15DOC0020

NorthStar Battery (NSB) Telecom Installation and Operation

Guide

Contents

0 Definitions ................................................................................................................. 3
1 Battery Safety ........................................................................................................... 3
1.1 Old Batteries ...................................................................................................... 3
2 Determining Battery Manufacturing Date .................................................................. 3
3 Handling ................................................................................................................... 4
3.1 Receiving the shipment ...................................................................................... 4
3.2 Do ...................................................................................................................... 4
3.3 Don’t ................................................................................................................... 5
4 Storage ..................................................................................................................... 5
4.1 Storage conditions ............................................................................................. 5
4.2 Shelf Life ............................................................................................................ 6
5 Commissioning ......................................................................................................... 6
5.1 Unpacking the Batteries ..................................................................................... 6
5.2 Checking the Voltage Spread............................................................................. 6
5.3 Putting the Batteries in Place ............................................................................. 6
5.4 Connecting the Batteries .................................................................................... 6
5.5 Discharge Rate .................................................................................................. 7
6 Maintenance ............................................................................................................. 7
6.1 Cleaning, Pesticides, and Chemicals ................................................................. 7
7 Silver Star Technology® ............................................................................................ 8
7.1 Self Discharge During Storage ........................................................................... 8
7.2 Putting the Battery In Service ............................................................................. 8
7.3 Charging Voltage ............................................................................................... 8

Date: 04-21-14 DCO-100046 DCN: SES-544-02-10 Page 1 of 14

8 Blue Star Technology® .............................................................................................. 9
8.1 Self Discharge During Storage ........................................................................... 9
8.2 Charging the batteries prior to operation ............................................................ 9
8.3 Boost Charging ................................................................................................ 10
8.4 Float Charging Voltage .................................................................................... 10
9 Blue+ ...................................................................................................................... 11
9.1 Self Discharge During Storage ......................................................................... 11
9.2 Putting the Battery In Service ........................................................................... 11
9.3 Boost Charging ................................................................................................ 12
9.4 Float Charging Voltage .................................................................................... 12
10 Red Star Technology® ......................................................................................... 13
10.1 Self Discharge During Storage ..................................................................... 13
10.2 Putting the Battery In Service ....................................................................... 13
10.3 Charging Voltage .......................................................................................... 13
11 Contact ................................................................................................................ 14

To help us better serve you, please visit our web site at

http://www.northstarbattery.com/survey/ and complete our Customer Survey.
We value and appreciate your input.

Date: 04-21-14 DCO-100046 DCN: SES-544-02-10 Page 2 of 14

0 Definitions Batteries are heavy objects.
The definition for each of the following terms or Use proper handling equipment
abbreviations describes the context employed safety gear during installation.
throughout this document.
Inappropriate lead acid battery
disposal can result in
Monobloc* A discrete unit of one (1) or more
environmental contamination.
2-V cells
Please dispose of batteries
Battery* A unit or module consisting of one according to local regulations.
(1) or more monoblocs
Battery may be returned,
VPC Volts per cell shipping pre-paid, to the
manufacturer or any distributor
Electrolyte Sulfuric acid diluted with de- for recycling.
ionized water and mixed with
sodium sulfate Batteries contain electrolyte
(diluted sulfuric acid in de-
* Terms may be used interchangeably given the
ionized water). Any fluid found
circumstance.
outside the batteries should be
regarded as electrolyte.
1 Battery Safety

For full information please read the Material

Safety Data Sheet (MSDS). The MSDS
document may be downloaded from the Internet
1.1 Old Batteries
at:

http://www.northstarbattery.com/MSD-430- Monoblocs which have reached their End of Life

01.pdf (EOL) should be removed from the application
they are in and disposed of in accordance with
When dealing with Valve Regulated Lead Acid federal, state, and local laws concerning the
Batteries (VRLA) some additional safety handling of hazardous materials and the
information is required. environment. EOL is an industry defined term
for VRLA batteries which indicates that the
monobloc has only 80% of its original capacity
Please read and observe the left.
installation and operation
instructions. 2 Determining Battery Manufacturing Date

When working on batteries The manufacturing codes for NorthStar are

wear appropriate Personal located in two places on the battery case.
Protective Equipment (PPE).
Refer to battery MSDS for 1. On the front (the top picture in figure 1).
complete list. 2. On the right hand side towards the rear
Do not expose the battery to an (the bottom picture in figure 1).
open flame or other ignition
source. During operation an Monoblocs manufactured prior to July 2005 are
explosive mixture of hydrogen only marked on the right rear side of the battery
gas may accumulate. case.
Battery terminals are always
energized and, if short-circuited,
cause electrical arcing. Always
use insulated tools.

