SECUPS系列电池安装和操作手册

第1节-一般信息

1.1 CELLYTE 6-12 UPS电池特性

CELLYTE 6-12 UPS电池是一种高倍率阀控式铅酸蓄电池

专为固定应用而设计。6-12 UPS电池使用吸收式玻璃垫（AGM）

技术。这种类型的电池没有特殊的通风或处理要求。因为

蓄电池中的电解液被固定，蓄电池被认为是干电池，可以

进行相应的处理和装运。

第2节-安全信息

2.1一般信息

铅酸蓄电池在安装和维护时需要小心。不安全安装或

维护程序可能导致重伤或死亡。电击或烧伤、酸烧伤

如果不采取适当的安全预防措施，可能导致火灾。

以下注意事项适用于所有蓄电池安装和维护工作。更多

有关详细信息，请参阅以下部分。

-在尝试安装、拆卸或执行维护工作之前，请断开所有电源。

充电时必须测量浮充电压，尤其要小心，因为短路

此时的电池不仅会造成人身伤害，还会导致严重的设备故障。

-不要损坏电池的任何部件，包括盖子、通风口、端子盖等。

-保持电池清洁干燥。使用½ 在4升水中加入1公斤小苏打，以中和

可能是酸。不要在电池的任何部位使用清洁剂或溶剂。不允许过度

灰尘积聚在电池或电缆上。

-保持蓄电池接头清洁、润滑和紧固。连接松动会减少

电池待机时间，导致电池起火。

2.2硫酸

CELLYTE 6-12 UPS电池组是一种铅酸电池，含有稀硫酸。

因为电解液是固定的，一旦发生破裂，液体酸不会泄漏或流动

从电池上。但是，如果触摸或处理电池的内部部件，

会与酸接触。

注意：如果硫酸与皮肤接触，会导致烧伤和严重伤害

或者眼睛。如果与硫酸接触，用水彻底冲洗并中和

任何残留酸与小苏打（1/2kg在4升水）。就医

马上。不要处理掉下来的电池或放在容器里的电池

破裂除了戴橡胶手套。不要试图拆卸电池。

2.3放气

所有的铅酸蓄电池在充电和浮充过程中都会释放一些气体。传统的

充满水的电池释放所有产生的气体到环境中，而阀门调节

电池将大部分气体在内部重新组合，很少释放到环境中。

与同等容量的浸没式电池相比，CELLYTE 6-12 UPS电池组释放出

气体体积小于或等于充满电池的1%。因为这个特点，没有什么特别的

正常使用条件下需要通风。

因为铅酸蓄电池会释放一些气体，所以不要在紧急情况下充电或使用蓄电池

不通风的空间或容器。这种气体主要由氢气组成，如果发生爆炸，就会爆炸

在狭窄的区域或空间里点燃的。保持火花、火焰或任何其他点火源（包括

吸烟材料）远离电池。

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小心：氢气可能爆炸，造成重伤和火灾。不允许有任何火焰

或靠近电池的点火源。始终在工作电池周围保持通风；

如果有任何关于排气或通风的问题，请联系SEC。

2.4触电

电池储存大量电能。即使是已放电的电池也能提供高电压

短路电流。使所有金属物体远离蓄电池端子。多单元系统

可以达到致命的电压。在对电池进行操作之前，请取出所有首饰。将所有工具盖上

乙烯基电气胶带，以尽量减少安装过程中对蓄电池短路的可能性。从不说谎

电池上的工具或其他金属物体。不允许在蓄电池上进行施工作业

除非用绝缘橡胶垫保护蓄电池，否则继续操作。

注意：短接蓄电池可能导致重伤、火灾或爆炸。不要试图工作

除非您熟悉电池安装程序并有足够的

安全信息和设备。在尝试安装前，请仔细阅读本手册

电池。如果对安全性有任何疑问，请在安装电池之前联系SEC。

安全始终是首要问题。

第3节-设备接收

3.1出厂检验

交货后，立即检查电池在运输过程中是否损坏。托盘损坏

或包装材料或杂乱无章的电池可能表明运输过程中处理粗暴、不当。

详细描述交货收据上的任何损坏（必要时拍照）

签字前。如果发现任何损坏，请立即联系承运人，请求检查

Section 1 - General information

1.1 CELLYTE 6-12 UPS battery characteristics

The CELLYTE 6-12 UPS Bloc battery is a high rate valve-regulated lead-acid recombinant battery

