STATIONARY BAE BATTERIES:

Vented Lead Acid (VLA) / Flooded

Installation and Operating Instructions

OPzS & OGi Series Batteries

Important Documents - Do Not Discard

 Stationary Vented Lead Acid (VLA) Batteries,
Installation and Operating Instructions
This publication defines the essential requirements for the proper storage, handling,
assembly, commissioning, operation, and maintenance of the BAE OPzS and OGi stationary
vented lead-acid batteries.

1.0 SAFETY PRECAUTIONS & WARNINGS

• Observe operating instructions and position them within sight of the battery!
• Work only on batteries under instruction of skilled personnel!

• When working on batteries wear safety glasses and protective clothing!

• Comply with accident prevention rules, local safety codes, as well as DIN VDE 0510, VDE
0105 part 1.

• No smoking! Do not expose the battery to an open flame, a glowing fire or sparks as
explosion and fire hazards exist.

• Acid splashes on the skin must be flushed with plenty of water.

• Acid splashes in eyes must be flushed thoroughly for at least 15 minutes with plenty of
water.
• Seek medical attention immediately!
• Remove clothing exposed to acid and wash with water immediately to avoid additional
contact with skin.

• Explosion and fire hazard due to explosive gases escaping from the battery.
• Caution! Metal parts of the battery are always live, therefore do not place items or tools on
the battery.
• Avoid short circuits!

• Caution! The electrolyte (diluted sulfuric acid) is extremely corrosive.

• Caution! Block batteries or cells are heavy!

• Ensure secure installation!
• Only use suitable transport equipment!

• Dangerous voltages!
• Shock hazard!

• Used batteries with this symbol are reusable goods and must be properly
recycled.
• Used batteries that are not recycled must be disposed of as special waste
in accordance with all local, state, and federal regulations.

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 Stationary VLA Batteries,
Installation and Operation Instructions
1.1 ELECTROLYTE HAZARDS
The electrolyte is dilute sulfuric acid, which is harmful to skin, and eyes. It is
electrically conductive and corrodes unprotected metal surfaces.

PRECAUTIONS
a) When handling electrolyte wear full eye protection, rubber or plastic gloves, apron and
boots.
b) If electrolyte contacts skin, wash it off immediately with large amounts of water.
Remove contaminated clothing.
c) If it contacts the eyes, thoroughly flush with water and seek immediate medical
attention.
d) Neutralize any spilled acid with a weak alkaline solution of 1 pound of bicarbonate of
soda dissolved in 1 gallon of water.
1.2 ELECTRICAL HAZARDS
A filled and charged battery presents a high voltage, high current shock and short
circuit hazard.

PRECAUTIONS
Observe standard safety measures when working on batteries:
a) Remove watches, rings or metal jewelry.
b) Wear rubber gloves and boots.
c) Use insulated tools.
d) Never lay tools or other metallic objects on the battery/cell.
e) Before working on the system disconnect the charger and load prior to closing and/or
opening battery connections. Use appropriate lockout/tag-out procedures.
1.3 EXPLOSIVE GASES
Batteries can generate gases which, when released, can explode, causing
blindness and other serious personal injury.

PRECAUTIONS
a) Always wear protective clothing and use the correct safety tools.
b) Eliminate any potential of sparks, flames or arcing.
c) Provide adequate ventilation.
Using the correct tools and wearing the proper safety equipment will help prevent injury
should an accident occur.

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 Stationary VLA Batteries,
Installation and Operation Instructions
TABLE OF CONTENTS:
INTRODUCTION ………………………………………………………………………………................................... 1

1.0 SAFETY PRECAUTIONS & WARNINGS ………………………..………………………………..……...……. 1

1.1 ELECTROLYTE HAZARDS ……………………………………………………...........……………………..…. 2
1.2 ELECTRICAL HAZARDS ……………………………………………………………………..…………………. 2
1.3 EXPLOSIVE GASES ………………………………………………………………………..……………………. 2

