pwl – general instructions for operations personnel€¦ · for the purposes of this document a...

PWL – General Instructions for Operations Personnel

GS Yuasa Energy Solutions, Inc.



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CONTENTS

Section Page

1. PURPOSE...............................................................................................32. PWL SERIES...........................................................................................33. COMPANY INFORMATION....................................................................44. CERTIFICATIONS.....................................................................................45. SAFETY AND HANDLING........................................................................56. EQUIPMENT FOR INSTALLATION AND REMOVAL.................................67. TRANSPORTATION.................................................................................68. DELIVERY INSPECTION..........................................................................69. STORAGE................................................................................................7 Table 9.0-A. Storage Period Based on Temperature............................7 Table 9.0-B. Typical Out-of-Box Conductance Values..........................710. CHARGING.............................................................................................8 Table 10.0-A. Maximum Recommended Recharge Current.................811. INSTALLATION CONSIDERATIONS.........................................................9 Table 11.0-A. Typical Conductance Reference Values..........................9 Table 11.0-B. Torque Specifications....................................................11 Table 11.0-C. Float and Temperature Compensation.........................1112. MAINTENANCE AND REPLACEMENT..................................................12 12.1 ROUTINE MAINTENANCE.........................................................12 12.2 END OF LIFE..............................................................................12

13. DISPOSAL.............................................................................................12



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1. PURPOSEThisdocumentisissuedtoprovidegeneralinformationrelatingtothisspecificproductlineforinstallationandmain-tenancepersonnel.Forthepurposesofthisdocumenta12Vblocorbatterywillbereferredtoasamodule.

2. PWL SERIESThePWLseriesisspeciallydesignedfortelecommunicationsapplications.ThePWLseriesispartofanextensivelineofmaintenancefree,gasrecombinantVRLAbatteriesofferedbyGSYuasaEnergySolutions,Inc.The13-yeardesignlifePWListhemostcost-effectivebatterysolutionoverthetotallifecycleforinstallationinyournetwork.



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3. COMPANY INFORMATIONGSYuasaEnergySolutions,Inc.isaU.S.subsidiaryofGSYuasaCorporationofJapan.Theparentcompany,GSYuasaCorporationisaglobalsupplierofhighquality,longlifeValveRegulatedLeadAcidbatteries(VRLA)batteriesaswellasmanyothertypesofleadacidbatteriesandotherbatterychemistries.GSYuasaistheworldleaderinmotorcycleandstandbystoragebatteriesprovidingsolutions forpowersports, telecommunications,UPS, renewableenergy,andemergencylighting.OfficesareinRoswell,Georgia,located25milesNorthofAtlanta,Georgia.

Officehoursare8:00AMET–5:00PMEasternTimeMondaythroughFriday.Themailingaddressandcontactinfor-mationarebelow.Fortechnicalsupport,customerserviceorassistancewiththisoranyotherGYESproduct:Call: 866-472-2879Email: [email protected]

GS Yuasa Energy Solutions, Inc.1150NorthmeadowParkway,Suite110Roswell,GA30076

Phone:678-762-4818Fax:678-739-2133www.gsyuasa-es.com

4. CERTIFICATIONSBatteriesareUL1989listed,GR-4228compliant,VerizonTPR-9802compliant,andNEBScertified.SpecifictechnicalquestionsregardingcertificationsmaybereferredtoourEngineeringDepartment.Call866-472-2879oremailcustomerservice@gsyuasa-es.com.

• NEBSCertified• GR-4228-CORE• GR-1089• GR-63• VerizonTPR-9802• UL1989Listed• UL94V-0Case



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5. SAFETY AND HANDLINGThefollowingprecautionsshouldbeobservedwhenhandlingandworkingwithbatteries.ItisrecommendedyoufollowyourCompany’sSafetyProceduresandPractices.