designed for stationary applications. The 6-12 UPS battery uses Absorbed Glass Mat (AGM)

technology. This type of battery has no special ventilation or handling requirements. Because

the electrolyte in the battery is immobilised, the batteries are considered dry batteries and can

be handled and shipped accordingly.

Section 2 - Safety information

2.1 General information

Lead acid batteries require care in installation and maintenance. Unsafe installation or

maintenance procedures can cause severe injury or death. Electrical shock or burns, acid burns

and fire can result if proper safety precautions are not followed.

The following precautions apply to all battery installation and maintenance work. For more

information, see the following sections.

- Disconnect all power before attempting to install, remove or perform maintenance work.

When on-charge float voltages must be measured, be particularly careful because shorting a

battery at this time can cause not only personal injury, but severe equipment failure as well.

- Do not tamper with any parts of the battery including cover, vents, terminal covers, etc.

- Keep batteries clean and dry. Use ½ kg of baking soda in 4 liters of water to neutralise any

possible acid. Do not use cleaners or solvents on any part of the battery. Do not allow excessive

dust to accumulate on the battery or cabling.

- Keep battery connectors clean, greased and tight. A loose connection can reduce

battery standby time and cause battery fires.

2.2 Sulphuric Acid

The CELLYTE 6-12 UPS Bloc is a lead acid battery and contains sulphuric acid in diluted form.

Because the electrolyte is immobilised, in the event of case rupture, no liquid acid will leak or run

from the battery. However, if the internal components of the battery are touched or handled,

contact with the acid will result.

CAUTION: Sulphuric acid can cause burns and serious injury if it comes in contact with your skin

or eyes. In the event of contact with Sulphuric acid, flush thoroughly with water and neutralise

any residual acid with baking soda (1/2kg in 4 liters of water). Seek medical attention

immediately. Do not handle batteries that have been dropped or where the container has been

ruptured except while wearing rubber gloves. Do not try to disassemble a battery.

2.3 Gassing

All lead acid batteries emit some gases during charging and float operation. Conventional

flooded batteries release all the gases produced to the environment whereas valve-regulated

batteries re-combines most of the gases internally, releasing very little to the environment.

Compared to a flooded battery of equal capacity, a CELLYTE 6-12 UPS Bloc battery releases a

gas volume of 1% or less than the flooded battery. Because of this characteristic, no special

ventilation is required under normal usage conditions.

Because some gas is released from lead acid batteries, never charge or use batteries in an

unventilated space or container. This gas consists of mostly hydrogen gas and can explode if

ignited in a confined area or space. Keep sparks, flame, or any other ignition source (including

smoking materials) away from batteries.

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CAUTION: Hydrogen gas can explode and cause serious injuries and fire. Do not allow any flame

or ignition source near batteries. Always allow some ventilation around operating batteries;

contact SEC if there are any questions regarding gassing or ventilation.

2.4 Electrical shock

Batteries store large amounts of electrical energy. Even a discharged battery can deliver a high

short circuit current. Keep all metallic objects away from the battery terminals. Multi-cell systems

can attain lethal voltages. Remove all jewelry before working on batteries. Cover all tools with

vinyl electrical tape to minimize the possibility of shorting a battery during installation. Never lay

tools or other metallic objects on batteries. Do not allow construction work over batteries to

proceed unless the battery is protected by insulating rubber mats.

CAUTION: Shorting a battery can cause serious injury, fire or explosion. Do not attempt to work

on a battery unless you are familiar with battery installation procedures and have adequate

safety information and equipment. Read this manual thoroughly before attempting to install the

battery. If there are any questions about safety, contact SEC before installing the batteries.

