GNB Industrial Power –

The Industry Leader.

SECTION 92.61 2015-02

Installation and Operating

Instructions

®
For

GNB Industrial Power, a division of Exide Technologies, is a

global leader in network power applications including
Based on over 100 years of technological innovation the Network
Power group leads the industry with the most recognized global
ABSOLYTE® GP Batteries
communication/data networks, UPS systems for computers brands such as ABSOLYTE®, GNB® FLOODED CLASSIC®,
and control systems, electrical power generation and MARATHON®, RELAY GEL®, SONNENSCHEIN®, and
distribution systems, as well as a wide range of other SPRINTER®. They have come to symbolize quality, reliability,
industrial standby power applications. With a strong performance and excellence in all the markets served.
manufacturing base in both North America and Europe and a
truly global reach (operations in more than 80 countries) in GNB Industrial Power takes pride in its commitment to a better
sales and service, GNB Industrial Power is best positioned to environment. Its Total Battery Management program, an
satisfy your back up power needs locally as well as all over the integrated approach to manufacturing, distributing and recycling
world. of lead acid batteries, has been developed to ensure a safe and
responsible life cycle for all of its products.

GNB Industrial Power

USA – Tel: 888.898.4462
Canada – Tel: 800.268.2698

www.gnb.com
UL Recognized Component
SECTION 92.61
93.10 2015-02
2010-12 A Division of Exide Technologies A Division of Exide Technologies
 INDEX
Page
SECTION 1
1.0 General Information.............................................................................................................. 1

SECTION 2
2.0 Safety Precautions................................................................................................................ 1
2.1 Sulfuric Acid Electrolyte Burns............................................................................................. 1
2.2 Explosive Gases................................................................................................................... 1
2.3 Electrical Shock and Burns................................................................................................... 1
2.3.1 Static Discharge Precautions for Batteries........................................................................... 1
2.4 Safety Alert........................................................................................................................... 2
2.5 Important Message............................................................................................................... 2

SECTION 3
3.0 Receipt of Shipment............................................................................................................. 2
3.1 Concealed Damage.............................................................................................................. 2

SECTION 4
4.0 Storage Prior to Installation.................................................................................................. 2
4.1 Storage Location.................................................................................................................. 2
4.2 Storage Interval..................................................................................................................... 2

SECTION 5
5.0 Installation Considerations................................................................................................... 2
5.1 Space Considerations.......................................................................................................... 2
5.2 Battery Location and Ambient Temperature Requirements................................................. 2
5.3 Temperature Variations......................................................................................................... 4
5.4 Ventilation............................................................................................................................. 4
5.5 Floor Loading........................................................................................................................ 4
5.6 Floor Anchoring.................................................................................................................... 4
5.7 Connecting Cables: Battery System to Operating Equipment............................................. 4
5.7.1 Paralleling............................................................................................................................. 4
5.8 Stacking Limitations............................................................................................................. 4
5.9 Terminal Plates..................................................................................................................... 4
5.10 Grounding............................................................................................................................. 4

SECTION 6
6.0 Unpacking and Handling...................................................................................................... 5
6.1 General................................................................................................................................. 5
6.2 Accessories.......................................................................................................................... 5
6.3 Recommended Installation Equipment and Supplies........................................................... 5
6.4 Unpacking............................................................................................................................. 5
6.5 Handling................................................................................................................................ 5

SECTION 7
7.0 System Arrangements.......................................................................................................... 6
7.1 Module Arrangements.......................................................................................................... 6
7.2 Dummy Cells within a Module.............................................................................................. 7

SECTION 8
8.0 System Assembly................................................................................................................. 7
8.1 Horizontal - Single Stack...................................................................................................... 7
8.1.1 Bottom I-Beam Supports...................................................................................................... 7
8.1.2 Handling................................................................................................................................ 8
8.1.3 Horizontal Stacking............................................................................................................... 8
8.2 Horizontal-Multiple Stacking................................................................................................ 10
8.2.1 Stack Tie Plates.................................................................................................................... 11
SECTION 9
9.0 Connections.......................................................................................................................... 12
9.1 Post Preparation................................................................................................................... 12
9.2 Connections - System Terminals.......................................................................................... 12
9.3 Connections - INTER-Module............................................................................................... 12
9.4 Connections - INTER-Stack................................................................................................. 12
9.5 Connections - Torquing........................................................................................................ 12
9.6 Connections - Check............................................................................................................ 12
9.7 Connection Resistance......................................................................................................... 12
9.8 Cell Numerals........................................................................................................................ 12
9.9 Warning Label....................................................................................................................... 12
9.10 Battery Nameplate................................................................................................................ 12

SECTION 10
10.0 Protective Module Covers.................................................................................................... 17
10.1 Module Cover Installation..................................................................................................... 17

SECTION 11
11.0 Initial Charge......................................................................................................................... 17
11.1 Constant Voltage Method..................................................................................................... 17

SECTION 12
12.0 Operation.............................................................................................................................. 18
12.0.1 Cycle Method of Operation.................................................................................................. 18
12.1 Floating Charge Method....................................................................................................... 18
12.2 Float Charge - Float Voltages............................................................................................... 18
12.3 Voltmeter Calibration............................................................................................................ 18
12.4 Recharge............................................................................................................................... 18
12.5 Determining State-of-Charge............................................................................................... 18
12.6 Effects of Float Voltage......................................................................................................... 19
12.7 Float Current and Thermal Management.............................................................................. 19
12.8 AC Ripple.............................................................................................................................. 19
12.9 Ohmic Measurements........................................................................................................... 19

SECTION 13
13.0 Equalizing Charge................................................................................................................. 19
13.1 Equalizing Frequency............................................................................................................ 19
13.2 Equalizing Charge Method................................................................................................... 20

SECTION 14
14.0 Pilot Cell................................................................................................................................ 20

SECTION 15
15.0 Records................................................................................................................................ 20

SECTION 16
16.0 Tap Connections................................................................................................................... 21

SECTION 17
17.0 Temporary Non-Use............................................................................................................. 21

SECTION 18
18.0 Unit Cleaning........................................................................................................................ 21

SECTION 19
19.0 Connections.......................................................................................................................... 21

SECTION 20
20.0 Capacity Testing................................................................................................................... 21
 LIST OF ILLUSTRATIONS

Page

3 Fig. 1A-B Typical Systems - Top View
5 Fig. 2 Packed Modules
5 Fig. 3 Unpacking Modules
6 Fig. 4 Handling - Lifting Strap Placement
6 Fig. 6A-B-C Typical Horizontal Stack Arrangements - Front Views
7 Fig. 7 Typical Horizontal Stack Arrangements - Back to Back and End to End
7 Fig. 8 Hardware Installation for 2.67” Wide I-Beam Support
7 Fig. 9 Hardware Installation for 4.5” Wide I-Beam Support
7 Fig. 10 Completed I-Beam Support to Module Installation
8 Fig. 11 Handling Module - Base Support Assembly
8 Fig. 12A Tip-Over Procedure - Shackle-Strap Usage
9 Fig. 12B Tip-Over Procedure
9 Fig. 13 Module with Base Assembly After Tip-Over
9 Fig. 14 Horizontal Stacking - Shackle-Strap Usage
10 Fig. 15 Handling and Stacking Horizontal Modules
10 Fig. 16 Hardware Installation Sequence
10 Fig. 17A Installing Hardware
10 Fig. 17B Completed Horizontal Stack
10 Fig. 18 Positioning Horizontal Base Modlule
11 Fig. 19A Horizontal Stacks - Back to Back Positioning
11 Fig. 19B Completed Horizontal Stacks - Side by Side
11 Fig. 20A-B Tie Plate Assemblies - Horizontal Stacks
13 Fig. 21 Various Inter Stack and Intra Stack Connections - Horizontal Arrangements
14 Fig. 22 Terminal Plate Kit - 6 Cell Modules
15 Fig. 23 Terminal Plate Kit - 3 Cell Modules
16 Fig. 24 Installation Guide for Absolyte GP Transparent Cover
22 Fig. 25 Absolyte Battery Maintenance Report

APPENDICES

24 A Temperature Corrected Float Voltages

25 B Maximum Storage Interval Between Freshening Charges Versus
Average Storage Temperature
26 C Bonding and Grounding of Battery Rack
27 D Absolyte GP Maximum Module Stack Heights
 SECTION 1 reduce hydrogen formation. Tests have shown that 99%
or more of generated gases are recombined within the
cell under normal operating conditions. Under abnormal
1.0 General Information
operating conditions (e.g. charger malfunction), the safety
valve may open and release these gases through the vent.
The Absolyte GP battery is of the valve-regulated lead-acid The gases can explode and cause blindness and other
(VRLA) design and so can operate with lower maintenance (e.g. serious injury.
no maintenance water additions) in comparison to conventional
flooded lead-acid batteries. The Absolyte GP VRLA design Keep sparks, flames, and smoking materials away from the
is also inherently safer than conventional flooded lead-acid battery area and the explosive gases.
batteries. Under normal operating conditions and use, the
Absolyte GP battery minimizes hydrogen gas release, and All installation tools should be adequately insulated to
virtually eliminates acid misting and acid leakage. However, minimize the possibility of shorting across connections.
there is the possibility that under abnormal operating
conditions (e.g. over-charge), or as a result of damage, misuse
and/or abuse, potentially hazardous conditions (hydrogen DANGER
gassing, acid misting and leakage) may occur. Thus, GNB ELECTRICAL SHOCK
recommends that Section 2.0 of these instructions entitled
“SAFETY PRECAUTIONS” be reviewed thoroughly prior AND BURNS
to commissioning, and strictly followed when working with
Absolyte GP batteries.
Never lay tools or other metallic objects on modules as
shorting, explosions and personal injury may result.