TABLE OF CONTENTS ………………………………………………………………………………………...……... 3

2.0 RECEIVING OF STATIONARY BATTERIES ………………………………………………....................…... 4

2.1 VISIBLE EXTERNAL DAMAGE………………………………………………………………….........……...….. 4
2.2 CONCEALED DAMAGE…………………………………………………………………………......………...….. 4
2.3 ACCESSORIES ………………………………………………………………………………………........……... 5

3.0 STORAGE AND MAINTENANCE ………………………………………………………….……...…......…..... 5

3.1 STORAGE AND MAINTENANCE: WET CHARGED BATTERIES …………………………………..…....... 5
3.2 STORAGE AND MAINTENANCE: BATTERIES REMOVED FROM OPERATION ……….………..…....... 5
4.0 UNPACKING & HANDLING ………………………………………………………………..…………......…..... 6
4.1 ACCESSORIES ………………………………………………………………………………………………....... 6

5.0 PRE-INSTALLATION PLANNING ……………………………………………………………………….....….. 6

5.1 RACKS (EXISTING RACK) ………………………………………………………………………..………....….. 7
5.2 RACKS (NEW RACK) ……………………………………………………...........………………..……...…...…. 7

6.0 BATTERY CELL/JAR INSTALLATION …………………………………………………………………....….. 7

6.1 TERMINAL PREPARATION …………………………………………………………………….………….……. 8
6.2 INTER-CELL CONNECTORS ……………………………………………………………………...…….………. 8
6.3 TERMINAL PLATES ……………………………………………………………………..………..……………… 9
6.4 FINAL INSTALLATION STEPS………………………………………………………………..………………….. 9

7.0 COMMISSIONING – SUPPLIED WET AND CHARGED ……………………………………………….…….. 10

7.0.1 COMMISSIONING WITH FLOAT CHARGE VOLTAGE – 2.23 VPC ……………………….….…… 11
7.0.2 COMMISSIONING WITH HIGHER CHARGING VOLTAGES – 2.33 TO 2.40 VPC ……...………. 11

8.0 INSTRUCTIONS FOR OPERATION …………………………………………………...………………………. 11

8.1 FLOAT CHARGING ………………………………………………………………………...…………………….. 11
8.2 EQUALIZATION CHARGING …………………………………………………………………..……………….. 11
8.3 CHARGING CURRENTS ………………………………………………………………………………...………. 12
8.4 TEMPERATURE-RELATED CHARGING VOLTAGE …………………………………………………...……. 12
8.5 OPERATING TEMPERATURE ………………………………………………………………………………….. 12
8.6 DISCHARGE CYCLE …………………………………………………………………………………………….. 12
8.7 RECHARGING CYCLE …………………………………………………………………………………………... 13

9.0 BATTERY MAINTENANCE …………………………………………………………….……………………….. 13

9.1 CLEANING OF BATTERIES ………………………………………………………………………….…………. 13
9.2 ADDITION OF WATER …..………………..………………………………………………………….………….. 13
10.0 PERIODIC INSPECTIONS ……………………………………………………………………………...………. 14
10.1 TOTAL SYSTEM VOLTAGE AND CURRENT ………………………………………………………...……… 14
10.2 INDIVIDUAL CELL VOLTAGES ………………………………………………………………………..………. 15
10.3 CELL TEMPERATURE ……..……………………………………………………………………………..……. 15

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 Stationary VLA Batteries,
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10.4 FLOAT CURRENT ………………………………………………………………………………………....……. 15
10.5 SPECIFIC GRAVITY (ELECTROLYTE DENSITY) ………………………………….…….…..……………… 15
10.6 CONNECTION RESISTANCE MAINTENANCE READINGS ………………………….……..……………… 16

11.0 IN-SERVICE CAPACITY TESTS …………………………………………………………………..………….. 16

SUPPLEMENT A: DRY CHARGED BATTERIES INSTRUCTIONS (Optional – may not be attached)

SA1.0 STORAGE AND MAINTENANCE: DRY CHARGED BATTERIES …………………………..…........ SA-1

SA2.0 FILLING AND FINAL INSTALLATION - FOR DRY CHARGED BATTERIES ………………………. SA-1
SA2.1 FILLING WITH SULFURIC ACID – FOR DRY CHARGED BATTERIES ………………..….…..……. SA-1
SA2.2 FINAL INSTALLATION STEPS …………………………………………………………....…..……….…. SA-2