SAFETY is always the primary concern.

Section 3 - Receipt of equipment

3.1 Delivery inspection

Immediately upon delivery, inspect the batteries for damage caused in transit. Damaged pallets

or packing material or disarrayed batteries could indicate rough, improper handling in transit.

Describe in detail (and take photographs if necessary) any damage on the delivery receipt

before signature. If any damage is found, contact the carrier immediately, request an inspection,

and file damage claim.

3.2 Hidden damage

Within 10 days of receipt, inspect all batteries for hidden damage. Measure and record open

circuit voltages (OCV's). If any damage is found, request an inspection by the carrier and file a

hidden damage claim. Do not delay this step as it may result in a loss of right of reimbursement

for hidden damages.

Section 4 - Storage

4.1 General

Do not store batteries outside, exposed to the elements. Store indoors in a cool, dry location. Do

not store batteries in temperatures over 30ºC. The recommended storage temperature is 25ºC

or less. Do not stack pallets or allow any other material to be stored on top of the pallets or

possible battery damage may occur. Do not store where the possibility of metallic objects falling

on the battery may occur.

4.2 Short term storage

If the batteries are to be stored for 6 months or less at 25ºC, before being put into service, nothing

need be done at this time. If the batteries are to be stored for longer than 6 months, at

temperatures greater than 25ºC, or installation is delayed beyond expected time, a storage

charge may be required. A storage charge is an equalisation charge applied to a battery that

is stored in open circuit (not float charging) condition.

See Section 6.5 for details.

If the storage temperature is 25ºC or less, CELLYTE 6-12 UPS Bloc batteries must be charged at

least every 6 months while in storage. For every 8ºC increase above 25ºC, the storage time

between charges is cut in half. Therefore at 33ºC the maximum storage time is 3 months. At 30ºC

the maximum storage time would be 4 to 5 months.

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Storage of batteries beyond the recommended temperatures or storage time without charging,

can result in loss of capacity, cell shorting and loss of float life. It can also void the battery's

warranty. Keep careful records of battery storage time and handling.

Section 5 - General installation procedures

CAUTION: Before attempting to install CELLYTE 6-12 UPS Bloc batteries study this section and the

section on safety thoroughly. Failure to do so could result in personal injury and battery or

equipment damage.

5.1 Battery location

5.1.1 Temperature

Battery location is very important in determining life and performance of the battery. The ideal

environment would be a dry, indoors, temperature regulated area. The ideal operational

temperature is 25ºC. Operation at temperatures below this will result in a loss of battery

performance and may result in a larger, more costly battery being needed. Operation at

temperatures above 25ºC will result in loss of battery operation life. For every 8ºC rise in battery

temperature above 25 ºC, the life of the battery will be cut in half. For example, the CELLYTE 6-

12 UPS Bloc battery with catalyst is designed for a 10 year float service life at 25ºC.

5.1.2 Temperature variation

Maintaining temperature balance across the string is very important for maximum battery life.

The difference between the maximum and minimum block temperature in a series string can be

no more than 3ºC. Excessive temperature variation will result in the need for equalisation and will

shorten battery life.

Sources of battery temperature variation can be placement of the battery system near a heat

source such as radiators, power equipment, windows or heating vents. Air conditioning vents

can also cause temperature variations. It is recommended that the battery location be designed,

engineered and monitored to minimize temperature variations.

5.1.3 Ventilation

Proper ventilation of CELLYTE 6-12 UPS Bloc batteries is important for two reasons:

(1) to minimize battery temperature variations and

(2) to minimize buildup of potentially explosive hydrogen gas.