! CAUTION! 2.3 Electrical Shock and Burns

Before proceeding with the unpacking, han- Multi-cell systems attain high voltages, therefore, extreme
dling, installation and operation of this VRLA caution must be exercised during installation of a battery
storage battery, the following general infor- system to prevent serious electrical burns or shock.
mation should be reviewed together with the
Interrupt the AC and DC circuits before working on batteries
recommended safety precautions.
or charging equipment.

Assure that personnel understand the risk of working with

batteries, and are prepared and equipped to take the nec-
SECTION 2 essary safety precautions. These installation and operating
instructions should be understood and followed. Assure that
2.0 Safety Precautions you have the necessary equipment for the work, including
insulated tools, rubber gloves, rubber aprons, safety goggles
2.1 Sulfuric Acid Electrolyte Burns and face protection.

DANGER SULFURIC
ACID ELECTROLYTE
BURNS
!
CAUTION!
“Warning: Risk of fire, explosion or burns. Do not disas- If the foregoing precautions are not fully under-
semble, heat above 50°C or incinerate.” Batteries contain stood, clarification should be obtained from your
dilute (1.310 nominal specific gravity) sulfuric acid electrolyte nearest GNB representative. Local conditions may
which can cause burns and other serious injury. In the event introduce situations not covered by GNB Safety
of contact with electrolyte, flush immediately and thoroughly Precautions. If so, contact the nearest GNB repre-
with water. Secure medical attention immediately. sentative for guidance with your particular safety
problem; also refer to applicable federal, state and
When working with batteries, wear rubber apron and rubber local regulations as well as industry standards.
gloves. Wear safety goggles or other eye protection. These
will help prevent injury if contact is made with the acid.­
2.3.1 Static Discharge Precautions for Batteries
DANGER
When maintaining the batteries, care must be taken to pre-
EXPLOSIVE GASES vent build-up of static charge. This danger is particularly
significant when the worker is electrically isolated, i.e. working
on a rubber mat or an epoxy painted floor or wearing rubber
­­2.2 Explosive Gases shoes.

Hydrogen gas formation is an inherent feature of all lead acid Prior to making contact with the cell, discharge static elec-
batteries. Absolyte GP VRLA batteries, however, significantly tricity by touching a grounded surface.
-1-
 temperatures will result in accelerated rates of self discharge.
Wearing a ground strap while working on a connected bat- For every 18°F (10°C) temperature increase above 77°F
tery string is not recommended. (25°C), the time interval for

2.4 Safety Alert the initial freshening charge and subsequent freshening
The safety alert symbol on the left appears charges should be halved. Thus, if a battery is stored at
95°F (35°C), the maximum storage interval between charges
!
throughout this manual. Where the symbol
appears, obey the safety message to avoid would be 3 months (reference Appendix B). Storage beyond
personal injury. these periods without proper charge can result in excessive
sulphation of plates and positive grid corrosion which is
detrimental to battery performance and life. Failure to charge
2.5 Important Message accordingly may void the battery’s warranty. Initial and
The
 symbol on the left indicates an impor- freshening charge data should be saved and included with
tant message. If not followed, damage to the battery historical records; (see Section 15 - Records).
and/or impaired performance of the battery
may result. SECTION 5
5.0 Installation Considerations

SECTION 3
!
3.0 Receipt of Shipment Prior to starting installation of the Absolyte Battery System, a
review of this section is strongly recommended.
Immediately upon delivery, examine for possible damage 5.1 Space Considerations
caused in transit. Damaged packing material or staining from
leaking electrolyte could indicate rough handling. Make a Any modifications, alterations or additions to
descriptive notation on the delivery receipt before signing. an Absolyte system, without the expressed
Look for evidence of top loading or dents in the steel mod- written consent of GNB Engineering, may void
ules. If cell or unit damage is found, request an inspection by any warranties and/or seismic qualifications.
the carrier and file a damage claim. Contact your GNB representative for additional
information.
3.1 Concealed Damage

Within 10 days of receipt, examine all cells for concealed It is important to know certain restrictions for the area where
damage. If damage is noted, immediately request an inspec- the battery is to be located. First, a designated aisle space
tion by the carrier and file a concealed damage claim. Pay should be provided to permit initial installation as well as
particular attention to packing material exhibiting damage for service or surveillance. After installation, any additional
or electrolyte staining. Delay in notifying carrier may result in equipment installed after the battery should not compromise
loss of right to reimbursement for damages. access to the battery system.
A minimum aisle space of 36 inches from modules / 33 inch-
SECTION 4 es from covers should be available adjacent to the battery
system. See Figure 1 for typical space allocations required.
4.0 Storage Prior to Installation Following the spacing requirements will aid in maintenance
of the battery and help maintain air flow to battery surfaces to
4.1 Storage Location enhance heat dissipation.
NOTE: When planning system space requirements, allow at
If the battery is not to be installed at the time of receipt, it is least 6 inches past system total length wherever a terminal
recommended that it be stored indoors in a cool [77°F (25°C) plate assembly is to be located. (See Figure 1A)
or less], clean, dry location. Do not stack pallets or cell termi-
Figure 1 A-B are typical. For total length, width and height
nal damage may occur.
dimensions of connected systems, consult layout/wiring dia-
gram for the particular system.
4.2 Storage Interval
5.2 Battery Location & Ambient
The storage interval from the date of battery shipment to Temperature Requirements
the date of installation and initial charge should not exceed
It is recommended that the battery unit be installed in a
six (6) months. If extended storage is necessary, the battery
clean, cool, dry location. Floors should be level. Absolyte
should be charged at regular intervals until installation can
batteries can be installed in proximity to electronic equip-
be completed and float charging can be initiated. When in
ment.
extended storage, it is advised to mark the battery pallets
with the date of shipment and the date of every charge. If A location having an ambient temperature of 75°F (24°C)
the battery is stored at 77°F (25°C) or below, the battery to 77°F (25°C) will result in optimum battery life and per-
should be given a freshening charge (perform per Section 11 formance. Temperatures below 77°F (25°C) reduce battery
Initial Charge) within 6 months of the date of shipment and charge efficiency and discharge performance. Temperatures
receive a freshening charge (perform per Section 11 Initial above 77°F (25°C) will result in a reduction in battery life (see
Charge) at 6 month intervals thereafter. Storage at elevated table below.)

-2-
 FIGURE 1A - HORIZONTAL END TO END

FIGURE 1B - HORIZONTAL BACK TO BACK

FIGURE 1 - TYPICAL SYSTEMS (TOP VIEW)