SA3.0 COMMISSIONING – DRY CHARGED BATTERIES …………...………………………….………..…. SA-3

SA3.1 COMMISIONING OF DRY CHARGED BATTERIES IN NORMAL CONDITIONS ……………...…... SA-3
SA3.1.1 COMMISSIONING VIA FLOAT CHARGE VOLTAGE - 2.23 VPC ……………..….…..……. SA-3
SA3.1.2 COMMISSIONING VIA HIGHER CHARGING VOLTAGES - 2.35 to 2.40 VPC ……...…… SA-3
SA3.2 COMMISSIONING OF DRY CHARGED BATTERIES WITH EVIDENCE OF SELF DISCHARGE ... SA-4
SA3.3 COMMISSIONING OF DRY CHARGED BATTERIES WITH EVIDENCE OF EXCESSIVE SELF
DISCHARGE ………………………………………………………………………..……………….……… SA-4
SA3.4 COMPLETION OF COMMISSIONING …………………………………….……………..…………..…… SA-5

2.0 RECEIVING OF STATIONARY BATTERIES

Every precaution has been made in packaging the batteries for shipment to assure their
safe arrival. IMMEDIATELY upon delivery (while carrier delivering the shipment is still on
site) please check the packaging materials for evidence of damage in transit and the Bill
of Lading to assure all parts are being delivered, including the accessories.
2.1 VISIBLE EXTERNAL DAMAGE
• Wet acid stains may indicate spillage or leakage of electrolyte on wet supplied cells
• Crushed “Do Not Stack” cones or damaged boxes could be evidence of rough
handling during transit and damage to cells.
If any of the above are observed, make a note of it on the bill of lading before signing.
NOTE: Shipping damage must be handled with the carrier -- not BAE Batteries USA
2.2 CONCEALED DAMAGE
It is recommended that the cells be unpacked and checked for concealed damage as
soon as possible. Freight carriers generally require that concealed damage be inspected
by the carriers representative within 10 days from date of delivery to determine
responsibility.
It is the receiving facility’s responsibility to notify the freight carrier of concealed damage.
If cells need to be unpacked, see Section 4.0

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 Stationary VLA Batteries,
Installation and Operation Instructions
2.3 ACCESSORIES
If possible, upon receiving the battery systems, check the accessory packages against
the included packing list for contents making certain that all the parts ordered with your
system are included.
3.0 STORAGE AND MAINTENANCE
BAE USA supplies lead-acid batteries in a fully charged, ready to use state.
Alternatively, the cells may be provided in a dry-charged (unfilled) state for either pro-
longed storage or export, refer to Supplement A of this manual for dry-charge battery
details.
Packaging depends on transit routes (domestic or export) and varies from simple shrink
wrapping on a pallet to seaworthy crating for export or special request.
Store batteries indoors in a clean, dry and cool location.
DO NOT stack pallets. Damage may occur and the warranty will be voided.
3.1 STORAGE AND MAINTENANCE: NEW WET CHARGED BATTERIES
Batteries provided filled (wet) and charged may be stored without further charging for a
limited period because of self-discharging and related chemical processes.
After a maximum storage period of 12 weeks at 25°C (77°F) or less (or 6 weeks at
ambient temperatures above 25°C (77°F)) the batteries must be charged by connecting
to a proper charger providing a continuous float charge of 2.23 volts per cell or providing
an equalization (boost) charge to the cells (See Section 8.2). Storage at high
temperatures results in accelerated rates of self-discharge and increases the frequency
of required boost charging if the cells are not on constant float charge.
Storage times exceeding the above maximums may result in plate sulfation which may
adversely affect electrical performance and expected life.
Adequate freeze protection must be met for low temperature storage, as this will damage
the battery and cause potentially hazardous leaking. A fully charged battery is more
resistant to freezing than a discharged one. As a battery loses charge, its specific gravity
decreases causing it to have a higher freezing temperature. The freezing temperature
versus specific gravity is shown in the table below. BAE VLA batteries have a specific
gravity of 1.240 kg/l at 68°F.
Specific Gravity Freezing point Specific Gravity Freezing point
(68°F) °C °F (68°F) °C °F
1.000 0.0 32.0 1.225 -39.8 -39.0
1.150 -15.1 5.0 1.250 -54.3 -65.0
1.175 -20.2 -4.0 1.275 -70.0 -93.0
1.200 -28.0 -18.0 1.300 -71.1 -95.0