1. Protectterminalsfromshortingduringtransportation.

2. Neverchargeavisiblydamagedmodule(individual12Vbatteryorbloc).

3. Neverchargeafrozenmodule.

4. Keepsparksorothersourcesofignitionawayfrommodule.

5. Useinsulatedtoolstoreducetheriskofshortingwhileinstallingorremovingmodule.

6. Donotlaytoolsormetalsobjectsonthetopofmodule.

7. Removewatches,ringsandotherjewelrywhenworkingaroundmodules.

8. Eyeprotectionandprotectivefootweararerecommendedandmayberequiredbyyouremployer.

9. Verifycircuitpolarityandstringconnectionsbeforeconnectingtothepowersystem.

10. Useproperliftingtechnique,mechanicalliftingequipmentorassistanceasrequiredwhenremovingorinstallingmodules.

11. DisconnectthemoduleorstringofmodulesfromtheDCpowersystemorcommonDCbuspriortoremoval.

12. Theoperatingareashouldbeventilated.

13. Modulescontaindilutedsulfuricacid.

CAUTION: Whilethemodulecaseisintact,itisunlikelytheuserwillcomeincontactwiththeacidcontainedinside.Shouldacidcomeincontactwitheyes,flushtheeyewithwateroreyewashsolutionandseekmedicalattention.Shouldacidcomeincontactwithskin,washwithaffectedareawithwaterandneutralizeimmediatelytoavoidchemicalburns.



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6. EQUIPMENT FOR INSTALLATION AND REMOVALThefollowingarerecommendedforpersonalprotectionandsafeinstallationorremovalofmodules. 1. Insulatedhandtools. 2. Fireextinguisher. 3. Acidspillkit. 4. Eyeprotection. 5. Eyewash. 6. Mechanicalliftingequipmentmayberequiredincertainapplicationssuchascontrolled environmentalvaults.

7. TRANSPORTATIONModule terminals shouldbeprotected fromshortingduring transportation.Newmodulesshould remain in theoriginalpackagingmaterialtoprotectthecaseandterminalsuntiltheyaretobeinstalled.Shockor‘bruising’causedbydroppingorroughhandlingofamodulecancauseinternaldamagetoplates,inter-cellstraps,orcompromisetheintegrityofthecase.Modulesbeingremovedfromserviceshouldlikewisebeprotectedwhenbeingtransportedfrom the job site or to the recycler. The PWL series is rated ‘NON-SPILLABLE’ and should be so labeled duringshipping.The Safety Data Sheet (SDS) isavailablefordownloadatthefollowinglink:http://www.gsyuasa-es.com

8. DELIVERY INSPECTIONUpon receipt inspect the pallet and packaging for visible damage. Inspect themodule terminals and terminalhardware fordamageormissingparts.Manyshipments include installationkits;applicationspecific installationmanual,terminalboltkits,cableassemblies,lugs,moduletraysormodulestands.Theentireshipmentshouldbeverifiedtoensureallcomponentsassociatedwiththeshipmentarepresent.Ifmissingcomponentsordamageisdiscovered,contactyourfreightcarrierorGYESforinstructions.



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Average Storage Temperature (Centigrade)

Typical Storage Period before Refresh Charging

Recommended Interval to Measure OCV

</=25° 12Months 6months26°-30° 8Months 4months31°-35° 6Months 3months36°-40° 4Months 2months

Model Siemens/MHOSOut-of-box

PWL12V28 305PWL12V38 670

PWL12V65FS 886PWL12V115FT 1579PWL12V155FS 1918

Table 9.0-A. Storage Period Based on Temperature

Table 9.0-B. Typical Out-of-Box Conductance Values

CustomerswishingtomeasureconductancetoevaluteincomingstockmayalsouseTable 9.0-B.

NOTE: ThevaluesfoundinTable 9.0-BarebasedoncharacterizationofcurrentstockbyGYESusingtheMidtronics Essential(CTE-1000)andUltra(CTU-6000).