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Figure 1 Location of manufacturing labels on
NSB batteries
Manufacturing codes are limited to 12 alpha-
numeric digits. There are two formats of
manufacturing code serial numbers, one created
prior to and another created after January 2009.
Format 1 (manufactured prior to January 2009)
Manufacturing serial number example:
A08310632031
A = A letter which specifies the model
number
The remaining digits are interpreted using
the format below:
MMDDYYXXXXX
MM = Month
DD = Date
YY = Year
XXXXX = Individual monobloc serial
number
Using the example shown above, the
serial number is interpreted as: model
number NSB100FT manufactured on
(083106) August 31, 2006 with individual
serial number of (32031) 32031.
Date: 03-10-14 DCR: 2605-S14
Format 2 (manufactured after January 2009)
Taking the example from Figure 1 above, it
can be interpreted as follows:
SA1090781486
SA = First two digits specify the model
number
1 = Manufacturing Facility (Plant NSBI = 1,
Plant NSBII = 2)
The remaining digits are interpreted using
the format below:
YY = Year
XXX = Three-digit Julian calendar date
(manufacturing date)
XXXX = Individual monobloc serial
number
The example of serial number in Figure 1,
SA1090781486 can be interpreted as:
model number NSB110FT manufactured in
th
NSB Plant 1 in 2009 (09), on the 78 day of
the Julian calendar or on March 19, with an
individual serial number of 1486.
3 Handling
3.1 Receiving the shipment
In addition to safety requirements (see section 1)
special care should be taken when handling
monoblocs. The following are some DOs and
DON’Ts.
3.2 Do
 Always use the handles on the
monoblocs when lifting or carrying them.
 Always have a straight back and lift
using your legs when lifting or carrying
monoblocs.
 Always have appropriate safety gear
(see safety section) available when
handling monoblocs.
 Always perform an Open Circuit Voltage
(OCV) check on a monobloc PRIOR to
installation. Verify that the OCV is
DCN: SES-544-02-10 Page 4 of 14
 appropriate for the monoblocs
application.
 Always perform a visual inspection of
the monobloc prior to handling. If any
damage or electrolyte leakage is
detected during this inspection do not
install the monoblocs. Isolate and
remove spilled electrolyte using proper
cleaning process.
 Always use the packing from new
monoblocs for transporting old
monoblocs for proper disposal. If
unavailable, place batteries on a pallet
and strap them down secure for
shipping. Having the monoblocs loose
during transportation can lead to either
an inadvertent discharge of the
monoblocs, or damage to the
monoblocs and electrolyte leakage.
 Always dispose of monoblocs in
accordance with local and national
requirements.
 Always follow the instructions provided
with the monoblocs when installing
them.
 Always use insulated tools when
handling monoblocs. Failure to do so
can lead to electric shock.
3.3 Don’t
 Don’t drag a monobloc along the floor.
Doing so could cause damage to the
monobloc case leading to a possible
leakage of electrolyte.
 Don’t install a monobloc into any
application that has been dropped. A
dropped monobloc could have damage
to either its internal or external casing
leading to a possible leakage of
electrolyte and damage to equipment.
 Don’t make the final connection to an
application until all batteries in the string
have had their interconnections finished.
The batteries contain a large amount of
stored energy, and can cause damage
from an energy discharge.
 Don’t dispose of batteries in unapproved
sites. The batteries contain electrolyte
and compounds of lead that are harmful
to nature and can contaminate the
environment if not disposed of properly.
 Don’t drill, or in any other way attempt to
breach the monoblocs case. Doing so
Date: 03-10-14 DCR: 2605-S14
could lead to a possible leakage of
electrolyte.
 Don’t force a monobloc into equipment.
Forcing the monobloc into equipment
can lead to a breach in the monoblocs
internal or external casing causing a
possible leakage or electrolyte or
electrical short circuit.
 Don’t move the monoblocs using the
terminals. The terminals are not
designed to support the weight of the
monobloc, and damage to internal
components could result.
4 Storage
4.1 Storage conditions
Below is a list of equipment that is
recommended to be on hand in the area where
monoblocs are stored.
1. DC volt meter
2. Battery chargers (a normal car battery
charger, purchased locally, is sufficient)
3. Mechanical lifting device (such as a fork
lift etc.)
4. Appropriate Personal Protective
Equipment (PPE), which is listed in the
battery MSDS at:
http://www.northstarbattery.com/MSD-430-
01.pdf
It is strongly recommended to store the
monoblocs in a cool dry environment. For more
information see “Self Discharge During Storage”.
The monoblocs should be stored in the original
containers. The packaging serves to protect the
monoblocs from harsh environmental conditions
and accidental damage. If they must be
removed, palletize them, and utilize as much of
the original packaging as possible.
DCN: SES-544-02-10 Page 5 of 14
 charged individually before being connected in
series. Refer to the recharge table(s) in this
manual for the particular monobloc type used.