3.2 STORAGE AND MAINTENANCE: BATTERIES REMOVED FROM OPERATION

Batteries that have been in service and taken out of operation must be maintained on
permanent float charge or must receive a periodic equalize charge not to exceed every 6
weeks at ambient temperatures at 25°C (77°F). Other conditions listed in Sections 3.0
and 3.1 apply. For extended storage periods please contact BAE USA or your local
representative for recommendations.

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 Stationary VLA Batteries,
Installation and Operation Instructions
4.0 UNPACKING-HANDLING
Single cells and multi-cell blocks may be received packed in individual Styrofoam
containers with shrink-wrap or packing cases, surrounded by foam, shrink-wrap and
attached to a wooden pallet. Carefully open the cases or carton to avoid possibly
damaging any of the cells or blocks.
NOTE: When removing the blocks or cells from the containers or cases always lift cells
from the bottom, never from the connectors or cell posts as this can damage cell
covers or post seals and void your warranty.
NOTE: A BAE lifting sling may be used on the larger capacity
cells and blocks - slip the lifting sling under the cell and
use the loops in the sling for hoisting the cell. Four
battery lift sizes are available based jar dimensions. .
• Small Block Lift Kit, L = 272 mm (10.7 in)
• Large Block Lift Kit, L = 385 mm (15.16 in)
• Small Cell Kit, H < 620 mm (24.4 in)
• Large Cell Kit, min: L x W x H, 145 x 205 x 700 mm
(5.71 x 8.07 x 27.56 in)
max: L x W x H, 220 x 580 x 855 mm
(8.66 x 22.83 x 33.66 in)
weight: 250 kg (551.1 lbs)
See the specific battery lifting sling operating instructions for details on use.
NOTE: A mechanical battery lift may also be used to move the cells.
If the cells were ordered wet (filled), immediately check the electrolyte level in each cell
or block. The electrolyte level should be between the maximum and minimum level lines
on the container. If the level is below the minimum line, check the container for damage.
If your visual inspection, after unpacking, indicates damaged posts, cell covers or jars, or
electrolyte levels are below the minimum line immediately contact BAE USA or your local
representative.
4.1 ACCESSORIES
When unpacking the cells, place the accessories along with the installation and operating
instructions in a safe location to avoid misplacement or loss. If you find any of the items
listed on the packing list are missing please contact BAE USA or your local
representative.
5.0 PRE-INSTALLATION PLANNING
We recommend batteries not be installed in battery rooms that are still under
construction; this avoids the risk of damage to the batteries during construction.
The installation of the individual cells is dependent on the size and type of cell and the
intended application of the battery. Standard designs provide for installation in battery
cabinets, conventional steel racks or seismic (earthquake resistant) racks.
For all installation options, the ideal designs should include acid-resistant coatings and
rail insulation to ensure that the required insulation between the rack and battery is
present over the life of the batteries.