-3-
Annual Average Maximum Percent
Battery Battery Reduction Four 9/16” (14.3 mm) holes are provided in each I-Beam sup-
Temperature Temperature In Battery Life
port for anchoring. To maintain seismic certification, use four
77°F (25°C) 122°F (50°C) 0% anchor bolts per horizontal support. Anchor design is the
86°F (30°C) 122°F (50°C) 30% responsibility of the purchaser/installer.
95°F (35°C) 122°F (50°C) 50%
104°F (40°C) 122°F (50°C) 66%
113°F (45°C) 122°F (50°C) 75% 5.7 Connecting Cables: Battery
122°F (50°C) 122°F (50°C) 83% System to Operating Equipment
For example: If a battery has a design life of 20 years at 77°F
(25°C), but the actual annual average battery temperature is The Absolyte cell is a UL recognized component. Battery
95°F (35°C), the projected service life of the battery is calcu- performance is based on the output at the battery terminals.
lated to be only 10 years. Therefore, the shortest electrical connections between the
battery system and the operating equipment results in maxi-
Temperature records shall be maintained by the user in accor- mum total system performance.
dance with the maintanence schedule published in this man-
ual. The battery temperature shall not be allowed to exceed DO NOT SELECT CABLE SIZE BASED ON CURRENT
the maximum temperature shown above. It is important to CARRYING CAPACITY ONLY. Cable size selection should
maintain the battery temperature as close to 77°F (25°C) as provide no greater voltage drop between the battery system
possible to achieve the optimum service life from your battery. and operating equipment than necessary. Excess voltage drop
will reduce the desired support time of the battery system.
5.3 Temperature Variations
5.7.1 Paralleling
Sources of heat or cooling directed on portions of the battery
can cause temperature variations within the strings, resulting Where it is necessary to connect battery strings in parallel
in cell voltage differences and eventual compromise of battery in order to obtain sufficient load backup time, it is important
performance. to minimize the difference in voltage drop between the
battery strings in parallel in order to promote equal load
Heat sources such as heaters, sunlight or associated equip- sharing upon discharge. Therefore, equal resistance of cable
ment can cause such temperature variations. Similarly, air con- connections for each parallel string is important. When
ditioning or outside air vents may cause cell string temperature paralleling multiple strings to a load or common bus, please
variations. Every effort should be made to keep temperature follow these guidelines:
variations within 5°F (3°C).
• Each parallel string must have the same number of cells
5.4 Ventilation ! (same string voltage).
• The cables connecting the positive and negative terminals
The Absolyte battery is a Valve Regulated Lead Acid (VRLA) of each string to the load (or bus) should be of the SAME
low maintenance design. Tests have confirmed that under SIZE (i.e. same capacity/cross-sectional area).
recommended operating conditions in stationary applications, • The cables connecting the positive and negative terminals
99% or more of gases generated are recombined within the of each string to the load (or bus) should be of the SAME
cell. In most cases, no special ventilation and or battery room LENGTH. Choose the shortest cable length that will connect
is required. Consult your local building and fire codes for the battery string that is furthest from the load, and cut all
requirements that may apply to your specific location. cables used to connect each string to the load to this same
length.
Hydrogen and oxygen gases can be vented to the atmosphere
under certain conditions. Therefore, the battery should never be 5.8 Stacking Limitations
installed in an air-tight enclosure. Sufficient precautions must
be taken to prevent excessive overcharge. There are recommended limits on stacked battery configura-
tions. Please refer to Appendix D for additional information.
5.5 Floor Loading ! NOTE: Horizontal module arrangement only.

The floor of the area where the battery system is to be 5.9 Terminal Plates
installed should have the capability of supporting the weight
of the battery as well as any auxiliary equipment. The total Each system is supplied with a terminal plate assembly for
battery weight will depend on the cell size, number of cells, the positive and negative terminations. These should always
as well as module configuration involved. Prior to installa- be used to provide proper connection to the operating equip-
tion, a determination should be made that the floor integrity is ment and cell terminals. Any attempt to connect load cables
adequate to accommodate the battery system. directly to cell terminal may compromise battery system per-
formance as well as the integrity of cell post seals.
5.6 Floor Anchoring
5.10 Grounding
Where seismic conditions are anticipated, floor anchoring
must be implemented. It is recommended that the modules or racks be grounded in
accordance with NEC and/or local codes. See Appendix C
Where non-seismic conditions are anticipated, anchoring of for recommended procedure.
horizontally stacked systems is recommended for maximum
stability.
-4-
 SECTION 6 6.3 Recommended Installation
Equipment and Supplies
6.0 Unpacking and Handling
• Fork lift or portable boom crane
• Chalk line
• Line Cord
• Torpedo level (Plastic)
• Plywood straight edge 1/2” x 4” x 48”
• Torque wrenches
• Ratchet wrench with 10, 13, 17, 19 mm sockets and 2
and 15 mm deep sockets
• Box wrenches of 10, 13, 15, 17 and 19 mm sizes
• Vinyl electrical tape
• Paper wipers
• 3M Scotch Brite® scour-pads™†
• Hammer drill (floor anchoring)

† Trademark of 3M

6.4 Unpacking
PACKED MODULES
Carefully remove bolts and protective shipping hood. See
Figure 2
Figure 3. Remove the bolts holding modules to shipping
pallet. Also remove hardware bolting upper channels of
6.1 General modules together. Do not remove modules at this time. Base
supports for horizontally stacked modules are more easily
Do not remove shipping materials if a storage period is attached before removing modules from pallet (see Section
planned, unless charging is required per Section 4.2. 8.0 System Assembly and Section 9.0 Connections).

The battery modules are generally packed in groups. Lag Note: Placement of modules on shipping pallet has no rela-
bolts retain the modules to the shipping pallet together with tionship to final installation.
a protective hood bolted in place. Modules are also bolted
together at the top adjacent channels. See Figure 2.

6.2 Accessories

Accessories are packed separately and will include the

following: (Note: Some items may not be provided depend-
ing on battery configuration).

• Layout/wiring diagram
• Installation and operating instructions
• Lifting straps and lifting shackles
• Protective covers and hardware
• Terminal plate assembly kits and covers
• Module tie plates (where required) (i.e. side-by-side
stacks)
• Vertical or horizontal supports (i.e. I-beams)
• Lead-Tin Plated copper intercell connectors UNPACKING MODULES
• Assembly hardware Figure 3



• NO-OX-ID® “A”* grease
• Battery warning label
• Battery nameplate
6.5 Handling
!
• Cell numerals with polarity indicators
• Shims (leveling) The design of the modular tray permits handling by a fork lift,
• Drift pins portable crane or by a hoist sling (see Figure 4). Whichever
• Seismic Shims (where required). method is used, make sure equipment can safely handle the
module weight.
*Registered Trademark of Sanchem Inc.
Always use the two lifting straps and four lifting shackles for
NOTE: Check battery components against supplied draw- lifting and placement of modules.
ings to assure completeness. Do not proceed with installa-
tion until all accessory parts are available.

-5-
 CAUTION!
If a fork lift or portable crane is used
to handle modules in a horizontal
position, a piece of insulating material
such as heavy cardboard, rubber
insulating mats or plywood should be
used between handling equipment
and module tops to prevent shorting
of module top connections with metal
parts of lift equipment.

Figure 6A

NOTE:
1) Straps must be criss-crossed.
2) Lifting shackle orientation and proper channel hole use
must be observed.
3) See Figure 14 for handling modules in horizontal orientation.
4) Never lift more than two joined modules with straps and hooks.
Figure 6B
HANDLING - LIFTING STRAP PLACEMENT
Figure 4

SECTION 7

7.0 System Arrangements

7.1 Module Arrangements

Absolyte batteries are recommended for installation in a

horizontal orientation only. However, vertical installation is
approved for 50G systems consisting of single cell modules.
Figures 6 and 7 are typical arrangements and are not intend-
ed to represent all configuration possibilities.

Module stack height limitation depends on cell size and

the seismic requirements of the application. Please refer to
Appendix D for additional information.
HORIZONTAL SINGLE STACK BACK TO BACK

Figure 6C

-6-
 NOTE: The use of leveling shims is required when assembling
any Absolyte system in order to meet seismic requirements.
Failure to use the shims to level each module and to fill spac-
es between tray channels during module assembly will result
in the assembly not meeting seismic certification criteria.

Similarly, install the remaining I-beam support on the other

side of the module (see Figure 10).

M10 x 40 BOLT

M10 FLAT WASHER

HORIZONTAL MULTIPLE STACKS
BACK TO BACK AND END TO END
TYPICAL HORIZONTAL STACK ARRANGEMENTS M10 WEDGE WASHER
Figure 7 M10 LOCK WASHER
M10 NUT

7.2 Dummy Cells within a Module

Where application voltage requires, a dummy cell can HARDWARE INSTALLATION FOR 2.67” WIDE I-BEAM SUPPORT
replace a live cell in a module. For example, a 46 volt, three- Figure 8
cell per module system may consist of seven full modules
and one module containing two live cells and either an empty
space, or a dummy cell.

SECTION 8

8.0 System Assembly

ACCESS SLOTS
8.1 Horizontal Single Stack

Consult layout/wiring diagram for total number and type of

M10 NUT
module assemblies in system. There can be varying combi- LOCK WASHER I-BEAM SUPPORT
nations of cell arrangements within the module. May contain WASHER
dummy cells depending on total system voltage. SEISMIC SHIM
WASHER
M10 BOLT
Compare required module assemblies called for on layout/
wiring diagram with modules in shipment for completeness HARDWARE INSTALLATION FOR 4.5” WIDE I-BEAM SUPPORT
Figure 9
before continuing further.

8.1.1 Bottom I-beam Supports

Locate bottom I-beam supports and M10 I-beam hardware

kit. I-beam supports and seismic shims should be attached
to the appropriate module assembly shown on the layout/
wiring diagram prior to removal from shipping pallet.