5.1.3.1 Ventilation & battery temperature variation

Recombinant batteries such as CELLYTE 6-12 UPS Bloc batteries give off a small amount of heat

during charging and float operations. Proper ventilation is important to remove this heat and to

prevent temperature differences from arising in the string. If the batteries are installed in a

cabinet, it should be designed to allow unobstructed air circulation and prevent temperature

build-up. Use angle iron support rails instead of shelves. If the batteries are on racks, sufficient air

circulation should be present to prevent temperature-layering effects. In an improperly designed

room, there can easily be a 5ºC difference in temperature between the floor and the ceiling. If

this difference exists in a series string, it will result in a need for equalisation and in reduced battery

life.

5.1.3.2 Ventilation and gassing

As noted, lead acid batteries emit small amounts of gas during normal charging and floating.

The gas composition while on float is approximately 80% by volume hydrogen with the remainder

being oxygen.

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CAUTION: Hydrogen gas can be explosive. Never install batteries in an airtight enclosure.

Ventilation must be provided to remove this hydrogen gas. Allow about 1 liter per hour per

battery of air exchange to prevent hydrogen accumulation.

NOTE: In most cases, the amount of air circulation required for battery cooling and temperature

variation maintenance will far exceed the amount of air circulation required to prevent gas

build-up. However, ensure some air exchange is present in the ventilation.

5.1.4 Floor loading

Before installing the batteries, it should be ascertained that the floor has the capability to support

the weight of the battery, rack or cabinet and related equipment. The total system weight will

be the sum of the batteries, rack or cabinet plus 5% for the battery connectors. It is the

responsibility of the installer to ensure adequate floor load carrying capabilities.

5.2 Seismic considerations.

CELLYTE 6-12 UPS Bloc batteries are capable of withstanding seismic events of UBC Zone 4

magnitude when properly installed in a suitably designed cabinet or rack. When seismic

capability is desired, suitable floor anchoring should be provided. Proper floor anchoring is the

responsibility of the installer.

5.3 Installation - cabinets

When installing CELLYTE 6-12 UPS Bloc batteries in cabinets, follow the recommendations of

Section 5.1.3.1 regarding cabinet ventilation. Ensure that the batteries are electrically insulated

from the cabinet frame. Standard battery spacing is 12 mm minimum between battery blocks. If

the cabinets are to be seismic rated, the batteries must be firmly strapped or otherwise attached

to the cabinet to prevent battery shifting during a seismic event. Proper installation is the

responsibility of the installer.

5.4 Installation - racks.

5.4.1 Existing racks

When CELLYTE 6-12 UPS Bloc batteries are to be installed on existing racks, ensure that the racks

are:

1. of proper size for the intended battery;

2. have sufficient weight carrying capability for the intended battery, including seismic

considerations, and of sufficient size to hold the number of blocks (plus the 12 mm needed

between blocks) for the complete system. Before the new batteries are installed, touch up any

nicks, scratches or acid marks on the rack with the paint provided by the manufacturer. Ensure

that the rail insulators are in good condition or replace. Check that the rack is level and re-level

if necessary. Check the floor anchors and re-torque all bolts of the rack to manufacturer's

specifications.

5.4.2 New racks

Assemble the rack according to the manufacturer's instructions. Ensure that the rack is level and

all bolts are properly torqued.

5.4.3 Installation

Determine the location of the positive and negative terminals of the battery with respect to the

rack location. When placing batteries on the rack, alternate the polarities for proper inter-cell

connection. Standard spacing between blocks is 12 mm, Position the batteries on the rack. Do

not drop.

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5.5 Electrical connections

Proper battery electrical connections are very important for the best battery performance and

utility. Improper battery connections can cause a loss of standby time or even a battery fire.

Follow the electrical connection instructions carefully and review Section 2.4 thoroughly before

working on the battery.

CAUTION: Remove all rings and watches before installing the connectors on the batteries. Ensure

that all tools are insulated with vinyl electrical tape to prevent shorting. Do not reach or lean

across batteries on step racks. Remember, hazardous voltages are present. Be aware of what

you are touching at all times.

5.5.1 Cable recommendations

User can take NEC table 110.14(C) as reference, which is a clear indication of the maximum

current allowed to pass through a wire with a particular cross sectional area.