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 Stationary VLA Batteries,
Installation and Operation Instructions
All racks should be properly aligned and all the bolted parts tightened thoroughly before
placing the cells on them. Use levelers/shims to compensate for irregularities in the floor
surface.
5.1 RACKS (EXISTING RACK)
If the cells are to be installed on an existing battery rack, the following inspection should
be made prior to installation to avoid any possibility of damage to the new battery.
a) Inspect all bolted connections to make sure that all are properly aligned and tight.
b) Check all painted surfaces making sure everything is clean and free of corrosion.
c) Make sure the rail insulation is clean and in place.
d) If the existing rack is not designed for the new batteries being installed this could
affect your seismic rating and battery warranty. Please contact BAE USA or your
local representative with questions.
If deficiencies are found with the existing rack - DO NOT INSTALL THE NEW CELLS
UNTIL CORRECTIVE ACTIONS ARE TAKEN.
If your inspection indicates that no corrective action is required, proceed with the cell/jar
installation (go to Section 6.0).
5.2 RACKS (NEW RACK)
Carefully unpack rack materials using care not to scratch the coated surfaces. Check
received parts against the Bill of Materials for the individual rack. If you find damage to
the rack components, file a claim against the carrier.
NOTE: If rack specific spill containment systems are used, then their installation will
likely have to be done while installing the rack. Refer to the manufacturer’s
recommended installation procedures.
Refer to the rack assembly drawing and installation instructions and proceed with rack
assembly.
• When assembled, battery racks must be level and in conformance with the rack
manufacture’s drawings and specifications supplied with the equipment. This will
ensure that neither individual cells nor rack assembly can topple, twist or overturn.
Use levelers to compensate for irregularities in the floor surface.
• Do not place battery cells on the rack until the rack has been completely assembled
with all bolts having been tightened. Otherwise, the weight of the cells may cause the
rack to shift and collapse.
• Never remove or loosen braces from a loaded battery rack, removal of braces could
allow the rack to shift or collapse.
If the new rack is not designed for the new batteries being installed this could affect your
seismic rating and battery warranty. Please contact BAE USA or your local
representative with questions.
6.0 BATTERY CELL/JAR INSTALLATION
SAFTEY REMINDERS – see Section 1 for details:

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 Stationary VLA Batteries,
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The electrolyte is dilute sulfuric acid, which is harmful to skin, and eyes. It is
electrically conductive and corrodes unprotected metal surfaces.

A filled and charged battery presents a high voltage, high current shock and
short circuit hazard.

Batteries can generate gases which, when released, can explode, causing
blindness and other serious personal injury.

To position the cells on the rack special auxiliary equipment, such as lifting straps
(Section 4.0) or other mechanical lifting gear, may be required. If necessary, this
equipment may be obtained from BAE Batteries USA.
An alignment guide should be used to aid in placing the cells properly on the rack.
Properly aligned cells will aid in connecting the cells together.
It is recommended that cells installation begin in the middle of the bottom tier with the
distance between the cells being determined from the center of the rack. In this way, it is
possible to make allowances toward the end of the rack(s). Planning the layout based on
cell dimensions and spacing ahead of time will prevent having to move cells on the rack
later.
Standard spacing between battery cells is 10 mm (0.394 in).
For a seismic rated rack, if cell spacers have been provided, install the spacers between
the cells during placement of each cell, otherwise insufficient spacing may be left to insert
them later. Install the remaining seismic battery rails for these racks once all cells are in
the proper position.
6.1 TERMINAL PREPARATION
Prior to assembling the inter-cell connectors to the cells, the plastic post covers should
be removed and the post contact surfaces should thoroughly cleaned by using the
provided wire brush and a clean cloth.
NOTE: Caution should be taken when using the wire brush as not to make contact with
other exposed metal areas to prevent short circuits.
Once clean, the post contact surfaces should have a light layer of no-ox grease applied.
These steps will insure the very best possible connection surface; once these surface
preparation steps are completed the connector to cell assembly can be performed.
6.2 INTER-CELL CONNECTORS
The individual cells are connected by either using the included thermoplastic-insulated
copper connectors or the lead plated copper connectors (type is dependent on cell type
and customer preference). The connectors are bolted to the threaded insert post using
either a stainless steel M10 Allen head bolt or a 17 mm hex head bolt (bolt type is
dependent on cell type).
All bolted connections should be made using a calibrated torque wrench to insure proper
tightness of the connection without causing any damage to the battery posts. The torque
settings for both of BAE bolt types (M10 Allen and 17mm Hex) is:
• 22 Newton-meters or 195 (194.7 actual) inch-pounds.

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 Stationary VLA Batteries,
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6.3 TERMINAL PLATES
For multi-terminal cell strings, terminal plate assemblies are provided standard for the +/-
customer connection cells. For single terminal cell strings the terminal plates are
purchased as an optional item. The standard terminal plates allow for customer
connection with either single hole or 2-hole 3/8” lugs with 1” spacing.
These terminal plate assemblies are to be bolted together using the following torques for
the terminal plate/bracket connection and the bracket to battery post connection.
Terminal plate covers are included as part of the terminal plate kit for safety.