NOTE: Seismic shims will be supplied with systems for which

they are required to maintain seismic compliance.

Secure I-beam support to a module channel as shown in supplied

drawing, with access slots outward. Please refer to Figure 8 and 9
for general hardware installation information. Seismic shims, when
supplied, are placed between the channel and the nut and ori-
ented so as to not extend beyond the end of the channel. Torque
hardware to 47 Newton-meters (35 ft-lbs) using insulated tools.
When correctly attached, the I-beam support will be flush with the
front module channel and approximately 13mm (0.50”) away from
the back of the module. The side of the I-beam support will be COMPLETED I-BEAM SUPPORT TO MODULE INSTALLATION
approximately 10mm (0.38”) away from the end of the channels. Figure 10

-7-
8.1.2 Handling E. Where floor anchoring is required, position module/base
assembly in desired location. Mark floor through I-beam
The module/base support assembly may now be removed holes and remove module/base assembly. Install floor
from the pallet using methods outlined in section 6.5, anchoring and reposition module/base assembly over
Handling. Also see Figure 11. Remaining modules may be anchoring. Prior to installing nuts and washers, check
removed in a similar manner. that assembly is level in both axes. Level using shims
provided. Torque anchor hardware to manufacturer’s rec-
ommended value.
8.1.3 Horizontal Stacking

In order to stack modules in the horizontal position, refer to

Figures 11 thru 13 to perform the tip-over procedure. The
module/base support assembly tip-over should be performed
first. This procedure can be performed using a portable
boom crane or fork lift in conjunction with the lifting straps
and lifting shackles supplied.

CAUTION!
DO NOT ATTEMPT TO PERFORM TIP-OVER OF
MODULE MANUALLY AS SERIOUS PERSONAL
INJURY AND MODULE DAMAGE MAY RESULT.

A. Install lifting strap using lifting shackles in channel base

holes at each end of module upper rear channel as
shown in Figure 12A.

B. Center the lifting hook onto strap and lift until strap is
under tension and raises bottom of module from floor
surface so that upper and lower diagonal corners are in a
vertical mode.

C. While exerting manual force on the upper rear of module,

lower hoist until module is in horizontal position.
See Figures 12B and 13. NOTE:
1) One strap with shackles used for tip-over
procedure.
!
D. When module is horizontal, install the four lifting shackles
and two lifting straps as shown in Figure 14. 2) Observe channel hole used as well as direction of
shackle insertion.
3) Tip over procedure for single modules only.

TIP OVER PROCEDURE

SHACKLE-STRAP USAGE
Figure 12A

F. U
 sing Steps A-D and the layout/wiring diagram, position
the next module on top of first so that channels of each
mate with one another using drift pins to align channel
holes. Make sure channel ends and sides of the upper
and lower modules are flush. Install serrated flange bolts
and nuts in open holes, finger tight. Remove lifting straps.
Use leveling shims to fill gaps between trays. See Figures
15, 16, and 17A.

G. At this time, check to see that the first two modules are
plumb front to back and side to side using wooden or
plastic level together with plywood straight edge. This is
to insure proper alignment for module interconnection
later on. Torque hardware to 47 Newton-meters
(35 Ft-Lbs).

HANDLING MODULE - BASE SUPPORT ASSEMBLY

Figure 11

-8-
TIP-OVER PROCEDURE MODULE WITH BASE ASSEMBLY
Figure 12B AFTER TIP-OVER
Figure 13

NOTE:
1) Straps must be criss-crossed
2) Lifting shackle orientation and proper channel hole use



! must be observed.
3) See Figure 4 for handling modules in vertical orientation.
4) Lift single modules only.

HORIZONTAL STACKING SHACKLE-STRAP USAGE

Figure 14

-9-
H. Proceed with stacking of remaining modules, checking
that stack is plumb in both axes as stacking progresses
before torquing hardware. Be certain to check the
layout/wiring diagram for correct horizontal orientation to
provide proper polarity interconnection as stacking
progresses. See Figure 17B.

COMPLETED HORIZONTAL STACK

Figure 17B

8.2 Horizontal-Multiple Stacks

HANDLING AND STACKING HORIZONTAL MODULES It is recommended that all of the first modules with bottom
Figure 15 supports attached (see Section 8.1.1) be placed in position
first. A chalk line floor mark should be used to assure all
stacks will be in a straight line. This applies for stacks end-
to-end or end-to-end and back-to-back. Also refer to Section
8.1.3, Items A through H (Item E for base module leveling).
Module ends should be butted together so that module side
channel ends meet (see Figure 18).
Refer to layout/wiring diagram for seismic shim requirements.
M10 SERRATED
FLANGE BOLT  t this time stack tie plates should be installed (see Section
A
8.2.1). It will be necessary to temporarily remove the hard-
ware fastening the base modules to the I-beams.
See Figure 20A. Install tie plates and hardware. Torque to 47
M10 SERRATED
FLANGE NUT Newton-meters (35 Ft-Lbs).
For stacks back-to-back, the two base modules are posi-
tioned to provide a minimum 4.5” spacing between the bot-
HARDWARE INSTALLATION SEQUENCE toms of the modules (not I-beam edges). See Figure 19A.
Figure 16 When all base modules are set in place, continue with stack-
ing of subsequent modules. Procedures for assembly of
multiple horizontal stacks are the same as outlined in sec-
tion 9.1. Also consult layout/wiring diagram. Each stack
should be built up in sequence to the same level until the
top modules in all stacks are the last to be installed. The use
of a line cord attached to upper module corners of opposite
end modules as stacking progresses aids in alignment. See
Figure 19B.

INSTALLING HARDWARE
Figure 17A
POSITIONING HORIZONTAL BASE MODULE
Figure 18
- 10 -
 SEISMIC SHIM
INSTALLED UNDER
TIE PLATE WHERE
APPLICABLE

HORIZONTAL STACKS — BACK TO BACK POSITIONING

Figure 19A

TIE PLATE BOTTOM MODULES

Figure 20A

COMPLETED HORIZONTAL STACKS — SIDE BY SIDE

Figure 19B

M10 SERRATED
8.2.1 Stack Tie Plate ­­ FLANGE BOLT

To achieve maximum stack stability, especially where seis-

mic conditions may exist, as well as proper interfacing of
interstack connections, metal tie plates are provided. The
plates used on stacks end to end are 3” x 1” x 1/8” with two
9/16” holes. Use one tie plate at each interface on only the
base and top modules of adjacent stacks. See Figures 20A
and 20B.

Position plates on the front and back channels and secure

with hardware shown. Where stacks have different levels,
install plates on shorter stack top module and adjacent mod-
ule. Torque hardware to 47 Newton-meters (35 Ft-Lbs).

This completes the mechanical assembly of the battery sys-

tem.
M10 SERRATED
FLANGE NUT
For installation of connections and terminal plate assembly,
see Section 9.

For installation of protective module cover, see Section 10. TIE PLATE TOP MODULES
Figure 20B

- 11 -
 SECTION 9 Cells are interconnected with connectors and hardware as
shown in Figures 21A and 21B
9.0 Connections
9.4 Connections - INTER-Stack
9.1 Post Preparation
Multiple stacks end to end are interconnected as shown in
Using either a brass bristle suede shoe brush or 3M Scotch Figure 21C and 21D. Follow procedures in Section 9.1 and
Brite scouring pad, brighten the flat copper terminal sur- Section 9.3. Also see Section 9.5, Connections - Torquing.
faces to ensure lowest resistance connections.
9.5 Connections - Torquing
Apply a thin film of NO-OX-ID “A” grease (supplied with bat-
tery) to all terminal mating surfaces. This will preclude oxida-

!
tion after connections are completed.

9.2 Connections - System Terminals

When all inter-module connections have been installed,
Each system is supplied with a terminal plate assembly for tighten all connections to 11.3 Newton-meters (100 in-lbs)
the positive and negative terminations. These should always Use insulated tools. All connections should be rechecked
be used to provide proper connection to the operating after the initial charge, due to heating during charge.
equipment and cell terminals. Any attempt to connect load
cables directly to cell terminals may compromise battery
system performance as well as the integrity of cell post 9.6 Connection - Check
seals.
Again, visually check to see that all module terminals are
For terminal plate assembly, see Figure 22 (6 cell modules connected positive (+) to negative (-) throughout the battery.
at low rate) or Figure 23. Consult layout/wiring diagram for
proper kit use. It is recommended that all components be Also measure the total voltage from terminal plate to termi-
assembled in place with hardware torqued to 11.3 Newton- nal plate. This should be approximately equal to 2.15 volts
meters (100 in-lbs). Retorque value is also 11.3 Newton- times the number of cells in the system, e.g., a 24 cell sys-
meters (100 in-lbs). tem would read: 24 x 2.15v = 51.6 volts.