Battery ratings are specified at the terminals of the battery. The cabling used to connect the

battery terminals to the load has a voltage drop (when the battery is discharging) that is

dependent on cable length and conductor size. The longer the cable run, the greater the

voltage drop. The smaller the cable wire diameter, the greater the voltage drop. Therefore, to

get the best performance from the battery, short, heavy cables are recommended. Do not size

the cables based on current carrying capacity only. A general rule of thumb is to allow no more

than a 30 mV of voltage drop per meter of cable run. As an example, if it is 10 meters from the

battery to the load, the cable should be sized to allow no more than 2 x 10 x .030 = 0.6 volt drop.

Inter-block cables are provided. In order to help select cable sizes for inter-tier and load

connections, the following table should be consulted:

CABLE PROPERTIES AT 20ºC U.S. CABLE AREA MAX. AMPS

SIZE AWG mm² 30mv DROP/M

8 8.4 15

6 13.3 23

4 21.2 37

2 33.6 59

1 42.4 74

0 53.5 93

00 67.4 117

000 85.0 148

0000 107.2 187

250 MCM 126.7 221

350 MCM 177.4 309

400 MCM 202.4 353

Use 1.74 amps/mm² for other cable sizes.

5.5.2 Terminal preparation

Gently clean the contact surface of the terminals with a brass bristle brush or a Scotch Brite pad.

Immediately after this cleaning, apply a thin layer of No-Ox-Id "A" or NCP-2 antioxidant grease

to the contact areas. A petroleum jelly such as "Vaseline" may also be used.

5.5.3 Connector installation

The CELLYTE 6-12 UPS Bloc batteries are supplied with hardware to attach the copper

interconnects or cables. Install the cables (positive of one battery to negative of the next) and

the hardware. Hand tighten only at this time to allow room for positioning of the blocks. Once all

cables are in place, all connections should be torqued to the values below:

12 UPS 100 to 110 5.1 N-m (45 in pound)

12 UPS 160 to 400 7.4 N-m (65 in -pounds)

6 UPS 645 /12 UPS 480 to 540 11.4 N-m (100 in.-pounds))

Do not over-torque.

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CAUTION: Use extreme care not to short the battery connections. CELLYTE 6-12 UPS Bloc batteries

are capable of very high short circuit currents containing a very high energy level.

Install the inter-tier cabling at this time, following the same general instructions as for installing the

inter-block connections. Attach the inter-tier cabling to the wall or the rack so that the weight of

the cable is not on the battery terminal. If using a stiff cable, pre-bend the cable so no 'spring'

force is placed on the battery terminals. Failure to support the cable weight could result in a

premature battery failure and loss of battery integrity.

5.5.4 Voltage checks

Visually check that all connections are properly made (positive to negative) and are tight.

Measure the total string voltage.

CAUTION: High voltage present.

The total string voltage should be approximately 12.5 volts or 6.25 volts for 6 volt, batteries,

multiplied by the number of blocks in the string. If the measured string voltage is not close to the

calculated value, recheck the battery connections to ensure proper polarity sequence and

measure the individual block voltages. Calculate the average bloc voltage and use this value

to refigure the string voltage. If the recalculated and measured string voltages do not match

reasonably well, contact your SEC representative for further instructions.

5.5.5 Battery to charger connection

Ensure that the charger is disconnected from the power line. If a battery disconnect is installed,

open it. The positive terminal of the battery bank should be connected to the positive terminal

of the charger and the negative terminal of the battery bank should be connected to the

negative terminal of the charger.

5.5.6 Paralleling of batteries

When greater battery capacity is desired than what is available from a single cell or string,

paralleling of batteries becomes necessary. Batteries must be properly paralleled in order to get

the best system performance and longest battery life. SEC recommends that no more than four

(4) strings of batteries be connected in parallel. The battery strings must be treated as equally as

possible. This means equal length cabling to a common collection point for the load cables,

uniform temperature between the strings and equal strings of batteries. Do not parallel flooded

batteries with valve-regulated batteries as the charge voltages differ between the types of

batteries.

