Installation & Maintenance Manual

Transcription

1 Product and Sales Enquiries EN-0b Within Australia tel 00 fax 00 New Zealand tel 00 fax 00 Head Office Enquiries - Cobalt St, Carole Pk, Qld 00. PO Box, Goodna 00 tel 00 fax 00 Installation & Maintenance Manual

2 contents Safety Precautions Product Warranty Safety Storage & Moving Batteries Installation Maintenance Diagnosis of Condition Battery Log 0 Disclaimer The information contained within this document has been derived from various competent sources and has been checked and authorised by Century Yuasa Batteries Pty Ltd. before publication. Whilst every care has been taken in the preparation of this document, Century Yuasa Batteries Pty Ltd shall not be held liable, either directly or in any consequential way, for acts or omissions by any party in the direct or indirect use of this information described herein.

3 precautions & warranty safety precautions Only personnel who have been trained in battery installation, charging and maintenance should be allowed to work on Enersun batteries. Servicing should be performed only by a competent service technician. Always follow the relevant Occupational Health & Safety regulations on handling batteries. Vented type lead acid batteries are considered to be hazardous according to the criteria established by Work Safe Australia. Refer to the Century Yuasa Batteries Material Safety Data Sheet (MSDS) for wet-lead acid batteries in order to understand the potential chemical hazards associated with lead acid batteries. product warranty Enersun SSR Century Yuasa Batteries Pty Ltd. warrants to the original user that Enersun SSR cells will be free from defects in material or workmanship for a period of three () years from the date of installation, provided that installation occurs within six months of date of shipment and cells have been used to manufacturer s specifications. Should Century Yuasa Batteries Pty Ltd. find any cells to be defective in materials or workmanship as described above, they will be repaired or replaced. Enersun SSDC Century Yuasa Batteries Pty Ltd. warrants to the original user that Enersun SSDC cells will be free from defects in materials or workmanship for a period of six () months from the date of purchase, when used to the manufacturer s specifications. Should Century Yuasa Batteries Pty Ltd. find any cells to be defective in materials or workmanship as described above, they will be repaired or replaced.

4 safety, storage & installation safety Recommended Safety Equipment General Safety Anti-electrostatic (cotton) Protective Clothing Anti-electrostatic Safety Footwear Safety Eyewear PVC Apron Rubber Gloves x 0ml single use eyewash bottles Soda Ash 0 litre Container Adequate ventilation must be provided in the battery enclosure or room, especially during recharge. Touching electrically conductive parts may result in an electric shock. Remove any loose metal objects on person such as pens, keys, metal watches and other relevant items prior to commencing work. If personal items such as wedding rings cannot be removed, they should be covered with gloves or other material to prevent accidental contact between them and live electrical parts of the system. A storage battery produces hydrogen and oxygen gases while on charge. Never place cigarettes, naked flames or sparks near batteries as this may cause an explosion. Appropriate signage must be installed. This needs to include the short circuit, amperage and voltage of the system. Spilled acid should be neutralised with bicarbonate of soda, soda ash, lime or other compatible neutralising agent. Ensure the area is well ventilated. Do not inhale the fumes. storage & moving batteries General Recommendations Store the battery in a cool and dry location. Ideally, the storage room temperature should be C ± C. Avoid direct sunlight and extreme temperature, such as near heating equipment. Batteries are heavy. Always practice correct handling procedures as recommended by NOHSC publications, National Standards for Manual Handling and National Code of Practice for Manual Handling All batteries should be stored under cover and on an impervious surface, away from sewer and storm water drains. Leaking or cracked batteries and / or cells must be adequately contained during storage and transportation. Always keep battery in upright position Do not allow foreign material into the battery cells. This will potentially reduce performance and the life of the battery. installation Bolt heads must be held while torquing/tightening the nut - Torque bolts to ± Nm Do not top up the cells with water upon receiving. Filling up should only be carried out after an equalising charge. Remove travel vent caps and replace them with float vent caps. Store the travel vent caps for future use in a clean plastic container. Use only distilled or de-ionised water suitable for battery for topping up. All battery installations in stand-alone power systems should comply with the relevant Australian Standards: a AS 0.() Secondary Batteries for use with stand-alone power systems: General Requirements b AS 0.() Secondary Batteries for use with Stand-alone power systems: Installation & Maintenance Do not lift batteries by the terminals. From a standing position, lifting loads over the -kg range should be avoided. Appropriate handling methods and / or apparatus should be employed. Safe electrical practices should be followed at all times, including the electrical isolation of components wherever applicable, and the use of suitably insulated tools.

