Battery Operation Guide

Version 1.2 May 2008

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Contents |

Contents
Important Safety Checklist..................................................................................................3 Before You Start................................................................................................................4 Checking Your Batteries ..................................................................................................4 Storing Your Batteries ....................................................................................................4 Installing Your Genergiser Batteries....................................................................................5 Positioning Your Batteries Safely ......................................................................................5 Installing Your Dry Charge Batteries .................................................................................6 Filling Your Dry Charge Genergiser Batteries........................................................................8 Calculating Acid Volume Required.....................................................................................8 Filling Your Dry Charge Battery Cells.................................................................................9 Charging Your Dry Charge Genergiser Batteries ................................................................. 10 Your Charging Equipment.............................................................................................. 10 Checking Your Batteries Prior To Charging ....................................................................... 11 Charging Your Dry Charge Batteries ............................................................................... 12 Commissioning Your Genergiser Batteries ......................................................................... 14 Applying Load Over Your Batteries.................................................................................. 14 Maintaining Your Genergiser Batteries Once In Use............................................................. 15 Bulk/Boost Charging Your Batteries ................................................................................ 15 Equalise Charging Your Batteries.................................................................................... 15 Getting Further Information .............................................................................................. 16 Standards and Disclaimer ................................................................................................. 16

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Important Safety Checklist |

This guide provides important safety, installation and operation instructions for your long life, deep-cycle Genergiser batteries.
PLEASE READ THIS DOCUMENT EXTREMELY CAREFULLY! Genergiser open-vented, lead acid batteries are potentially dangerous and can cause serious injury when handled incorrectly. Batteries can explode when exposed to sparks or naked flame!

Important Safety Checklist

PLEASE ADHERE TO THE FOLLOWING ESSENTIAL SAFETY PRECAUTIONS! Genergiser batteries are filled with a form of diluted sulphuric acid named electrolyte. Electrolyte is an extremely corrosive substance, giving off explosive gases whilst under charge, and especially when undergoing a higher than normal voltage equalise charge.

Keep an adequate supply of water and a neutralising agent (such as a bicarbonate of soda solution) close to hand at all times. These may be used in the event of personal contact with, or spillage of, the electrolyte. Ensure a first-aid kit, plastic apron, goggles or head visor, surgical gloves and booties, eye-wash station and a fire extinguisher are fitted to the wall of the battery room. Appropriate information and warning signage should also be clearly displayed in the battery room. Keep batteries separated from any other form of electrics (eg. chargers, inverters, inverters/chargers, DC to DC converters, etc.) that may produce a spark due to electrical changeover switchgear. Install your Genergiser batteries in a well ventilated, lockable room that is rodent and child proof. For further information refer to the ventilation section 3.3 of the Australian Standard AS2676.1 Part 1:Vented Cells. If possible, pressurise the battery room with a ventilator fan triggered by a high battery voltage sensor or contact relay. Set the ventilator fan to trigger when voltage reaches the level where batteries start producing hydrogen gas under charge (generally around 2.3 volts per cell and above). Restrain your battery cells firmly to prevent movement or damage during an earthquake. Use insulated tools to prevent or reduce the transfer of electricity. DO NOT rest any tools on top of battery cells. Remove all forms of jewellery and metal attached to your body. Serious injury may result if these come into contact with battery terminals.

Batteries contain corrosive material.

NEVER discard them through common rubbish disposal.

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| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Before You Start |

Before You Start

Checking Your Batteries
As soon as you receive your Genergiser batteries, check they have been delivered in good condition. In the unlikely event of damage, contact the freight company immediately to inspect any damage that may have occurred. Where Genergiser batteries are supplied filled and pre-charged, check each cell is filled to the maximum level. Use additional acid of the same mixture/acid content (known as specific gravity, or SG) if required. Contact Genkit Nelson Ltd for further information should you be in doubt.

Storing Your Batteries

The shelf life of filled and charged battery cells is limited. Prior to use, always leave your batteries stored in their original packaging as this offers a form of seismic restraint. Removing battery cells from packaging risks irrepairable damage should an earthquake occur.