To check the proper paralleling of the strings, connect the strings in the final form and place a

load on the battery. Measure the load cable voltage drops. The voltage drops should match

within 10%.

Section 6 - Operation

6.1 Initial Charge

SEC recommends that 12 UPS batteries be given an initial charge / equalisation charge at the

time of installation in order to ensure that the batteries are fully charged and the bloc voltages

are uniform. If an initial charge is not given at the time of installation then block float voltages

may take some months to become uniform. The initial or equalise charge voltage for the CELLYTE

12 UPS Bloc battery is 2.40 volts per cell at 25ºC. Calculate the initial charge voltage for your

installation based on either the number of cells in the string or the number of blocks in the string.

Turn on the charger and raise the charger output voltage (using the equalisation control) to the

calculated value. Leave the string charging at this level for 24 hours. At the end of this time,

reduce the charger output voltage to the float voltage level. See Section 6.2. Just prior to

reducing the string voltage to the float voltage, measure the block voltages and charge current

if possible.

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If the charger output cannot be raised to the calculated initial charge voltage or the load

cannot tolerate a charge voltage this high, raise the charger output voltage to the maximum

permissible level.

At voltages below 2.29 VPC adequate equalisation will not be obtained. Contact your SEC

representative for additional details on procedures to equalise a battery under these conditions.

If the ambient temperature is not 25ºC, the initial charge voltage will have to be temperature

compensated (TC). TC is the process whereby the charge voltage is changed as the function of

the battery temperature. The temperature correction factor (TCF) for CELLYTE 6-12 UPS Bloc

batteries is -0.005 volts / cell / ºC from a 25ºC baseline temperature. As the battery temperature

rises (falls) above (beneath) 25ºC, the charge voltage must be reduced (raised) the TCF amount

for every degree of change. The formula to calculate the temperature corrected voltage is:

TCV = CV (25ºC) + [T-25 ºC] x (-0.005 v/c)

As an example, if the initial charge were going to be performed at 30ºC the temperature

corrected, reduced, charge voltage would be:

TCV = 2.40 + (30-25) x (-0.005 v/c) = 2.375 vpc

6.2 Float voltage

The float voltage is sometimes known as the continuous charge voltage. It is very important that

it be calculated and set properly for maximum battery life and performance. The purpose of the

float voltage is to provide enough float voltage and current to the battery to compensate for

the battery self-discharge and maintain the battery in a fully charged condition of readiness.

Failure to properly follow float voltage recommendations can result in loss of warranty and

premature battery failure.

6.2.1 Float voltage requirement

The recommended float voltage for the CELLYTE 6-12 UPS Bloc batteries is 2.25 – 2.30 +/- 1% volt

/cell at 25ºC.

6.2.2 Float voltage temperature compensation

The float voltage temperature compensation factor is: -0.003 volts per cell per ºC from at 25ºC

baseline. For other temperatures use the following table.

Temperature (ºC) Float Charge V/C

10 2.295

15 2.280

20 2.265

25 Baseline 2.250

30 2.235

35 2.220

For temperature outside of this range, see below formula to calculate to float voltage.

FV = FV (25ºC) + [T-25 ºC] x (-0.003 v/ºC)

6.3 Maximum charge current

The charge current is normally limited by using the recommended float voltage. At higher charge

voltage the maximum charge current should be limited to prevent the possibility of charging the

batteries at a higher rate than they can efficiently accept. Greater than recommended

maximum charge currents can result in excessive battery heating and gassing and a shortened

battery life.

For the maximum charging current of a model, please find the dimension table in the catalog.

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6.4 Recharge

Recharge batteries immediately or as soon as possible after a discharge. Do not wait more than

24 hours to initiate the recharge after the batteries have been discharged. Failure to follow this

recommendation could result in a permanent loss of capacity due to plate sulphation. The

approximate recharge time can be calculated as follows:

Charge Time Hr = F x (

AH discharged

Available charge current)

where F = 3 if the batteries are charged at the float voltage and F = 2 if an equalisation voltage

is needed.