5 maintenance maintenance It is strongly recommended that the Enersun Battery Log Book be used to keep record of the battery condition. This practice will ensure that the battery is kept in the best operating condition to maximise service life. The log book will also assist in determining warranty claims. Always record battery type, application, installation date, number of cells and date codes. Specific Gravity - Temperature Correction The specific gravity of the electrolyte varies with temperature. Any reading observed on a hydrometer must be corrected, as follows, to be meaningful. For each C by which the electrolyte temperature exceeds C, add 0. point (0.000) to the specific gravity as read on the hydrometer. Example: A hydrometer reading.0 S.G. at C is corrected for the specific gravity at C as follows:.0 + (-) x = =. S.G. Maintain Cells Fully Charged It is important that the cells are not permitted to remain in a discharged condition for a prolonged period of time, as damage may result. The cells must always be immediately recharged after a discharge With regard to floating voltage values and equalising charge settings, the specified values shall be taken only as a guide for normal duty. Specific settings depend on the application, duty cycle and working conditions. These factors have to be balanced to give optimum battery service life. Do not discharge cells below. VPC (0% DOD) as this will shorten service life and void the warranty. General Maintenance DO NOT LET ELECTROLYTE DROP BELOW THE SPECIFIED LEVEL, AS THE SERVICE LIFE WILL BE REDUCED. Clean the batteries with a clean damp cloth. Never allow the battery to be splashed or deposited with oils or organic solvents such as gasoline, paint thinner or paraffin, nor have it impregnated with these types of compounds. MAKE SURE VENT PLUGS ARE FIRMLY SECURED. Avoid dusting by cloth duster or cleaning with dry cloth (particularly chemical textile) as they will generate static electricity which can be dangerous. Touching electrically conductive parts may result in electric shock. Be sure to wear rubber gloves before inspection and maintenance work. If the battery has not received an equalising charge during the last month, give it an equalising charge following a routine charge regime. If after equalising charge the battery falls outside the recommended S.G for electrolyte, consult with the supplier of the battery. Measured Maintenance Monthly # -Months Total System Voltage Yes Yes Individual Cell(s) Voltage Pilot Only All Level of Electrolyte All All Specific Gravity of Cell(s) Pilot Only All Temperature of Cell(s) Pilot Only All Impedance Measurement of Cell(s) Pilot Only All Torque Connection(s) No All Visual Inspections Monthly # -Months Inter-Cell Connection(s) - Yes Inter-Tier Connection(s) - Yes Jar Condition - Yes Post / Terminal Condition* - Yes # This is recommended in the first couple of months that the batteries are installed * Make note of any build-up of corrosion, signs of cracking / heating and or stress. Electrical Specifications Specific C SSDC Range.0 to.0 SSR Range. to.0 Equalisation C Max Vdc Min Hrs SSDC Range.0 vpc Hours* SSR Range.0 vpc Hours* SSDC Range SSR Range Float C Max Vdc. vpc. vpc AMPS Battery Minimum Maximum SSDC SSDC SSR SSR SSR SSR SSR SSR -.0.0

6 diagnosis of condition diagnosis of condition a) Fault Finding/Trouble Shooting The following indicates a cell in a healthy, charged condition: Specific gravities all within the limits after temperature correction Float voltage correct Gassing from cells when switched to boost charge The following indicates a cell has been undercharged: Specific gravities low and irregular Float voltage low No gassing when the system is switched to boost charge An undercharged battery is caused by: Charge voltage and/or currents too low Insufficient boost charges (current or duration) Battery undersized for duty cycle Extra load added to system Faulty/wrong setting of regulator The following indicates a cell that has been overcharged: Specific gravities irregular Float voltage high Boost voltage high Excess gassing on float charge Low electrolyte levels Excessive water consumption An overcharged battery results from: Excessive periods of boost charge Too high charging rate Float voltage setting too high If there is evidence of undercharging or overcharging, then adjust the charge rates according to the cell type. State of Charge State of Charge diagnosis of condition State of Charge vs Specific Gravity SSDC batteries 00% 0% 0% 0% 0% 0% 0% 0% % State of Charge State of Charge vs Specific Gravity SSR batteries 00% 0% 0% 0% 0% 0% Specific gravity 0% 0% % State of Charge Specific gravity 0

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