Wet Charge Battery Cells: Where your Genergiser batteries are supplied filled and pre-charged, place the battery cells on charge within 30 days of receipt. If possible, place batteries on a float charge of 2.25 VpC until use. Installation and charging instructions are explained later in this guide. NOTE! Extended periods with no charge can cause permanent damage and greatly reduce battery cell capacity and service life.

Dry Charge Battery Cells: If adequately sealed and protected against humidity and condensation, dry charge Genergiser batteries may be stored in their original packaging for approximately 4 years prior to use. Once dry charge batteries have been filled and charged they are known as wet charge battery cells. Pages 7 to 14 of this manual describe the steps to convert dry charge battery cells.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Installing Your Dry Charge Genergiser Batteries |

Installing Your Genergiser Batteries

Positioning Your Batteries Safely
In every installation, place battery cells above the floor on a structure that is well insulated at the bottom (eg. wood or rubber). Use seismic bars to firmly restrain battery cells in case of earthquake. Where seismic bars are made from material other than wood, line the seismic bars with wood or rubber facing the battery cell casings. Ideally, each row of battery cells should be placed at differing heights (with the highest at the back) to allow easy visibility of cell electrolyte levels. Number each battery to enable accurate records to be kept about the performance of each cell.

Batteries, generators and inverter/electrics should NEVER be installed in the same room. Install electrics in a separate room adjoining the battery room. Generators must not be located within close proximity of the battery or electrics rooms.

Figure 1: An example installation containing two strings of 48 Vdc (nominal) seismically restrained battery cells in two rows each. The battery cells are placed on marine ply with wooden seismic restraining bars. Note the appropriate signage and safety equipment displayed.

In Figure 1 above, seismic bars are placed between the wall and the back row, in between the rows, and at the front of the battery bank. 10mm marine grade threaded rods are inserted from the front through all three seismic bars, terminating on the outside of the back wall. The rods are secured at each end using stainless steel dome nuts and washers. Insulated by 12mm plastic tubing covering each bar, resulting in the rods being protected from electrolyte spillage and corrosion.

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Installing Your Dry Charge Genergiser Batteries |

Installing Your Dry Charge Batteries

STEP 1 Positioning the battery cells Place the batteries on the battery stand structure so that the blue (-) terminal can be connected to the red (+) terminal of the next cell. Position each cell an equal distance apart to the exact lengths of the connecting straps provided. NOTE! For multiple row battery banks, where a row ends with a blue (-) terminal, the row directly above or below should start with a red (+) terminal. These blue (-) and red (+) terminal row ends will later be connected via an emergency fuse disconnect at the end of each battery row. The battery row end fuse disconnect should be rated at 50% higher than the DC power disconnect in the adjoining electrics room.

STEP 2 Cleaning the battery terminals Remove all bolts and washers from the battery terminal posts. Clean each terminal post with fine sandpaper.

STEP 3 Connecting the battery straps Connect all battery straps, bolting each connecting strap down to a torque setting of 15 Newton metres (N/m). This is equivalent to 11 pounds per square inch. Apply an anti-corrosive protective substance (eg. petroleum jelly) to each terminal. NOTE! Battery straps bolt on one way only. Each strap has a cap at each end to cover and insulate the bolts. Fastening the battery straps the wrong way around will make correct placement of the cap difficult.

Figure 2: Galvanised steel bars lined with wood have been used to seismically restrain the battery cells in this example.

Figure 3: The fuse disconnect box can be seen on the far right of this image, located between the orange cabling.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Installing Your Dry Charge Genergiser Batteries |

STEP 4 Wiring up the fuse disconnect A fuse disconnect is used to disengage the battery bank and make it electrically safe to work on. Using the correct size and quality of battery cable, wire up the load end of your battery bank to the fuse disconnect in the adjoining electrics room. Contact Genkit Nelson Ltd for further information on the most appropriate battery cable to be used with your battery bank if you are unsure. NOTE! Engage the emergency battery disconnect first, followed by the main battery fuse disconnect in the adjoining electrics room, once the cells have been filled and are ready for initial charge.

STEP 5 Securing the seismic bars Secure the seismic bars, taking care not to tighten the bars to the extent that the battery cell casings buckle or distort.