Do not exceed the maximum charge currents listed in Section 6.3.

6.5 Equalisation charge

The equalisation charge voltage of the CELLYTE 6-12 UPS Bloc battery is 2.40 Vpc at 25°C. While

equalisation is not required under normal operating conditions, it is possible to operate the

battery in such a way that equalisation would be needed. These conditions would include:

- Temperature variation in the string greater than 3ºC

- Low float voltage

- Low operational temperature without temperature compensation

- Frequent deep discharges

- Rapid recharge required

- Long delay in recharging the battery after a discharge

- Unevenly paralleled string balance

Equalisation should be performed on an 'as needed' basis. The standard equalisation would be

24 hours at a constant voltage of 2.400 vpc at 25ºC. For equalisation at voltages and

temperatures other than the above, see Section 6.1 for methods to compensate.

Section 7 - Storage

When installed CELLYTE 6-12 UPS Bloc batteries will not be used (floated) for a period of time, the

following procedure should be followed:

1. Equalise charge the battery (refer to Section 6.5).

2. Disconnect the battery from all loads. Do not allow any loads, no matter how small, to

remain connected.

3. Equalise charge the battery every 6 months when the storage temperature is 20ºC or less.

For every 8ºC rise in storage temperature, reduce the storage/equalisation interval by half.

4. Perform an equalisation charge on the battery prior to returning to service. During the

storage time, particularly if it is extended, it is recommended to continue to monitor and record

battery voltage levels. Measure and record the battery open circuit voltage just before

equalisation and then record the on-charge voltage and current just prior to completing the

charge. Refer to Section 4.0 for more information.

Section 8.0 - Maintenance and record keeping

Maintenance and record keeping is critical to battery life and warranty continuance. Proper

maintenance will ensure that the batteries are being correctly used and will be available when

needed. Proper record keeping will ensure that, if there is a problem with a battery, the customer

can demonstrate the batteries were correctly used and so maintain the warranty.

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8.1 General maintenance

General maintenance of the battery means keeping the battery and surrounding area clean

and dry.

Since CELLYTE 6-12 UPS Bloc batteries are of low maintenance design, there is no addition of

water or specific gravity checks needed for the life of the battery. The only required

maintenance action is an annual re-torque of the battery connections; see Table 1 in Section

5.5.1 for re-torque values. Review Section 2.4 on Electrical Shock before performing this action.

CAUTION: Use only insulated tools.

Do not use any solvents or strong cleaners on or around the batteries. A dry brush may be used

to remove any dust accumulations. If required, a solution of 1 kg of baking soda in 4 liters of water

may be used as a multipurpose cleaner if more stubborn stains or dirt accumulations are present.

Follow the rack or cabinet manufacturer's instructions for maintenance if required.

8.2 General records

8.2.1 Installation records

When the battery is first received, record:

- Date of receipt,

- Condition of the battery blocs,

- Open circuit voltage of each bloc

- Date of installation

- Original P.O. number

- Installer (s)

- Equalisation time and voltage

- Any unusual storage conditions.

- Individual block float voltages,

- Ambient temperature,

- Float current,

- Battery temperature,

- String float voltage.

8.2.2 Maintenance records

Twice per year, record the following:

- Block float voltages

- String voltage

- Float current

- Ambient temperature

- Battery temperature

- Battery conditions

- Any unusual charges or discharges - last 6 months.

Keep the above records in a safe place for review by maintenance personnel. Remember, these

records are mandatory for any warranty claim on the battery.

Section 9 - Capacity testing

9.1 General

Discharge testing of the battery is performed to determine the battery capacity. There are two

reasons for performing this test:

(1) A ratings test discharge - the intention here is to determine the percent of battery capacity

as compared to the rated capacity. This is typically an 8 hour discharge test.