Torque setting for

Connection
BAE SS Hardware
Type
N-m (in-lbs)
Angle Bracket to
22 N-m (195 in-lbs)
Battery Post

Terminal Plate to
28 N-m (247 in-lbs)
Angle Bracket

If the cells were received Dry Charged (unfilled), go to Supplement A, Section SA2.0, Filling
and Final Installation – for Dry Charged Batteries.
6.4 FINAL INSTALLATION STEPS
Once the cells have been installed and the connections completed, the following items
should be completed.
• Clean the battery room with all installation debris being removed.
• Although already done during unpacking, check the electrolyte level in each cell or
block to assure spillage has not happened during handling and installation. The
electrolyte level should be between the maximum and minimum level lines on the
container. If for any reason electrolyte was lost during installation, contact BAE USA
or your local representative.
• Once the battery room has been cleaned, all of the cells should be wiped down and
cleaned using a damp cloth – dampen the cloth with clear (distilled) water. See
Section 9.1 on cleaning of cells.
NOTE: DO NOT use cleaners or chemicals to clean the cells without prior written
approval from BAE.
• Once the cells have been thoroughly cleaned, apply the supplied cell numbering
stickers to the upper left or right hand corner of the face of the cells as desired.
o Please note the cells should always be numbered from the most positive cell to
the most negative cell.
• Apply the provided polarity labels as appropriate to the most positive and most
negative cell in the system.

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 Stationary VLA Batteries,
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• Following IEEE 484 guidelines BAE recommends measuring and recording
connection resistance readings to verify connection integrity and to provide a
baseline of each connection. Recommendations for how to measure these readings
is contained in the IEEE 484 guideline document, but all connection resistance
readings must be measured directly off the battery posts.
o Measure and record inter-cell connection resistances. This value verifies the
adequacy of initial installation and provides a reference for future maintenance
testing.
o Review the records of each connection-resistance measurement, separated by
connection type (i.e., inter-cell, inter-tier, inter-rack). Compute a separate
average for each connection type. The calculated average must be within BAE
specification for the connection type.
o Identify connections if the measured resistance is the greater of 1.1 x the average
resistance of each connection type, or the average resistance for the connection
type plus 5 micro-ohms. Unmake, clean, and remake the identified connections
and re-measure the identified connection resistances.
• Ensure the proper warning and safety signs are present and installed properly for the
battery room.
• Additionally please ensure the proper Personal Protection Equipment (PPE), spill
containment or cleanup kit and eyewash are present within the battery room as
required per the local or national codes. Please contact your local BAE
representative if any of these items are needed for your installation.
7.0 COMMISSIONING - SUPPLIED WET AND CHARGED
Prior to starting the charge, make sure to check the tightness of the terminal connections
and verify the proper polarity on each cell. Remember, the charger positive connection
must be connected to the battery positive terminal. DO NOT APPLY CHARGE TO THE
BATTERIES YET.
Before applying any charge to the batteries the following steps must be completed.
• If not already installed, install all flame arrestor vents onto cells. The arrestor vents
will be a fixed or funnel flip top style. Do not charge cells with shipping caps
installed.
• Measure and record the Open Circuit Voltage (OCV) of each cell and ambient
temperature. The extent the batteries have discharged during storage determines
the commissioning process for the cells.
o If OCV is ≥ 2.075V, then the float charge commissioning process will be used as
defined in 7.0.1
o If OCV is < 2.075V but ≥ 2.065V, then a higher boost charge as defined in 7.0.2
will be required
o If OCV is < 2.065V contact BAE USA or your local representative.
Once the pre-commissioning charge measurements are completed, the commissioning
charge can begin. Use the process as determined by the OCV measurements above.