Alternatively the monoblocs may be matched in

each string so that all the monoblocs with
voltage spread less than 0.15V.

5.3 Putting the Batteries in Place

Different ways to correctly store monoblocs
Make sure the monoblocs are all evenly spaced,
aligned and rest on a flat surface. Resting the
4.2 Shelf Life monoblocs on an acid resistant, electrically
NorthStar batteries have a two year shelf life at insulating surface is strongly recommended.
+25° C (+77°F).
5.4 Connecting the Batteries

5 Commissioning The monoblocs shall be connected into series

Always use the installation instructions provided
with the monoblocs and follow all outlines for
safety and handling mentioned earlier in this
document.
5.1 Unpacking the Batteries
When received, a visual check should be made
on the monoblocs. If the monoblocs show
transportation damage, physical damage to the
case, leaking electrolyte etc., they should not be
installed, and a claim should be initiated
immediately.
Make sure all the accessories are present in the
delivery. Please observe the cardboard material
around the monoblocs has no bottom! The
cardboard should be removed prior to lifting the
monoblocs. Please keep all packing material for
future use if possible.
using the cable and connectors designed for the
particular layout of your delivery. Refer to the
particular layout of the system. Please observe
the risk for arcing and high currents when
connecting the monobloc string to the system.
Preferably the last connection should be made
at distance from the monobloc string. If the
system comprises a monobloc circuit breaker or
any other means of disconnection this shall be in
an off condition when connecting the monobloc
to the system. Before connecting cables, clean
contact surface and apply a light coating of anti-
oxidizing grease to contact surfaces. A torque
wrench must be used for tightening the bolts on
the battery. The covers shall be put back after all
connections have been completed. Please
observe that when heavy cables are used, these
need to be supported in order not to stress the
monoblocs terminals. The insulation covers
should be put back after all connections have
been completed. See the figures below:

If the monoblocs cannot be put into place Insulation Cover

directly in the end application and need to be put
on the floor/ground, put some of the cardboard
material under them in order to protect the
monobloc from hard surfaces. An alternative
material is to use the top of the crate that the
monoblocs were shipped in.

5.2 Checking the Voltage Spread

Before connecting the monoblocs in series, the

voltage variation must be checked. If the voltage
varies more than 0.15 V of the maximum
monobloc reference, the monoblocs should be

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5.5 Discharge Rate

In this document, the charge and discharge

rates (amps) are expressed as multiples of 10,
where 10 is the current for a 10-hour discharge
to 100% depth-of-discharge (DOD). These
values serve to normalize data across a range of
monobloc sizes. Consider the following example:

10-h discharge capacity NSB 100FT = 100 Ah

(EODV = 1.80 VPC @ 25°C).

1 x 10 = 1 x (10-h discharge current)

1 x 10(NSB 100FT) = 1 x 10A = 10 A
2 x 10(NSB 100FT) = 2 x 10A = 20 A

6 Maintenance
6.1 Cleaning, Pesticides, and Chemicals

The plastic monobloc containers are not

compatible with many commercially available
chemicals including cleaning products and
insecticides. These chemicals can damage the
monobloc case and cause leakage of electrolyte.
If the monobloc needs to be cleaned, use water.
Do not spray insecticides directly on the
monoblocs.