Refer to Sections 9.1 and 9.3 for electrical contact surface

preparation of terminal plate components. 9.7 Connection Resistance

As shown, terminal plate assembly can be varied to satisfy Electrical integrity of connections can be objectively estab-
module terminal location as well as orientation of terminal lished by measuring the resistance of each connection.
plate in a horizontal or vertical plane. Do not make connec- These resistances are typically in the microhm range.
tions to operating system at this time. Meters are available which determine connection resistance
in microhms. Be sure that the probes are touching only the
9.3 Connections - INTER-Module posts to ensure that the contact resistance of connector to
post is included in the reading.
Consult layout/wiring diagram for correct quantity of lead-
tin plated copper connectors required at each connection. Resistance measurements or microhm measurements
Follow procedure in Section 9.1 and brighten lead-tin plat- should be taken at the time of installation and annually
ed surfaces coming in contact with copper posts. Apply a thereafter. Initial measurements at installation become the
film of NO-OX-ID “A” grease to these areas. NOTE: Apply a bench mark values and should be recorded for future moni-
minimum amount of grease to cover the surface. As a rule: toring of electrical integrity.
“If you can see it, it’s too much”. Where multiple connec-
tors are required across any single connection, brighten It is important that the bench mark value for all similar con-
both sides of connectors along the entire length. Grease nections be no greater than 10% over the average. If any
these areas as well. It is recommended when install- connection resistance exceeds the average by more than
ing connectors that the upper bolts be installed first to 10%, the connection should be remade so that an accept-
reduced risk of accidental shorting. able bench mark value is established.

Bench mark values for connection resistances should also

WASHERS SHOULD BE INSTALLED WITH THE CURVED
be established for terminal plates, where used, as well as
EDGE TOWARD THE CONNECTORS.
cable connections. Bench mark values should preferably be
established upon installation.

All bench mark values should be recorded. Annually, all con-

nection resistances should be re-measured. Any connection
which has a resistance value 20% above its benchmark
value should be corrected.
BOLT WASHER CONNECTOR POST

- 12 -
 TWO POST CELLS FOUR POST CELLS
INTER-MODULE CONNECTION INTER-MODULE CONNECTION
A B

TWO POST CELLS FOUR POST CELLS

INTER-STACK CONNECTION INTER-STACK CONNECTION
C D

1) See Section 9 - Connections

2) Torque hardware to 11.3 Newton-meters (100
in-lbs).
3) Consult layout/wiring diagram received with battery
system
4) Curved edge of washer should face the connector.

VARIOUS INTER STACK AND

INTER-MODULE CONNECTIONS
HORIZONTAL ARRANGEMENTS

Figure 21

- 13 -
Figure 22

- 14 -
 CABLE LUGS
(NOT SUPPLIED)

MODULE
CHANNELS

Figure 23

- 15 -
 TO ASSEMBLE THE ABSOLYTE GP MODULE COVER, THE FOLLOWING ARE NEEDED:

ITEM QUANTITY

CLEAR COVER 1
STANDOFF LEG 4
KEY 4
TOP CLOSEOUT 1*
*TOP MODULE COVER ONLY

TOP MODULE
COVER

INSTALL TOP CLOSEOUT ON TO INSTALL COVERS ONTO

7 8
CLEAR COVER OF TOP MODULE: STANDOFF LEGS.
CUT TO ALLOW FOR TERMINAL
PLATE AS REQUIRED

INSTALLATION GUIDE FOR ABSOLYTE GP MODULE COVER

Figure 24

- 16 -
9.8 Cell Numerals Failure to perform the freshening charge within the limits
stated in Section as well as failure to perform the initial
A set of pressure sensitive cell numerals and system polarity charge upon installation of the battery 4 will affect the per-
labels are supplied and should be applied at this time. formance and life of the battery and may void the warranty.

Cell numerals should be applied to the top of the module 11.1 Constant Voltage Method
and as close to the cell being identified as possible. Suggest
application to cell restraint bars or to module channels. Constant voltage is the only charging method allowed. Most
Designate the positive terminal cell as #1 with succeeding modern chargers are of the constant voltage type.
cells in series in ascending order.
Determine the maximum voltage that may be applied to the
The system polarity labels should be applied next to the posi- system equipment. This voltage, divided by the number of
tive and negative terminals. cells connected in series, will establish the maximum volts
per cell (VPC) that is available.
9.9 Warning Label
! Table B lists recommended voltages and charge times for the
initial charge. Select the highest voltage the system allows to
Apply pressure sensitive warning label provided on a promi-
perform the initial charge in the shortest time period.
nently visible module side or end (The module cover is rec-
ommended).
NOTE: Time periods listed in Table B are for 77°F. For other
temperatures a compensation factor of .003 V/°F (.0055 V/°C)
9.10 Battery Nameplate per cell is recommended. The minimum voltage is 2.20 VPC,
temperature correction does not apply below this voltage.
For future reference and warranty protection, apply pressure
sensitive nameplate on a prominently visible module. Fill in TEMPERATURE CORRECTION
date of installation and the specified capacity and rate.
V corrected = V25°C - (( T actual-25°C) x ( .0055V/°C)) or
Make sure surfaces are free of dirt and grease by wiping with V corrected = V77°F - ((T actual-77°F) x (.003V/°F))
clean, dry wipers to ensure proper label adhesion. See Appendix A for standard values.

For protective module cover installation, see Section 10. STEP 1

A. Set constant voltage charger to maximum setting without

SECTION 10 exceeding 2.35 VPC. Example: For a target charge of

!
2.35 VPC on a 24-cell system, you would set the charger
10.0 Protective Module Covers voltage to 56.4 volts.

Each module is provided with a transparent protective cover Depending on the battery’s state of charge, the charger
to help prevent accidental contact with live module electrical may go into current limit at the beginning and decline
connections, and to provide easy visual access to the system. slowly once the target charge voltage is reached.

When all system assembly has been completed, as well as B. Record time and current at regular intervals – every hour
initial testing including initial charge and cell float voltage as a minimum.
readings, all covers should be installed. Covers should remain
in place at all times during normal operation of the battery C. Continue charging the battery until there is no further drop
system. in charge current over 3 consecutive hours. This could
take days if the battery has been in storage for a long time.
10.1 Module Cover Installation
D. When the current has stabilized, proceed to step 2.
Refer to Figure 24 for installation of the transparent Module
Covers. Install standoff legs and standoff keys first, as shown. STEP 2

The cover is then installed by grasping it so that the GNB logo A. C ontinue the charge for the time listed in Table B
is upright. Locate slots at the bottom of cover to the bottom depending on the charger voltage setting. The time is IN
standoff legs and slide in place. Locate the holes at top of ADDITION to the time spent charging in Step 1. Example,
cover and install to top standoff legs.Refer to Figure 24. charge for 12 hours if the charger voltage is set to 2.35
VPC.
TABLE B
SECTION 11
INITIAL CHARGE (77°F)
11.0 Initial Charge CELL VOLTS TIME-HRS (Minimum)
2.30 24
Batteries lose some charge during shipment as well as dur- 2.35 12
ing the period prior to installation. A battery should be given
its initial charge at installation. Battery positive (+) terminal B. Record cell voltages hourly during the last 3 hours of the
should be connected to charger positive (+) terminal and bat- charge time. If, after the charge time has completed, but
tery negative (-) terminal to charger negative (-) terminal. the lowest cell voltage has continued to rise, you may
extend the charge, monitoring cell voltages hourly, until
the lowest cell voltage ceases to rise.
- 17 -
C. Proceed to Step 3. TEMPERATURE CORRECTION
V corrected = V25°C - (( T actual-25°C) x ( .0055V/°C)) or
STEP 3 V corrected = V77°F - ((T actual-77°F) x (.003V/°F))