The various images within this guide illustrate appropriate signage required by health and safety regulations. Also visible are extra components such as gloves, booties, plastic jugs, plastic funnel, goggles and head visor. These are stored in plastic containers or wall mounted. Not visible, but installed on the inside walls, are inter-battery disconnects and a fire extinguisher. Genkit can supply appropriate signage and equipment if required.

Figure 4: In this example, a fan is used to pressurise the battery room should the batteries start producing hydrogen gas during charge. Air is drawn in through the external stainless steel vent on the left and exhausted through three vents in the battery room. The vents (of which two are visible) have been placed in line with the two battery banks on either side of the door, and one above the door.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Filling Your Dry Charge Genergiser Batteries |

Filling Your Dry Charge Genergiser Batteries

When dealing with acid, always use protective clothing such as goggles or head visor, apron, gloves and booties. Have a first-aid kit, fire extinguisher, eye-wash station and minimum of 10 litres of water close to hand at all times. It is recommended a neutralising agent (such as a bicarbonate of soda solution) and cloth are also close to hand. These may be used in the event of personal contact with, or spillage, when filling the cells. NEVER allow the neutralising agent to spill into battery cells!

Calculating Acid Volume Required

The appropriate amount of acid with the correct SG required will be supplied by Genkit with your dry charge batteries. Contact Genkit Nelson Ltd (http://www.genkit.biz) for further information about this if required. NOTE! Genkit will ensure you have a sufficient volume of acid available. Failure to completely fill battery cells within a short timeframe can cause serious and irreparable damage to cells. NOTE! Initial charge must take place within 12 hours of filling battery cells.

Table 1 below shows the typical impurity levels of acid supplied by Genkit for your batteries.

TABLE 1 : Maximum Impurity Levels For Optimum Results Impurity Iron Cadmium Lead Selenium Other Impurities Parts per million (mg/litre) 7 5 2.5 0.05 30

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Filling Your Dry Charge Genergiser Batteries |

Filling Your Dry Charge Battery Cells

STEP 1 Filling the battery cells Fill each battery cell to the maximum level mark and leave to settle for approximately 6 hours. During this time, the separators and plates will absorb the electrolyte. The cells will often warm up to above the surrounding air temperature, especially in hotter climates. The cells should cool again over approximately 12 hours. NOTE! Use only glass or plastic utensils (eg. jugs and funnels) to fill the battery cells.

STEP 2 Checking electrolyte level Through absorption, the electrolyte levels will have reduced in each cell. Within 12 hours of initially filling the cells, top them up again to the maximum level mark ready for their initial charge. During the initial 12 hours you will notice a rise in overall voltage.

STEP 3 Fitting the vent caps Fit the anti-splash vent caps provided as you fill each cell. These replace the simple caps originally fitted for transportation purposes and will also indicate which caps have been filled.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Charging Your Dry Charge Genergiser Batteries |

Charging Your Dry Charge Genergiser Batteries

Your Charging Equipment
Unless you use a sophisticated inverter charger, such as the Trace, OutBack or Power Solutions Australia, you may use a constant voltage charger (refer to Figure 5 below). Genkit can supply constant voltage chargers that are designed to produce a low ripple charge effect. This type of charger needs to be fitted with two potentiometers: one adjusts the voltage between 2.20 and 2.65 volts per cell (VpC); the second adjusts current output.

Figure 5: The light brown box shown on the left side of this image is a constant volt charger. The small grey boxes positioned on the top left of the constant volt charger face are the potentiometers.

NOTE! NEVER charge the battery bank at more than 10% of its rated capacity, based on the 10 hour discharge rate (C10), as marked on the side of the Genergiser battery casings. Examples: 24x2 volt cells (48Vdc nominal) 600 amp/hr C10 maximum charge current = 60 amps dc 12x2 volt cells (24Vdc nominal) 1000 amp/hr C10 maximum charge current = 100 amps dc

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Charging Your Dry Charge Genergiser Batteries |

Checking Your Batteries Prior To Charging

STEP 1 Making final checks Inspect the battery cells do not have any acid spillage. Ensure the electrolyte in each cell is filled exactly to the maximum level mark. Check the battery cells are symmetrically and evenly positioned. Ensure the seismic bars are not fastened too tightly against the cell casings. Double-check all terminal polarity connections and that the interconnecting straps, emergency battery and main battery fuse disconnects are firmly and correctly in place. Ensure the anti-splash caps provided are fitted and firmly fastened.