Date: 03-10-14 DCR: 2605-S14 DCN: SES-544-02-10 Page 7 of 14

 7 Silver Star Technology®

The following table shows approximate charge

7.1 Self Discharge During Storage
During storage, lead acid batteries will gradually
self discharge. It is recommended to maintain
State of Charge (SOC) above 50% by routinely
recharging the monoblocs.
times based on monobloc OCV, and assuming
the power avaliable for recharge is relatively low.
If the charging system is properly sized, a fast
charging regime may reduce the charge time.
For further details consult the Telecom
Application Manual.

The graph below shows that the rate of self OCV Recharge Time
discharge increases as the temperature >12.80 V 3 day charge @ 2.27 VPC
increases, hence requiring shorter recharge
intervals. 12.6-12.8 V 3 day charge @ 2.27 VPC
12.3-12.6 V 1 day charge @ 2.41 VPC
12.1-12.3 V 1 day charge @ 2.41 VPC

7.3 Charging Voltage

In order to achieve the design life, the

recommended float charging voltage must be
employed. The recommended float voltage is
2.27 ± 0.02 VPC (VPC) @ 25°C. This equates to
13.62 ± 0.12 V per monobloc provided that the
temperature will be close to 25°C. For other
temperatures, refer to our Table 2 below. For
7.2 Putting the Battery In Service UPS equipment multiply the voltage with the
number of monoblocs.
Depending on the voltage of the monoblocs at
the time of installation charge at elevated Table 2
voltage may be needed. In order to maximize
T °C / °F V (float) 24 V 48 V
life it is recommended that the monobloc be fully
20 / 68 13.74 ± 0.12V 27.48 ± 0.24V 54.96 ± 0.48V
recharged prior to initial startup. Measure the
voltage across the terminals of the monoblocs 25 / 77 13.62 ± 0.12V 27.24 ± 0.24V 54.48 ± 0.48V
and consult “Self Discharge During Storage” to 30 / 86 13.50 ± 0.12V 27.00 ± 0.24V 54.00 ± 0.48V
determine % SOC. 35 / 95 13.38 ± 0.12V 26.76 ± 0.24V 53.52 ± 0.48V

Date: 03-10-14 DCR: 2605-S14 DCN: SES-544-02-10 Page 8 of 14

 8 Blue Star Technology®

8.1 Self Discharge During Storage 8.2 Charging the batteries prior to
operation
During storage, lead acid batteries will gradually
®
self discharge. It is recommended to maintain Blue Star Technology batteries must be fully
State of Charge (SOC) above 50% by routinely charged prior to operation. The following table
recharging the batteries. gives the charging time required to reach full
SOC.
The graph below shows that the rate of self
discharge increases as the temperature
increases, hence requiring shorter recharge
intervals. Recharge Time
Current Limit (A)
VPC 1*I10 2*I0 4*I10 10*I10
1
2.27 V 2 Days 1 Day 1 Day
Day
12
2.35 V 12 hrs 6 hrs 6 hrs
hrs
2.45 V 12 hrs 6 hrs 6 hrs 6 hrs

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8.3 Boost Charging
A boost charge allows for the fastest recharge
following a deep discharge, or after long storage
time. The boost charging voltage shall be 2.35
VPC provided that the temperature is nominal
+25°C (+77°F). The following graph shows the
recommended charging profile:
NSB Boost Recharge Regime for Blue Star
®
Technology :
Boost Float
The table above shows the time needed to
recharge following a 100% Depth of Discharge
(DoD) cycle, depending on the maximum charge
current available.
8.4 Float Charging Voltage
The float charging voltage shall be 2.27 VPC
provided that the temperature is a nominal
+25°C (+77°F). If the site cannot be climate
controlled, float voltage must be adjusted
according to the graph below:

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 9 Blue+

9.1 Self Discharge During Storage 9.2 Putting the Battery In Service

During storage, lead acid batteries will gradually
self discharge. It is recommended to maintain
State of Charge (SOC) above 50% by routinely
recharging the batteries.
The graph below shows that the rate of self
discharge increases as the temperature
increases, hence requiring shorter recharge
intervals.
Depending on the voltage of the monoblocs at
the time of installation charge at elevated
voltage may be needed. In order to maximize
life it is recommended that the monobloc be fully
recharged prior to initial startup. Measure the
voltage across the terminals of the monoblocs
and consult “Self Discharge During Storage” to
determine % SOC.
The following table shows approximate charge
times based on monobloc OCV, and assuming
the power avaliable for recharge is relatively low.
If the charging system is properly sized, a fast
charging regime may reduce the charge time.
For further details consult the Telecom
Application Manual.