The initial charge is complete. Charger voltage can now See Appendix A for standard values.
be reduced to float voltage setting per Section 12.2. For
a target float charge of 2.25 VPC on a 24-cell system, you Modern constant voltage output charging equipment is recom-
would set the charger voltage to 54 volts. mended for the floating charger method of operation of GNB
Absolyte batteries. This type of charger, properly adjusted to the
recommended float voltages and following recommended surveil-
SECTION 12 lance procedures, will assist in obtaining consistent serviceability
and optimum life.
12.0 Operation
After the battery has been given its initial charge (refer to
12.0.1 Cycle Method of Operation Section 11), the charger should be adjusted to provide the
recommended float voltages at the battery terminals.
In cycle operation, the degree of discharge will vary for dif-
Do not use float voltages higher or lower than those recom-
ferent applications. Therefore, the frequency of recharging
mended. Reduced capacity or battery life will result.
and the amount of charge necessary will vary. The amount of
charge necessary depends on the number of ampere hours
Check and record battery terminal voltage on a regular
discharged. Generally, Absolyte GP cells require approx-
basis. Monthly checks are recommended. See Section 15.0,
imately 105-110% of the ampere-hours removed to be Records, second bullet. If battery float voltage is above or
returned to achieve a full state of charge. below the correct value, adjust charger to provide proper
voltage as measured at the battery terminals.
The upper voltage settings recommended, given that the
maxium charge current is 5% of the nominal C100 Amp-hour 12.3 Voltmeter Calibration
rating and ambient temperatures of 25°C (77°F), are as fol-
lows:
Panel and portable voltmeters used to indicate battery float
2.28 ± 0.02 VPC @ 0-2% DOD voltages should be accurate at the operating voltage value.
2.33 ± 0.02 VPC @ 3-5% DOD The same holds true for portable meters used to read indi-
2.38 ± 0.02 VPC @ >5% DOD vidual cell voltages. These meters should be checked against
a standard every six months and calibrated when necessary.
Due to the variety of applications and charging equipment
(particularly in Photovoltaic systems) it is recommended that
you contact an GNB representative when determining proper 12.4 Recharge
recharge profiles.
All batteries should be recharged as soon as possible follow-
ing a discharge with constant voltage chargers. However, to
12.1 Floating Charge Method
recharge in the shortest period of time, raise the charger out-
put voltage to the highest value which the connected system
In this type of operation, the battery is connected in parallel will permit. Do not exceed the voltages and times listed in
with a constant voltage charger and the critical load circuits. Table C, Section 13.2.
The charger should be capable of maintaining the required
constant voltage at battery terminals and also supply a nor-
12.5 Determining State-of-Charge
mal connected load where applicable. This sustains the bat-
tery in a fully charged condition and also makes it available
to assume the emergency power requirements in the event If the normal connected load is constant (no emergency load
of an AC power interruption or charger failure. connected), the following method can be used to determine
the approximate state-of-charge of the battery. The state-of-
charge can be identified to some degree by the amount of
12.2 Float Charge - Float Voltages charging current going to the battery. When initially placed
on charge or recharge following a discharge, the charging
Following are the float voltage ranges recommended for the current, read at the charger ammeter, will be a combination
Absolyte Battery System. Select any “volts per cell” (VPC) of the load current plus the current necessary to charge the
value within the range listed that will result in the series string battery. The current to the battery will start to decrease and
having an average volts per cell equal to that value. will finally stabilize when the battery becomes fully charged.
If the current level remains constant for three consecutive
RECOMMENDED FLOAT RANGE (@77°F) hours, then this reflects a state-of-charge of approximately
2.23 to 2.27 VPC 95 to 98%. For most requirements, the battery is ready for
use.
NOTE: Recommended float voltages are for 77°F. For other
temperatures a compensation factor of .003 V/°F (.0055 V/°C) If the normal connected load is variable (i.e. telecommunica-
per cell is recommended. The minimum voltage is 2.20 VPC, tions), the following method may be used to check the state-
temperature correction does not apply below this voltage. The of-charge of the battery. Measure the voltage across a pilot
maximum voltage is 2.35 VPC, temperature correction does cell (See Section 14.0 for definition of pilot cell). If the voltage
not apply above this voltage. is stable for 24 consecutive hours, the battery reflects a state
of charge of approximately 95%.

- 18 -
 “Reference” ohmic values are of dubious value because so
12.6 Effects of Float Voltage many factors can affect the way the readings are made and
displayed by the devices. Connector configuration and AC
Float voltage has a direct effect on the service life ripple as well as differences between readings of temperature
of your battery and can be the cause of thermal instability. and probe placement will prevent the ohmic devices from
generating consistent and meaningful data. The meters work
A float voltage above the recommended values reduces ser- better with monoblocs and small capacity VRLA products
vice life. The chart below shows the effects of float voltage and less well with large (>800-Ah) VRLA and flooded battery
(temperature corrected) on battery life. designs. Users should be particularly skeptical of data
taken on series-parallel VRLA battery configurations as the
Temperature corrected 77°F (25°C) Percent
feedback signal to the device may follow unforeseen paths
Float voltage per cell Reduction
that can overwhelm it.
Minimum Maximum in Battery Life
2.23 2.27 0% It is best for users to establish their own baseline values
2.28 2.32 50% for their battery as specifically configured. Do not rely on
2.33 2.37 75% reference values.
Voltage records must be maintained by the user in accor-
dance with the maintanence schedule published in this man- If users wish to enhance normal maintenance and record-
ual. To obtain the optimum service life from the battery, it is keeping with ohmic measurements, GNB recommends the
important to make sure the battery’s float voltage is within trending of this data over time. Use a first set of readings
the recommended range. taken 6 months after initial charge and installation as the
baseline data. Subsequent measurements should be taken
12.7 Float Current and Thermal Management using the same device over the life of the battery. Because
cell positioning within the string (connector configuration to a
Increased float current can portend a condition known as particular cell) can affect the reading, always compare each
thermal runaway, where the battery produces more heat than cell at baseline to itself in the new data. Standalone ohmic
it can dissipate. VRLA batteries are more prone to thermal data is not sufficient to justify warranty cell replacement.
runaway because the recombination reaction that occurs at
the negative plate, and reduces water loss, also produces Responsible ohmic device manufacturers acknowledge that
heat. High room temperature, improper applications, there is no direct relationship between percent ohmic change
improper voltage settings, and incorrect installation practices from baseline and battery capacity. A change from baseline
can increase the chances of thermal runaway. of 25% or less is in the normal noise or variability range.
Changes between 25% and 50% may call for additional
As with good record-keeping practices, monitoring float scrutiny of the system. An IEEE compliant discharge test is
current can prevent a minor excursion from becoming a usually warranted on systems exhibiting more than a 50%
major issue. change from baseline. Consult an GNB representative for
specific questions about ohmic data.
12.8 AC Ripple
SECTION 13
AC ripple is noise or leftover AC waveform riding on the DC
charge current to the battery that the rectifier did not remove. 13.0 Equalizing Charge
It is usually more pronounced in UPS than telecom systems.
Proper maintenance of the UPS capacitors will reduce the Under normal operating conditions an equalizing charge is
amount of ripple going into the battery. not required. An equalizing charge is a special charge given
a battery when non-uniformity in voltage has developed
Establishment of absolute limits for AC ripple has always between cells. It is given to restore all cells to a fully charged
been problematic because the degree of damage it causes condition. Use a charging voltage higher than the normal
depends on the wave shape, peak-to-peak magnitude and float voltage and for a specified number of hours, as deter-
frequency. Accurate characterization of AC ripple requires mined by the voltage used.
an oscilloscope and even then, only represents a picture of
the ripple at that moment in time. Non-uniformity of cells may result from low float voltage due
to improper adjustment of the charger or a panel voltme-
Whatever its exact characteristics, AC ripple is always ter which reads an incorrect (higher) output voltage. Also,
harmful to batteries. Depending on its particular properties, variations in cell temperatures greater than 5°F (2.78°C) in the
ripple can result in overcharge, undercharge and micro- series string at a given time, due to environmental conditions
cycling that can prematurely age the battery. The most or module arrangement, can cause low cells.
common and damaging result of AC ripple is battery heating
which can lead to thermal runaway. AC ripple will decrease 13.1 Equalizing Frequency
battery life and should be reduced as much as possible.
An equalizing charge should be given when the following
conditions exist:
12.9 Ohmic Measurements
A. The float voltage of any cell (as per Section 14.0) is less
Impedance, resistance and conductance testing is than 2.18 VPC.
collectively known in the industry as ohmic measurements.
Each measurement is derived using a manufacturer-specific B. A recharge of the battery is required in a minimum time
and proprietary algorithm and / or frequency. This means period following an emergency discharge.
that one type of measurement cannot be converted or related
easily to another.
- 19 -
C. Individual cell(s) float is more than +/- 0.05 volts from aver- charge, monitoring cell voltages hourly, until the lowest cell
age. voltage ceases to rise.
D. Accurate periodic records (See Section 15) of individual C. Proceed to Step 3.
cell voltages show an increase in spread since the previ-
ous semi-annual readings. STEP 3
An annual equalize charge is recommended to help ensure
The Equalize charge is now complete. Charger voltage can
uniform cell performance.
now be reduced to float voltage setting per Section 12.2.
For a target float charge of 2.25 VPC on a 24-cell system,
13.2 Equalizing Charge Method you would set the charger voltage to 54 volts.