STEP 2 Engaging the fuse disconnect In the following order: Close the emergency fuse disconnect in the battery room. Close the main battery fuse disconnect in the adjoining electrics room.

Figure 6: The four red cables attached under the small grey boxes at the bottom right of this image show both fuse disconnects in the closed position.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Charging Your Dry Charge Genergiser Batteries |

Charging Your Dry Charge Batteries

Providing the battery cells have cooled (down to 35C in hotter or 30C in medium climate conditions), the battery bank is now ready for its first charge. NOTE! The initial charge is the most important.

STEP 1 Starting the charge Start the charge with the voltage set at 2.40 volts per cell (VpC). Set the current at 5% of the amp/hr rating as marked on the battery cell casing (eg. 30 amps for 600 amp/hr C10).

STEP 2 Monitoring the charge Monitor and record the following parameters every 3 hours: The specific gravity (SG) ratings of each battery cell. The voltage reading of each battery cell across opposite polarity. The voltage reading across two battery cells of similar polarity, to ensure there is perfect contact between these cells. There should be less than 5 milliamps difference between this and the battery cell opposite polarity voltage reading above. The battery temperatures. NOTE! Reduce the charge rate should battery temperatures rise by more than 3% of the initial reading.

Reduce the charge rate should cell voltage rise considerably faster in some batteries than others. This allows time for the lazier cells to catch up.

STEP 3 Increasing the charge If the monitoring in Step 2 above causes no concerns: After approximately 24 hours, increase the charge rate to 7.5% of the amp/hr rating as marked on the battery cell casing. After a further 12 hours, increase the charge rate again to 10.0% of the amp/hr rating as marked on the battery cell casing.

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Charging Your Dry Charge Genergiser Batteries |

STEP 4 Increasing the voltage Once the battery bank voltage reaches 2.40 volts per cell (VpC), increase the voltage to 2.50 VpC. Once the battery bank voltage reaches 2.50 VpC and has remained so for at least 24 hours, increase the voltage to 2.60 VpC. Ensure each and every battery cell reaches 2.60 VpC, or as close to as possible. Should some cells read higher than this, immediately reduce the charge voltage until the highest reading is 2.60 VpC to allow the lazier cells to catch up. Maintain all the battery cells at 2.60 VpC for approximately 6 hours.

NEVER allow any battery cell to be overcharged at any time!

STEP 5 Completing the charge The initial charge is considered complete when: Each battery cell has maintained 2.60 volts per cell (VpC) consistently for a 6 hour period. Each battery cell has reached specific gravity (SG) 1.225 and maintained this for 6 hours at 20C. Refer to Table 2 below. After shutting down the charging parameters, the battery cells should be left to settle for 2 hours. Each cell should settle to about 2.13 to 2.15 VpC. After leaving the battery cells to settle, all cell voltages are within 5% of each other. Should this not be the case, further constant charging at 2.60 VpC is required for a few more hours. NOTE! The entire charging process could take up to 70hrs to complete. Once dry charge batteries have been filled and charged, they are now wet charge battery cells.

Table 2 below indicates the specific gravity (SG) statistics at a nominal 20C. It shows temperature variances for Genergiser OPzS cells, with the electrolyte situated at maximum level.

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Commissioning Your Genergiser Batteries |

TABLE 2 : Electrolyte Specific Gravity (SG) Temperature C Batteries with electrolyte sp.gr. 1.240 kg/litre 6 8 10 12 14 16 18 20 22 24 26 28 30 1.235 1.233 1.232 1.231 1.229 1.228 1.226 1.225 1.224 1.222 1.221 1.219 1.218

Commissioning Your Genergiser Batteries

Applying Load Over Your Batteries
Following initial charge, once your batteries have settled, apply a load over the battery bank equivalent to 5% of the amp/hr rating as marked on the battery cell casing, until each cell reaches 1.95 volts per cell (VpC). Remove the load and record each battery cell voltage. Cells should be within 5% of one another. Where this is not the case, repeat the above charge/discharge exercise until discharged voltages are within the 5% range.