OCV Recharge Time

>12.80 V 3 day charge @ 2.27 VPC
12.6-12.8 V 3 day charge @ 2.27 VPC
12.3-12.6 V 1 day charge @ 2.41 VPC
12.1-12.3 V 1 day charge @ 2.41 VPC

Date: 03-10-14 DCR: 2605-S14 DCN: SES-544-02-10 Page 11 of 14

9.3 Boost Charging
A boost charge allows for the fastest recharge.
The boost charging voltage shall be 2.35 – 2.45
VPC. The following graphs show the charge
acceptance based on charging voltage.
Date: 03-10-14 DCR: 2605-S14
9.4 Float Charging Voltage
The float charging voltage shall be 2.27 VPC
provided that the temperature is a nominal
+25°C (+77°F). If the site cannot be climate
controlled, float voltage must be adjusted
according to the graph below:
DCN: SES-544-02-10 Page 12 of 14
 10 Red Star Technology®

The following table shows approximate charge

10.1 Self Discharge During Storage
During storage, lead acid batteries will gradually
self discharge. It is recommended to maintain
State of Charge (SOC) above 50% by routinely
recharging the batteries.
times based on monobloc OCV, and assuming
the power avaliable for recharge is relatively low.
If the charging system is properly sized, a fast
charging regime may reduce the charge time.
For further details consult the Telecom
Application Manual.

The graph below shows that the rate of self

discharge increases as the temperature OCV Recharge Time
increases, hence requiring shorter recharge
intervals. >12.80 V 3 day charge @ 2.27 VPC
12.6-12.8 V 3 day charge @ 2.27 VPC
12.3-12.6 V 1 day charge @ 2.41 VPC
12.1-12.3 V 1 day charge @ 2.41 VPC

10.3 Charging Voltage

In order to achieve the design life, the

recommended float charging voltage must be
employed. The recommended float voltage is
2.27 ± 0.02 VPC (VPC) @ 25°C. This equates to
13.62 ± 0.12 V per monobloc provided that the
temperature will be close to 25°C. For other
10.2 Putting the Battery In Service temperatures, refer to our Table 2 below. For
UPS equipment multiply the voltage with the
Depending on the voltage of the monoblocs at number of monoblocs.
the time of installation charge at elevated
voltage may be needed. In order to maximize Table 2
life it is recommended that the monobloc be fully
T °C / °F V (float) 24 V 48 V
recharged prior to initial startup. Measure the
20 / 68 13.74 ± 0.12V 27.48 ± 0.24V 54.96 ± 0.48V
voltage across the terminals of the monoblocs
and consult “Self Discharge During Storage” to 25 / 77 13.62 ± 0.12V 27.24 ± 0.24V 54.48 ± 0.48V
determine % SOC. 30 / 86 13.50 ± 0.12V 27.00 ± 0.24V 54.00 ± 0.48V
35 / 95 13.38 ± 0.12V 26.76 ± 0.24V 53.52 ± 0.48V

Date: 03-10-14 DCR: 2605-S14 DCN: SES-544-02-10 Page 13 of 14

11 Contact

NorthStar in the Americas

NorthStar Battery Company LLC
4000 Continental Way
Springfield, MO, 65803,
United States of America
info@northstarbattery.com
Tel: +1 417 575 8200
Fax: +1 417 575 8250

NorthStar in Europe, Middle East, Africa

SiteTel Sweden AB
Staffans Väg 6-8
Box 7039, SE-192 07 Sollentuna, Stockholm,
Sweden
emea@northstarsitetel.com
Tel: +46 8 410 102 00
Fax: +46 8 638 06 00

NorthStar in Asia-Pacific
SiteTel Shanghai Co Ltd
Building 9, 1201 Gui Qiao Road
Jin Qiao Export Process Zone, 201206
Shanghai, China
asia@northstarsitetel.com
Tel: +86 21 5899 7610
Fax: +86 21 3872 2201

SiteTel Shenzhen
15/F, Kerry Plaza Tower 2
No.1 Zhong Xin Si Road
Shenzhen, China
shenzhen@northstarsitetel.com
Tel: +86 755 3304 3068

Date: 06-28-13 DCR: 2336-S13 DCN: SES-544-02-09 Page 14 of 14