9. STORAGEModulesshouldbestoredinacool,cleananddryplacenottoexceedtherangefrom-20oto40oC.Modulesshippeddirectlytothecustomerdonotrequirerefreshcharginguponreceipt.Modulesstoredforextendedperiodsmayrequirearefreshchargepriortoinstallationorfurtherstorage(Table 9.0-A).TheOpenCircuitVoltage(OCV)shouldbemeasuredbeforeinstallationandperiodicallyduringstorage.ModuleswithanOCVof12.5V oraboveat25oC(77oF)donotrequirerefreshcharging.

ShouldtheOCVbelessthan12.5V,applyarefreshchargebychargingthebatteryfor48hoursat13.6Vatacurrentnottoexceed25%ofratedcapacity.

NOTE: Chargingshouldbeconductedinacool,dryandwellventilatedlocation.Thebatteriesshouldnotbeexposedtodirectsunlightduringchargingorstorage.Temperaturesshouldoptimallybeintherangeof70-77oF.Thechargingcurrentshouldberegulatedto25%oftheratedcapacityofthebattery.Forexample,a100Ahbatteryratedatthe8hourrateshouldnotbechargedatacurrentabove25A.

Batteriesshouldnotbeallowedtofallbelow12.5Vduringstorage.Batteriesbetween12.1Vand12.4Vmay be recoveredandfurtherstoredbyapplyingarefreshorboostcharge.IntheunlikelyeventbatteriesarestoredbeyondthepointwheretheOCVfallsbelow12.1V,contactGYES Customer Service.



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10. CHARGINGPerformanceandlifeisinpartinfluencedbythepowersystemandtheoperatingtemperature.Thisisespeciallytrueforbatteriesusedintelecommunicationsstandbyfloatapplications.TheoperatingtemperaturerangeforthePWLseriesis-40°Cto+55°C(shorttermexcursionsto65°Carepermissible).

Floatvoltageandproperlyfunctioningtemperaturecompensationarethekeystolongbatterylife.Therecommendedfloat voltage range at 25°C is found on the product label for eachmodel of thePWL series. High temperaturecompensation begins at 26°C and low temperature compensation begins at 24°C. The exact points at whichtemperaturecompensationbegincanbevariedslightlyaslongasthebatteryiskeptwithintherecommendedfloatrangeadjustedfortemperature.

Therateofincreaseforlow temperaturecompensationis+0.003Vperdegreecentigradepercell(+3mV/°C/cell)andtherateofdecreaseforhigh temperature compensationis-3mV/°C/cell.Asexampleatypical48Vpowersystemwouldbeadjusted tobeginhigh temperature compensation at 26°Cat the rateof -0.072V (72mV)perdegreecentigrade.Ifthetemperatureprobeatthestringmeasured30°Candthefloatwasadjustedto54.0Vat25°C,thepowersystemshoulddecreaseor‘temperaturecompensate’thefloatvoltagefrom54.0Vto53.64V.Likewise,ifthebatterytemperaturefallsto15°Cthepowersystemwouldincreasethefloatfrom54.0Vto54.72V.Thisisofcoursebasedonanexamplefloatof54.0Vat25°C.

NOTE: YourCompanymayhavespecificguidelinesforfloatvoltageandtemperaturecompensationcalculatedtokeepthemoduleorstringwithintherecommendedrangeadjustedfortemperature.

Excessivecurrentwhilerechargingthemoduleorstringafteradischargeeventmaycauseinternalheating.ThemaximumrecommendedrechargecurrentforthePWLseriesisfoundinTable 10.0-A.

Model AmperesPWL12V28 6

PWL12V38 8

PWL12V65FS 16

PWL12V115FT 29

PWL12V155FS 39

Table 10.0-A. Maximum Recommended Recharge Current



11. INSTALLATION CONSIDERATIONSInthissectionaregeneralconsiderationsforbatteryinstallation.

1. ReviewyourCompany’sSafetyPracticesandSection 5 “SAFETYANDHANDLING”.2. Acceptancepriortoinstallationshouldincludeavisualinspectionfordamageorabnormalitiesinaddition toverifyingtheOCVis12.5V or above (Section 9“STORAGE”).