Should battery cells require topping up, NEVER add further acid. Use only good quality de-ionised distilled water. NEVER use rain or boiled water!

If you are unsure how to apply a load over your batteries, contact Genkit Nelson Ltd (http://www.genkit.biz) for further information.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Maintaining Your Genergiser Batteries Once In Use |

Maintaining Your Genergiser Batteries Once In Use

Bulk/Boost Charging Your Batteries
Once batteries have been commissioned, a bulk/boost charge, usually driven automatically by a generator/charger, is required where batteries are used and semi-discarged regularly. In hybrid systems using wind, solar and/or hydro, the bulk/boost charge driven by a generator is introduced as a normal form of backup where renewable input may be insufficient.

STEP 1 Configurting the generator for bulk/boost charge: Configure the generator/charger to automatically start bulk/boost charge when low battery condition is identified, ie. where batteries drop to 35% depth of discharge (DOD). This represents the amount of battery capacity that has been used. The generator should be configured to automatically charge the bank to no more than 10% of its amp/hr rating, as marked on the battery cell casing. NOTE! A voltage of 2.40 volts per cell (VpC) must be held as an absorption charge for a minimum of 2 hours in every instance to validate the Genergiser 5 year warranty.

Equalise Charging Your Batteries

An equalise charge is necessary in the following circumstances: After every 30 full discharge and charge cycles. For example, if batteries are discharged to a controlled 30% depth of discharge (DOD; the amount of battery capacity that has been used) daily, an equalise charge is recommend every 75 days. For battery life longevity, batteries should never be dischaged more than 30%. Whenever distilled de-ionised water is added. This ensures the electrolyte within the cells mixes adequately with the added water and specific gravity (SG) is reduced. When voltage difference between battery cells exceeds 5%. Due to the chemical nature of batteries, oxidation builds up on the plates over time, reducing the ability for cells to hold charge. When waste deposits build up on the battery plates, an equalise charge helps to remove it, resulting in improved battery performance and life longevity. This waste is then deposited at the bottom of the cell casings.

STEP 1 - Performing an equalise charge: Charge the cells initially at 10% of the amp/hr rating, as marked on the battery cell casing, until a voltage of 2.55 volts per cell (VpC) is achieved. Continue this absorportion charge, holding 2.55 VpC for approximately 3hrs or thereabouts.

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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Getting Further Information |

Getting Further Information

Please dont hesitate to contact us with any questions, or requests for further technical information, that you may have. Genkit Nelson Ltd PO Box 884 Nelson, New Zealand Telephone: Facsmile: Email: Website: +64 3 547-3056 +64 3 547-3068 info@genkit.net http://www.genkit.biz

Standards and Disclaimer

If you are considering a remote area power supply installation including this type of battery installation, Genkit Nelson Ltd advises you familiarise yourself with the following standards. While all reasonable attempts have been made to ensure the accuracy and reliability of the content within this Operation Guide, Genkit Nelson Ltd does not accept any liability for any loss or damage which may directly or indirectly result from power supply system installations that do not conform with these standards. AS1319-1994 AS1768(int):2003 AS1940-1993 AS/NZS3000:2000 AS3010.1-1987 AS/NZS3100:2002 AS/NZS3760:2003 AS4086.1-1993 AS4086.2-1997 AS4509.1-1999 AS4509.2-1999 AS4509.3-1999 AS60529-2004 Safety signs for the occupational environment Lightning protection The storage and handling of flammable and combustible liquids Wiring rules Electrical installations supply by generating set Part 1 Approval and test specification In-service safety inspection and testing of electrical equipment Secondary batteries for use with stand alone power systems + Part 1: General requirements Secondary batteries for use with stand alone power systems + Part 2: Installation and maintenance Stand alone power systems Part 1: safety requirements Stand alone power systems Part 2: system design guidelines Stand alone power systems Part 3. Installation and maintenance Degrees of protection provided by enclosures

| Genkit Nelson Ltd | Genergiser Battery Operation Guide | Version 1.2

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