Constant voltage charging is the method for giving an equal- SECTION 14

izing charge. Determine the maximum voltage that may
be applied to the system equipment. This voltage, divided 14.0 Pilot Cell
by the number of cells connected in series, will establish
the maximum volts per cell that may be used to perform A pilot cell is selected in the series string to reflect the gen-
the equalizing charge in the shortest period of time (not to eral condition of cells in the battery. The cell selected should
exceed 2.35 VPC applicable at 77°F, 25°C). Refer to Table C be the lowest cell voltage in the series string following the
for voltages and recommended time periods. initial charge. See Section 11.0 - Initial Charge. Reading and
recording pilot cell voltage monthly serves as an indicator of
NOTE: Charge volts listed in Table C are for 77°F. For other battery condition between scheduled overall individual cell
temperatures a compensation factor of .003 V/°F (.0055 readings.
V/°C) per cell is recommended. The minimum voltage is
2.20 VPC. The maximum voltage is 2.35 VPC. Temperature
correction does not apply outside of this range.
SECTION 15

V corrected = V25°C - ((T actual-25°C) x (.0055 V/°C))or 15.0 Records

V corrected = V77°F - ((T actual-77°F) x (.003 V/°F))
The following information must be recorded at installation,
See Appendix A for standard values. and annually for every year of operation after installation.
These records must be maintained throughout the
STEP 1 life of the battery and made available for review by GNB
representatives for capacity or life related warranty claims.
A. Set constant voltage charger to maximum setting without Failure to collect and store these maintenance data will void
exceeding 2.35 VPC. the warranty. Please review the warranty statement specific
to the battery application for any additional requirements.
Example: For a target charge of 2.35 VPC on a 24-cell
system, you would set the charger voltage to 56.4 volts. • Individual cell voltages

B. Record time and current at regular intervals – every hour • Overall string voltage
as a minimum.
• Ambient temperature immediately surrounding battery
C. Continue charging the battery until there is no further drop
in charge current over 3 consecutive hours. • B attery temperature at several places throughout the
string. Recommend 1 reading per battery stack. More data
D. When the current has stabilized, proceed to step 2. points are recommended for larger batteries and to check
for temperature gradients. Readings on the tray, cell cover
STEP 2 or negative terminal are good places to measure battery
temperature. Take readings away from HVAC sources.
A. Continue the charge for the time listed in Table C
depending on the charger voltage setting. The time is IN • F loat current measured at stack to stack connections
ADDITION to the time spent charging in Step 1. (optional)

Example, charge for 12 hours if the charger voltage is set to • Ohmic measurements (optional). Baseline ohmic readings
2.35 VPC. of individual cells should be taken 6 months from the date
of initial charge.
TABLE C
• Retorque connectors as part of annual maintenance.
EQUALIZE CHARGE (77°F)
ONCE PER YEAR READINGS ARE THE ABSOLUTE
CELL VOLTS TIME (HOURS) MINIMUM REQUIRED TO PROTECT WARRANTY. More
2.30 24 frequent readings are recommended, especially for critical
2.35 12 sites. Good record-keeping will prevent minor issues from
escalating into more serious problems over time. See Figure
B. Record cell voltages hourly during the last 3 hours of the 25 for sample record-keeping form.
charge time. If, after the charge time has completed, but the
lowest cell voltage has continued to rise, you may extend the

- 20 -
 SECTION 16 SECTION 19

16.0 Tap Connections 19.0 Connections

Tap connections should not be used on a battery. This can Battery terminals and intercell connections should be cor-
cause overcharging of the unused cells and undercharging of rosion free and tight for trouble-free operation. Periodically
those cells supplying the load, thus reducing battery life. these connections should be inspected.

SECTION 17

17.0 Temporary Non-Use

! CAUTION!

DO NOT WORK ON CONNECTIONS

An installed battery that is expected to stand idle longer WITH BATTERY CONNECTED TO
than the maximum storage interval (see Sec. 4.2), should be CHARGER OR LOAD.
treated as stated below. The maximum storage interval is 6
months if stored at 77°F.
If corrosion is present, disconnect the connector from the
Give the battery an equalizing charge as per Section 13. terminal.
Following the equalizing charge, open connections at the
battery terminals to remove charger and load from the bat- Gently clean the affected area using a suede brush or Scotch
tery. Brite scouring pad. Apply a thin coating of NO-OX-ID “A”
grease to the cleaned contact surfaces, reinstall connectors
Repeat the above after every 6 months (77°F) or at the and retorque connections to 11.3 Newton-meters (100 inch
required storage interval. See Section 4.2 for adjustments pounds).
to storage intervals when the storage temperature exceeds
77°F. ALL TERMINAL AND INTERCELL CONNECTIONS SHOULD
BE RETORQUED AT LEAST ONCE EVERY YEAR TO 11.3
To return the battery to normal service, re-connect the bat- NEWTON-METERS (100 INCH POUNDS).
tery to the charger and the load, give an equalizing charge
and return the battery to float operation. NOTE: Design and/or specifications subject to change
without notice. If questions arise, contact your local
sales representative for clarification.
SECTION 18

18.0 Unit Cleaning SECTION 20

Periodically clean cell covers with a dry 2” paintbrush to 20.0 Capacity Testing
remove accumulated dust. If any cell parts appear to be
damp with electrolyte or show signs of corrosion, contact When a capacity discharge test is desired, it is recommend-
your local GNB representative. ed that it be performed in accordance with IEEE-1188*, latest
revision.

CAUTION! An equalizing charge, as described in Section 13.2, must be

completed within 7 days prior to the capacity test. The bat-
Do not clean plastic parts with solvents, teries must be returned to float charging immediately after
detergents, oils, mineral spirit or spray the equalize charge completes. Allow the batteries to float at
type cleaners as these may cause crazing least 72 hours prior to capacity discharge.
or cracking of the plastic materials.
After the capacity discharge has completed, the batteries can
be recharged in the shortest amount of time by following the
equalize charge procedure described in Section 13.2.

*IEEE-1188: Recommended Practice for Maintenance,

Testing, and Replacement of Valve-Regulated Lead-Acid
(VRLA) Batteries for Stationary Applications.

- 21 -
 DATE: ABSOLYTE BATTERY MAINTENANCE REPORT
COMPANY: SERIAL NUMBER: PAGE 1 OF
ADDRESS: BATTERY LOCATION / NUMBER:
A Division of Exide Technologies
No. of CELLS: TYPE: MANUF. DATE: INSTALL DATE:
SYSTEM VOLTAGE: TEMPERATURE: CHARGER VOLTAGE: CHARGER CURRENT:
Cell Conn. Ohmic Cell Conn. Ohmic Cell Conn. Ohmic Cell Conn. Ohmic
No. Volts Resist. C / R / I Tem p No. Volts Resist. C / R / I Tem p No. Volts Resist. C / R / I Tem p No. Volts Resist. of Exide
A DivisionC / R Technologies
/ I Temp
1 31 61 91
2 32 62 92
3 33 63 93
4 34 64 94 A Division of Exide Technologies

5 35 65 95
6 36 66 96
7 37 67 97
8 38 68 98
9 39 69 99
10 40 70 100
11 41 71 101
12 42 72 102
13 43 73 103
14 44 74 104
15 45 75 105

- 22 -
16 46 76 106

Figure 25.1
17 47 77 107
18 48 78 108
19 49 79 109
20 50 80 110
21 51 81 111
22 52 82 112
23 53 83 113
24 54 84 114
25 55 85 115
26 56 86 116
27 57 87 117
28 58 88 118
29 59 89 119
30 60 90 120

ADDITIONAL COMMENTS:
 DATE: ABSOLYTE BATTERY MAINTENANCE REPORT
COMPANY: SERIAL NUMBER: PAGE 1 OF
ADDRESS: BATTERY LOCATION / NUMBER:
A Division of Exide Technologies
No. of CELLS: TYPE: MANUF. DATE: INSTALL DATE:
SYSTEM VOLTAGE: TEMPERATURE: CHARGER VOLTAGE: CHARGER CURRENT:
Cell Conn. Ohmic Cell Conn. Ohmic Cell Conn. Ohmic Cell Conn. Ohmic
No. Volts Resist. C / R / I Temp No. Volts Resist. C / R / I Temp No. Volts Resist. C / R / I Temp No. Volts A Division of
Resist. CExide
/ RTechnologies
/ I Temp
1 31 61 91
2 32 62 92
3 33 63 93
4 34 64 94 A Division of Exide Technologies

5 35 65 95
6 36 66 96
7 37 67 97
8 38 68 98
9 39 69 99
10 40 70 100
11 41 71 101
12 42 72 102
13 43 73 103

- 23 -
14 44 74 104

Figure 25.2
15 45 75 105
16 46 76 106
17 47 77 107
18 48 78 108
19 49 79 109
20 50 80 110
21 51 81 111
22 52 82 112
23 53 83 113
24 54 84 114
25 55 85 115
26 56 86 116
27 57 87 117
28 58 88 118
29 59 89 119
30 60 90 120