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(2) A service test discharge - this test is to determine the battery standby time under the ac

UPSl load conditions of intended battery usage.

The ratings test discharge is usually performed using a suitably designed and sized load bank to

provide a constant DC current load to the battery. The test is performed for the specified period

of time to an end-point voltage per cell (usually 1.67 - 1.80 vpc) with the ampere hour capacity

of the battery calculated by multiplying the load current by the number of hours of run time. The

ac UPSl AH capacity can be compared to the rated AH capacity to determine percentage

capacity. This type of test is usually used as an acceptance test of the battery.

The service test is usually performed by placing the ac UPSl load on the battery and determining

the ac UPSl time the battery will support the load. This test is done, in the case of a UPS, by

switching into a test mode where the battery becomes the primary source and the normal AC

line becomes the back-up. If the load is not critical, the AC input can simply be shut off to

simulate a loss of power event and total system operation can be verified as well. A load bank

can be used if the normal battery load is well defined.

9.2 Test procedure

The battery test procedure for either test is:

(1) Ensure the battery is fully charged before capacity testing and that all connections are

clean and tight. If the battery has not been on float for at least one week, perform an

equalisation charge, return the battery to float charge and allow at least 1 hour to stabilise.

(2) Prepare the load bank or test load system. Ensure all temporary cable connections are

secure and connected to the proper polarity and have sufficient current carrying capacity.

(3) Determine the battery temperature by measuring and recording the temperature of every

6 blocs. Average the readings to determine average battery temperature. Measure the battery

temperature in the middle of the side (preferably) or the end wall of the container.

(4) If a ratings test is being performed, the load current or power must be temperature

corrected if the battery temperature is significantly different from 25ºC. The formula for

calculating corrected load is: Temperature corrected load = load at 25ºC x CF, where CF is the

capacity Correction Factor for temperature. The following table should be used:

Test Temperature Capacity Correction

(ºC) Factor (CF)

0 0.73

5 0.81

10 0.86

15 0.94

20 0.97

25 1.00

30 1.02

35 1.04

If the service test is being performed, no temperature correction is necessary.

(5) Just prior to starting the discharge test, measure and record the individual bloc voltages,

the string voltage and float current (if available).

(6) Remove or disconnect the charger from the battery string.

(7) Connect the load to the battery and start a timer. Monitor the string voltage and record

the lowest voltage reached and the time reached (this is called the coup de fouet and is

indicative of a fully charged battery).

(8) Record the load current, string and individual cell voltages on a regular basis. A minimum

of three sets of readings should be taken. The time interval between sets of readings will vary

based on the expected test time. For example, take readings every hour for the first 4 hours of

an 8 hour rating test. For the following 3 hours take readings every ½ hour. For the last hour, take 

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readings every 15 minutes. For a 15 minute UPS discharge, readings every 1 to 3 minutes would

be desirable.

(9) Continue the discharge until the string voltage drops below the end-point voltage per cell

times the number of cells in the string. For example:

1.75 Vpc x 60 cells = 105.0 Volts is the stop discharge

(10) Stop the timer and remove the load from the battery.

(11) Recharge the battery using the existing charger or an external charger. An equalise

voltage may be used to reduce charge time.

(12) Record the discharge time and calculate % capacity if a ratings test was performed.

(13) Keep a copy of all the test data with the battery records.

9.3 Discharge test notes:

(1) . CELLYTE Bloc 6-12 UPS batteries are shipped at 95% capacity. Full capacity will be achieved

after a few cycles.

(2) String voltage should be measured at the battery terminals, not at the load connections.

(3) Accurate meters are essential for correct test results. Ensure that all meters, shunts, etc., are

properly calibrated before use.

(4) If a long duration test is being performed, the terminal-to-terminal voltage drop across the

inter cell connections should be measured and recorded. This will serve as a reference for any

needed terminal maintenance work and will assist in verifying the battery integrity.

(5) A float voltage check after the test and recharge is recommended.