NOTE:Nootherpre-installationacceptancetestingisrequired.CustomerswhowishtoperformconductancetestingmayestablishareferencebaselinevalueorusethevaluesinTable 11.0-A.ThesevaluesarebasedoncharacterizationofcurrentstockbyGYESusingtheMidtronicsEssential(CTE-1000)andUltra(CTU-6000).

3. Donotinstallmodulesinanairtightenclosure.

4. Modulesmaybeinstalledinanelectronicsequipmentcabinetwhererequired.

5. Liftandmovemodulescarefullytoavoidpersonalinjuryordamagetothemodule.

NOTE:Insomecases,thismayrequiretwotechniciansormechanicalliftingequipment.Neverlifta modulebytheterminaloranattachedbatterycableorbatterysupplyharness.

6. Donotinstallmodulesthathavebeendropped,damagedorshowanyindicationofleakageorcorrosionat theterminals.

NOTE: Damagetothecaseorterminalsmayresultinprematurefailureorshortenthelifeofthemodule.

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Table 11.0-A. Typical Conductance Reference Values

Model Siemens/MHOS30 Days on float

PWL12V28 360

PWL12V38 700

PWL12V65FS 960

PWL12V115FT 1740

PWL12V155FS 1935



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7. Donotinstallmodulesnearsourcesofignition.

NOTE:Underabnormaloperatingconditions,VRLAmodulesmaygenerateflammablehydrogengas. Gassingduetooverchargingmayoccurduetoapowersystemmalfunction,improperlyadjusted floatvoltageortemperaturecompensationorashortedcell.

8. Verifythepolarityiscorrectbeforeconnectingtheloadorpowersystemtoamoduleorstringofmodules.

9. Donotmixnewandoldmodulestogetherinthesameseriesstring.

NOTE:GYESrecommendsmodulesgreaterthan1.5yearsinservicenotbemixedinthesameseriesstring duetheriskofstringimbalance.Asmodulesage,chargeacceptancewillalsochange.

10. Modulesbeingconnectedinseriestoformastringshouldbeatornearthesamestateofcharge.

11. Modulesinstalledasastringshouldbenumberedstartingwithmodule#1atthemainpositivethen sequentiallynumbereachmoduletothelastmoduleatthemainnegativeterminalofthestring.

12. Allowatminimum2mmspacingbetweenmoduleswheretheadditionalspaceisavailableonthemodule trayorinsidethemodulecompartment.Additionalseparationisdesirablewhenavailable.

13. Cleanterminalsandcableconnectionswithabrasswirebrushbeforeassembly.

NOTE:TheapplicationofelectricalgradegreasesuchasSanchemNo-Ox-IDA-Specialispermitted.

14. Damagedorcorrodedlugsorcablingshouldberepairedorreplacedbeforeinstallinganewmoduleor stringofmodules.

15. Connectionstomoduleterminalsshouldbemadeusingtherecommendedtorquespecifiedontheproduct label(Table 11.0-B).

CAUTION: Excessivetorquemayleadtopostsealfailure.



16. Verifythepowersystemfloatvoltageandtemperaturecompensationaresetcorrectly(See Table 11.0-C below and Section 10“CHARGING”).

NOTE: YourCompanymayhavespecificguidelinesforfloatvoltageandtemperaturecompensation calculatedtokeepthemoduleorstringwithintherecommendedrangeadjustedfortemperature

NOTE: The PWL12V28 or PWL12V38 maycomeequippedwithapre-installedbatterycableassembly forcertainapplications.Theseterminalboltsornutsweretightenedatourfacilityusingcalibratedwrenchesanddonotrequirere-torque.Re-torqueisnotrequiredforanyGYESterminalhardware.However,ifrequiredbyyourCompanythevaluesinTable 11.0-B maybeused.

