pyl – general instructions for operations personnel...pyl – general instructions for operations...

PYL – General Instructions for Operations Personnel

GS Yuasa Energy Solutions, Inc.



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CONTENTS

Section Page

1. PURPOSE...............................................................................................32. PYL 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. PURPOSE

Thisdocumentisissuedtoprovidegeneralinformationrelatingtothisspecificproductlineforinstallationandmain-tenancepersonnel.Forthepurposesofthisdocumenta12Vblocorbatterywillbereferredtoasamodule. 2. PYL SERIES

ThePYLseriesisspeciallydesignedfortelecommunicationsapplications.ThePYLseriesispartofanextensivelineofmaintenancefree,gasrecombinantVRLAbatteriesofferedbyGSYuasaEnergySolutions,Inc.The10-yeardesignlifePYListhemostcost-effectivebatterysolutionoverthetotallifecycleforinstallationinyournetwork.



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3. COMPANY INFORMATION

GSYuasaEnergySolutions,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. CERTIFICATIONS

BatteriesareUL1989listed,GR4228compliant,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 HANDLING

Thefollowingprecautionsshouldbeobservedwhenhandlingandworkingwithbatteries.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 REMOVAL

Thefollowingarerecommendedforpersonalprotectionandsafeinstallationorremovalofmodules. 1. Insulatedhandtools. 2. Fireextinguisher. 3. Acidspillkit. 4. Eyeprotection. 5. Eyewash. 6. Mechanicalliftingequipmentmayberequiredincertainapplicationssuchascontrolled environmentalvaults.

7. TRANSPORTATION

Module terminals shouldbeprotected fromshortingduring transportation.Newmodulesshould remain in theoriginalpackagingmaterialtoprotectthecaseandterminalsuntiltheyaretobeinstalled.Shockor‘bruising’causedbydroppingorroughhandlingofamodulecancauseinternaldamagetoplates,inter-cellstraps,orcompromisetheintegrityofthecase.Modulesbeingremovedfromserviceshouldlikewisebeprotectedwhenbeingtransportedfromthejobsiteortotherecycler.ThePYLseriesisrated‘NON-SPILLABLE’andshouldbesolabeledduringshipping.The Safety Data Sheet (SDS) isavailablefordownloadatthefollowinglink:http://www.gsyuasa-es.com

8. DELIVERY INSPECTION

Upon 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.



9. STORAGEModulesshouldbestoredinacool,cleananddryplacenottoexceedtherangefrom-20oto40oC.Modulesshippeddirectlytothecustomerdonotrequirerefreshcharginguponreceipt.Modulesstoredforextendedperiodsmayrequirearefreshchargepriortoinstallationorfurtherstorage(Table 9.0-A).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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Average Storage Temperature (Centigrade)

Typical Storage Period before Refresh Charging

Recommended Interval to Measure OCV



Model AmperesPYL12V45FS 5PYL12V80TT 8PYL12V90TT 9PYL12V90FS 9

PYL12V100FA 25PYL12V100FS 10PYL12V100FT 23PYL12V140TT 35PYL12V155FT 15PYL12V160FT 16PYL12V185FT 19PYL12V200FT 20

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10. CHARGING

Performanceandlifeisinpartinfluencedbythepowersystemandtheoperatingtemperature.Thisisespeciallytrueforbatteriesusedintelecommunicationsstandbyfloatapplications.TheoperatingtemperaturerangeforthePYLseriesis-40°Cto+55°C(shorttermexcursionsto65°Carepermissible).

Float voltage and properly functioning temperature compensation are the keys to long battery life. Therecommendedfloatvoltage rangeat25°C is foundon theproduct label foreachmodelof thePYL series.Hightemperaturecompensationbeginsat26°Candlowtemperaturecompensationbeginsat24°C.Theexactpointsatwhichtemperaturecompensationbegincanbevariedslightlyaslongasthebatteryiskeptwithintherecommendedfloatrangeadjustedfortemperature.

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.ThemaximumrecommendedrechargecurrentforthePYLseriesisfoundinTable 10.0-A.

Table 10.0-A. Maximum Recommended Recharge Current



11. INSTALLATION CONSIDERATIONS

Inthissectionaregeneralconsiderationsforbatteryinstallation.

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).

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Table 11.0-A. Typical Conductance Reference Values

ModelSiemens/MHOS30 Days on float

PYL12V45FS 854PYL12V80TT 1163PYL12V90TT 1566PYL12V90FS 1395

PYL12V100FA 1252PYL12V100FS 1180PYL12V100FT 1659PYL12V140TT 2015PYL12V155FT 1976PYL12V160FT 1903PYL12V185FT 2255PYL12V200FT 2023



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3. Donotinstallmodulesinanairtightenclosure.

4. Modulesmaybeinstalledinanelectronicsequipmentcabinetwhererequired.

5. Liftandmovemodulescarefullytoavoidpersonalinjuryordamagetothemodule.

NOTE:Insomecases,thismayrequiretwotechniciansormechanicalliftingequipment.Neverlifta modulebytheterminaloranattachedbatterycableorbatterysupplyharness.

6. Donotinstallmodulesthathavebeendropped,damagedorshowanyindicationofleakageorcorrosionat theterminals.

NOTE: Damagetothecaseorterminalsmayresultinprematurefailureorshortenthelifeofthemodule.

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:Somemodulesmaybeequippedwithapre-installedbatterycableassemblyforcertainapplications.Theseterminalboltsornutsweretightenedatourfacilityusingcalibratedwrenchesanddonotrequirere-torque.Re-torqueisnotrequiredforanyGYESterminalhardware.However,ifrequiredbyyourCompanythevaluesinTable 11.0-Bmaybeused.

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Model Top Boltin-lbsTop Bolt

NmTop Bolt Socket

Front Bolt in-lbs

Front Bolt Nm

Front Bolt Socket

PYL12V45FS 43.4 4.9 10mm 26.55 3.0 8mmPYL12V80TT 43.4 4.9 10mm NA NA NAPYL12V90TT 43.4 4.9 10mm NA NA NAPYL12V90FS 90 10.17 13mm 43.4 4.9 10mm

PYL12V100FA NA NA NA 43.4 4.9 10mmPYL12V100FS NA NA NA 43.4 4.9 10mmPYL12V100FT 43.4 4.9 10mm 43.4 4.9 10mmPYL12V140TT 43.4 4.9 13mm NA NA NAPYL12V155FT 90 10.17 13mm 43.4 4.9 10mmPYL12V160FT 90 10.17 13mm 43.4 4.9 10mmPYL12V185FT 90 10.17 13mm 43.4 4.9 10mmPYL12V200FT 90 10.17 13mm 43.4 4.9 10mm

Table 11.0-B. Torque Specifications

Table 11.0-C. Float and Temperature Compensation

VpC @ 25°C High Temp StartLow Temp

Start Slope

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.

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12. MAINTENANCE AND REPLACEMENT

12.1 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. DISPOSAL

Lead 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.americasbatteryrecyclers.orgorwww.batterycouncil.org.

pyl – general instructions for operations personnel...pyl – general instructions for operations...

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