ADDITIONAL COMMENTS:
 APPENDIX A
Temperature Corrected Float Voltages
Expressed in Volts per Cell

Float Voltage at 25°C Float Voltage at 77°F

2.23 2.24 2.25 2.26 2.27 2.23 2.24 2.25 2.26 2.27
3 2.35 55 2.30 2.31 2.32 2.33 2.34
4 2.35 2.35 56 2.29 2.30 2.31 2.32 2.33
5 2.34 2.35 57 2.29 2.30 2.31 2.32 2.33
6 2.34 2.35 58 2.29 2.30 2.31 2.32 2.33
7 2.33 2.34 2.35 59 2.28 2.29 2.30 2.31 2.32
8 2.33 2.34 2.35 60 2.28 2.29 2.30 2.31 2.32
9 2.32 2.33 2.34 2.35 61 2.28 2.29 2.30 2.31 2.32
10 2.32 2.33 2.34 2.35 62 2.28 2.29 2.30 2.31 2.32
11 2.31 2.32 2.33 2.34 2.35 63 2.27 2.28 2.29 2.30 2.31
12 2.31 2.32 2.33 2.34 2.35 64 2.27 2.28 2.29 2.30 2.31
13 2.30 2.31 2.32 2.33 2.34 65 2.27 2.28 2.29 2.30 2.31
14 2.30 2.31 2.32 2.33 2.34 66 2.26 2.27 2.28 2.29 2.30
Battery Temperature (°C)

15 2.29 2.30 2.31 2.32 2.33 67 2.26 2.27 2.28 2.29 2.30
16 2.28 2.29 2.30 2.31 2.32 68 2.26 2.27 2.28 2.29 2.30

Battery Temperature (°F)

17 2.28 2.29 2.30 2.31 2.32 69 2.25 2.26 2.27 2.28 2.29
18 2.27 2.28 2.29 2.30 2.31 70 2.25 2.26 2.27 2.28 2.29
19 2.27 2.28 2.29 2.30 2.31 71 2.25 2.26 2.27 2.28 2.29
20 2.26 2.27 2.28 2.29 2.30 72 2.25 2.26 2.27 2.28 2.29
21 2.26 2.27 2.28 2.29 2.30 73 2.24 2.25 2.26 2.27 2.28
22 2.25 2.26 2.27 2.28 2.29 74 2.24 2.25 2.26 2.27 2.28
23 2.25 2.26 2.27 2.28 2.29 75 2.24 2.25 2.26 2.27 2.28
24 2.24 2.25 2.26 2.27 2.28 76 2.23 2.24 2.25 2.26 2.27
25 2.23 2.24 2.25 2.26 2.27 77 2.23 2.24 2.25 2.26 2.27
26 2.23 2.24 2.25 2.26 2.27 78 2.23 2.24 2.25 2.26 2.27
27 2.22 2.23 2.24 2.25 2.26 79 2.22 2.23 2.24 2.25 2.26
28 2.22 2.23 2.24 2.25 2.26 80 2.22 2.23 2.24 2.25 2.26
29 2.21 2.22 2.23 2.24 2.25 81 2.22 2.23 2.24 2.25 2.26
30 2.21 2.22 2.23 2.24 2.25 82 2.22 2.23 2.24 2.25 2.26
31 2.20 2.21 2.22 2.23 2.24 83 2.21 2.22 2.23 2.24 2.25
32 2.20 2.21 2.22 2.23 2.24 84 2.21 2.22 2.23 2.24 2.25
33 2.20 2.21 2.22 2.23 85 2.21 2.22 2.23 2.24 2.25
34 2.20 2.21 2.22 2.23 86 2.20 2.21 2.22 2.23 2.24
35 2.20 2.21 2.22 87 2.20 2.21 2.22 2.23 2.24
36 2.20 2.20 2.21 88 2.21 2.22 2.23 2.24
37 2.20 2.21 89 2.20 2.21 2.22 2.23
38 2.20 90 2.20 2.21 2.22 2.23
39 2.20 91 2.21 2.22 2.23
92 2.21 2.22 2.23
93 2.20 2.21 2.22
94 2.20 2.21 2.22
95 2.21 2.22

- 24 -
- 25 -
 APPENDIX C

BONDING & GROUNDING OF BATTERY RACK

INTRODUCTION
1. To insure personnel safety, and equipment protection, operation, and reliability, the battery rack should be connected to the
Common Bonding Network (CBN).

2. E
 lectrical continuity between modules is provided through the use of serrated hardware. If continuity between the horizontal
supports (I-beams) and the bottom module is desired, the use of a grounding kit (GNB P/N: K17ABSGPGRND) is required.
This kit is available through your local GNB representative.

GROUNDING KIT INSTALLATION

1. Each kit consists of the following components:
(2) #6 AWG, 12 in. 90°C cables
(4) “C” shaped beam clamps
(4) 1/4-20 x 0.75 in. bolts
(4) 1/4-20 x 1.00 in. bolts

2. U
 sing (1) 1/4-20 x 1.00 in. bolt per beam clamp, connect (1) beam clamp to the I-beam flange and (1) beam clamp to the back
flange of the module (see Figure 1). Be sure to securely tighten the bolts such that the paint is penetrated (see Figure 2).

3. Attach each end of cable assembly to a beam clamp using (1) 1/4-20 x 0.75 in. bolt per end (see Figure 3). Tighten hardware securely.

4. Repeat Steps 2 and 3 for the second horizontal support (I-beam).

Figure 1: Beam Clamp Installation Figure 2: Adequate Paint Penetration Figure 3: Cable Assembly Installation

CONNECTING TO THE CBN

1. The recommended location for attaching the frame ground is the back “C” channel on the
upper module of the stack (see Figure 4).

Figure 4: Recommended Frame

Ground Location

2. Once the location is determined, it will be necessary to drill (2) holes for the frame ground conductor/lug (installer supplied).
Note, hole size and spacing will be dependent on the lug.

3. Using a grinder, etc., remove the paint from around the holes drilled in Step 2.
Apply a thin film of NO-OX-ID “A” grease to the bare metal and attach the frame ground conductor/lug.

- 26 -
 APPENDIX D
Absolyte GP Maximum Module Stack Heights
Horizontal Arrangement

1997 UBC Ground Level Zone

Series Height 1 2B 3 4
10 high 100G33 100G33 100G31 100G17
100G 9 high 100G33 100G33 100G33 100G23
8 high 100G33 100G33 100G33 100G33
10 high 90G15 90G15 90G15 90G09
90G 9 high 90G15 90G15 90G15 90G11
8 high 90G15 90G15 90G15 90G15
10 high 50G09 50G09 50G09 50G09
50G 9 high 50G11 50G11 50G11 50G11
8 high 50G15 50G15 50G15 50G15

IEEE 693-2005 Certification Level

Series Height High Moderate
10 high
100G 8 high X
5 high X
10 high
90G 8 high X
5 high X
10 high
50G 8 high X
5 high X

IBC 2012 Certification

Series Height SDS at/below grade SDS above grade
10 high
100G* 8 high 0.81 0.51
5 high 0.81 0.51
10 high
90G 8 high 0.81 0.51
5 high 2.50 1.56
10 high
50G 8 high 0.81 0.51
5 high 2.50 1.56
*For higher SDS design, contact GNB Aurora

- 27 -
GNB Industrial Power –
The Industry Leader.

SECTION 92.61 2015-02

Installation and Operating

Instructions

®
For

GNB Industrial Power, a division of Exide Technologies, is a

global leader in network power applications including
Based on over 100 years of technological innovation the Network
Power group leads the industry with the most recognized global
ABSOLYTE® GP Batteries
communication/data networks, UPS systems for computers brands such as ABSOLYTE®, GNB® FLOODED CLASSIC®,
and control systems, electrical power generation and MARATHON®, RELAY GEL®, SONNENSCHEIN®, and
distribution systems, as well as a wide range of other SPRINTER®. They have come to symbolize quality, reliability,
industrial standby power applications. With a strong performance and excellence in all the markets served.
manufacturing base in both North America and Europe and a
truly global reach (operations in more than 80 countries) in GNB Industrial Power takes pride in its commitment to a better
sales and service, GNB Industrial Power is best positioned to environment. Its Total Battery Management program, an
satisfy your back up power needs locally as well as all over the integrated approach to manufacturing, distributing and recycling
world. of lead acid batteries, has been developed to ensure a safe and
responsible life cycle for all of its products.

GNB Industrial Power

USA – Tel: 888.898.4462
Canada – Tel: 800.268.2698

www.gnb.com
UL Recognized Component
SECTION 92.61
93.10 2015-02
2010-12 A Division of Exide Technologies A Division of Exide Technologies