be

determined and corrected. Elevated temperatures

and shorted cells are both situations which can

lead to thermal runaway.

Individual Battery

Float Charging Voltage

While the battery string may be charged at an

average of between 2.25 and 2.3 volts per cell,

ot all cells will float at the exact average voltage.

Each cell has a somewhat different impedance

and rate of oxygen recombination and will therefore

exhibit a slightly different float voltage at the

same float current. For example, all the 12 volt

batteries in a string charged at 2.3 volts per cell

will not float at 13.8 VDC but may vary from 13.3

to 14.5 and still be normal. f the system is equalized

for 24 hours upon installation, or after with an

extended time in float service, this spread in float

voltage will normally decrease.

Refer to table 1, Electrical Characteristics, for

each series battery as listed in the documents

noted in the table of contents, which lists the

minimum and maximum DC float voltages to be

measured across batteries in a series string. f an

individual battery measures too low, it may be an

indication of a shorted cell.

f an individual unit measures too high, it may be

an indication of increased resistance within the

cell. f one unit measures very high while the

balance of the units in the string indicate near the

open circuit value, the high voltage cell may have

an open circuit.

Shorted cells within the string will lead to

increased voltage applied to the remaining

good cells in the string and higher float current.

For example, a 24 cell string charging at 55.2

VDC (2.3 v/c) which has 2 shorted cells will be

charging the remaining 22 cells at 2.5 v/c

(55.2 VDC/22 cells) and the resulting increase

in float current is sure to result in eventual

thermal runaway.

A battery with a shorted or open cell can usually

be confirmed by comparing the impedance of the

individual units or by comparing the AC ripple

voltage measured across the individual units.

DO NOT perform a high rate load test on batteries

that are suspected of having a shorted or open

cell. This would be hazardous since a spark

internal to the cell could ignite the internal gases.

A battery suspected of having a shorted or open

cell should be removed and replaced immediately.

More information concerning the measurement

and interpretation of individual battery float

voltages is contained in the Technical Bulletin

" ntegrity Testing" #41-7264.

2.15 2.2 2.25 2.3 2.35 2.4 2.45 2.5

Milliampere Float Current Per Ampere Hour Capacity

Figure 3 - Float Current Vs. Voltage

Figure 3-Float Current Vs. Voltage

41-7546/0213/CD 9 www.cdtechno.com

High Rate Momentary Load Test

The high rate momentary load test is a functional

test of the individual battery within the series

string. t does not replace a capacity test but it

does indicate if the battery is functional at least

up to the ampere capability of the test load.

A typical load used for batteries in the 30 to 600

ampere range is 100 amperes. The voltage of

the unit 10 seconds after application of the test

load should be at least 1.7 v/c average (10.2,

5.1, 3.4,and 1.7 VDC) for 12, 6, 4 and 2 volt

batteries respectively) or the battery should be

suspected of being open, shorted, discharged or

of very high resistance and low capacity.

Never perform the high rate momentary load

test on a battery suspected of having a shorted

or open cell. Full face protection should always

be worn during this test, since a spark internal

to a cell could ignite the residual gasses within

the cell.

More information concerning this test and

the minimum voltages to be expected by part

number is contained in the Technical Bulletin

" ntegrity Testing" #41-7664.

Impedance Testing

The normal wear out mode of the VRLA

battery includes corrosion of the plate grids,

deterioration of the plate active material and

some drying of the electrolyte. Abnormal failure

modes would include deterioration of the

conductive path and excessive drying of the

electrolyte. These processes will all increase the

resistance of the affected cells and periodic

measurement of the impedance, resistance or

conductance of the cells and trending of this data

can indicate string uniform gradual degradation

and loss of capacity with time. This is shown in

Figure 4.

Rapid changes in individual units may indicate

shorted, open and drying cells and cells with

deteriorating conductive paths.

individual units in the string proportional to their

relative resistance. Therefore in the absence of

an impedance, resistance or conductance test

set, the AC ripple voltage across the individual

units can be measured with a DVM and compared

to each other and the norm as an indication of

their relative resistance and condition.

f the resistance of the batteries has increased by

30% over that when it was new, the battery

should be further tested to determine the cause

and if necessary the battery or system should be

capacity tested to assure reliability.

More information on this topic is contained in the

Technical Bulletin " mpedance and Conductance

Testing" #41-7271.

Interunit Connecting Resistance

High resistance in the interunit connections and

loose connecting hardware can cause excessive

voltage drop during discharge resulting in reduced

operating time and in the extreme case even

cause melting of the battery terminals and

potentially a fire.

The contacting surfaces of all connections should

be brushed clean, removing all lead oxide and

contamination, protected with a special

antioxidation grease, and tighten.

100

110

120

130

140

0102030405060708090100

% Original Value

% LIFE

100

0102030405060708090100

% rated capacity

Figure 4 - VRLA Battery mpedance and

Conductance Vs. Capacity and Age

When an AC ripple voltage appears across a

string of batteries it will be subdivided across the

41-7546/0213/CD 10 www.cdtechno.com

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