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Model Top Boltin-lbs

Top BoltNm

Top Bolt Socket

Front Bolt in-lbs

Front Bolt Nm

Front Bolt Socket

PWL12V28 22.1 2.5 8mm NA NA NAPWL12V38 22.1 2.5 8mm NA NA NA

PWL12V65FS 43.4 4.9 10mm 43.4 4.9 10mmPWL12V115FT 90 10.17 13mm 43.4 4.9 10mmPWL12V155FS 43.4 4.9 10mm NA NA NA

Table 11.0-B. Torque Specifications

Table 11.0-C. Float and Temperature Compensation

Model VpC @ 25°C High Temp Start

Low Temp Start Slope

PWL12V28 2.23-2.27 26°C 24°C 3mV/°C/CellPWL12V38 2.23-2.27 26°C 24°C 3mV/°C/Cell

PWL12V65FS 2.25-2.3 26°C 24°C 3mV/°C/CellPWL12V115FT 2.25-2.3 26°C 24°C 3mV/°C/CellPWL12V155FS 2.25-2.3 26°C 24°C 3mV/°C/Cell

GS Yuasa Energy Solutions, Inc.1150 Northmeadow Pkwy. Suite 110Roswell, GA 30076 (800) 472-2879

www.gsyuasa-es.com

ABOUT GS YUASA ENERGY SOLUTIONS, INC. GS Yuasa Energy Solutions, Inc. is an American subsidiary of GS Yuasa Corporation, the world’s second largest battery company and a 100+ year old Japanese corporation. GS Yuasa Energy Solutions (GYES) was formed in 2019 to address the growing energy storage and reserve power markets. GYES brings together and leverages GS Yuasa Group’s advanced technologies with proven American market successes in lithium, telecom, UPS, alarm & security, and energy storage into a single business unit.

500-10

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r.2.102-20

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12. MAINTENANCE AND REPLACEMENT12.1 Routine MaintenanceRoutinemaintenance is not required by GYES. Visual inspection of themodule casing and terminalsmay beincludedaspartofyourCompany’ssiteorpowersystemroutinepractices.Thisvisualinspectionshouldbeusedtoidentifyphysicalabnormalitiessuchascorrosion,swelling,cracking,orleakingwhichindicateaneedforfurthertestingorevaluationofthemodulesandpowersystem.Re-tighteningmoduleterminalhardwareisnotrequired.However,ifyourCompanyrequiresre-torqueaspartofaroutinemaintenance,theterminalsshouldbecarefullytightenedwithatorquewrenchtothespecificationfoundontheproductlabel.

Thelifeofthemoduleisgreatlyinfluencedbythepowersystem.Inallcasesfloatvoltageshouldbesetandadjustedfor temperature (See Section 10 “CHARGING”). In non-environmentally controlled applications, temperaturecompensation is required. It is imperative the power systembe adjusted correctly for float and temperaturecompensationandathermalortemperatureprobeinstalledonthestring.

Theabilityofthepowersystemtocorrectlyadjustthefloatfortemperatureisdependentonthepowersystem’stemperatureorthermalprobe.Moduletemperatureisbestreadbyathermalprobeplacedonthesideofthebatteryfor‘paddletype’probesoronthenegativeterminalfor‘ring-type’probes.Periodicorroutinemaintenanceofthepowersystemisessentialtomaximizinglife.

Batteryrechargecurrentlimitshouldbeadjustedwhererequiredtolimitthecurrentduringarechargeevent.See Section 10“CHARGING”formaximumrechargecurrentrecommendation.

12.2 End of LifeModulesoramodulestringshouldbereplacedwhentheyhavereachedEndofLife.TheEOLisdefinedas80%ofratedcapacityasdeterminedbyaconstantcurrentdischargetest.

13. DISPOSALLead acid battery recycling is an environmental success story.More than 95% of all battery lead is recycled.Cooperation between suppliers and customersmake this closed loop life cycle possible. Batteries should berecycledinaccordancewithapplicablegovernmentregulations.Formoreinformationaboutrecycling,contactGYESorseewww.americasrecyclers.orgorwww.batterycouncil.org.

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