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 Stationary VLA Batteries,
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7.0.1 COMMISSIONING WITH FLOAT CHARGE VOLTAGE – 2.23 VPC
Place the batteries into service on float charge at 2.23 VPC. After a period of 24
hours the batteries should be in a fully charged condition.
Although not necessary for initial commissioning, some users have standard
commissioning processes with a 24 to 72 hour equalize charge for their strings
prior to placing them into service. This equalize charge will not harm the battery.
7.0.2 COMMISSIONING WITH HIGHER CHARGING VOLTAGES - 2.33 to 2.40 VPC
Place the batteries into service on equalize charge at 2.33 to 2.40 VPC. After a
period of 24 to 72 hours the batteries should be in a fully charged condition.
Once the commissioning charge is completed, measure and record the electrolyte
specific gravity and temperature of each cell. A proper range hydrometer and
thermometer are included with the standard BAE battery accessories. The following is
the nominal acid density (Specific Gravity) at the maximum electrolyte level at a fully
charged condition:
Single Cell Nominal Specific Gravity and Tolerance for the BAE OGi and OPzS Cells:
1.240 ±0.01 kg/l at 25°C (77°F); yielding a range of 1.230 to 1.250 kg/l
Note that the level of electrolyte in the cell will affect the reading – see Section 10.5 for
details.
Once the commissioning charge and electrolyte readings are completed, if the electrolyte
levels are not at the maximum level, you may top off cells to the maximum level with
purified or distilled water.
8.0 INSTRUCTIONS FOR OPERATION
This section provides the operating instructions and detailed behavior of the BAE VLA
lead-acid of batteries.
The instructions for operation and maintenance contained in subsequent sections should
be combined or may be supplemented by site specific detailed procedures for necessary
testing and inspections. Special testing may be required under certain conditions (DIN,
VDE, and KTA for export) and IEEE for domestic applications as set forth by the user.
8.1 FLOAT CHARGING
BAE Stationary lead-acid storage batteries are designed so that optimum life and
available capacity are achieved with a float voltage of 2.23 VPC +/- 1% between 10°C
(50°F) and 30°C (86°F).
Total string float voltage will be 2.23 V x number of cells +/-1% nominal.
Higher or lower charging voltages can be detrimental as overcharging or undercharging
will reduce the batteries life expectancy.
8.2 EQUALIZATION CHARGING
After deep discharges, or inadequate recharging, equalizing charging is necessary. This
may be carried out as follows:
a) At an increased voltage of (2.33 to 2.40 V) x number of cells up to a maximum of 72
hours.

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 Stationary VLA Batteries,
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b) At currents according to the Section 8.3 Charging Currents below
Because it is possible to exceed the permitted load voltages, appropriate measures must
be taken, e.g. switch off the load.
If the maximum temperature of 45°C (113°F) is exceeded, the charging must be stopped
or switched to float charge to allow the temperature to drop.
The equalize charge is completed when the single cell voltages and electrolyte densities
do not increase for two consecutive hours.
Lower equalize voltages increase the equalize duration but decrease the gas emissions
generated.
8.3 CHARGING CURRENTS
The charging current on the BAE cells does not need to be limited until the battery
voltage has reached 2.40 VPC x number of cells - thereafter the charging current has to
be limited to 5A per 100 Ah of battery capacity.

8.4 TEMPERATURE-RELATED CHARGING VOLTAGE

A temperature-related adjustment of the charging voltage within monthly averaged
battery temperatures of 10°C (50°F) to 30°C (86°F) is not necessary.
For temperatures below 10°C (50°F) in the monthly average the charging voltage should
be increased by 0.005 volts per 1°C (1.8°F).
For temperatures above 30°C (86°F) in the monthly average the charging voltage should
be decreased by 0.004 volts per 1°C (1.8°F) to reduce water decomposition and
corrosion.
Most standard chargers sold today have temperature compensation capabilities to
manage the charge voltage. See individual charger specs for capability and verify that it
is active.
8.5 OPERATING TEMPERATURE
All nominal data for BAE stationary batteries is stated based on an operating temperature
of 25°C (77°F), the recommended operating temperature range for the BAE cells is 10°C
(50°F) to 30°C (86°F). To maximize life and performance the ideal operating
temperature range is 20°C (68°F) to 25°C (77°F).
Higher constant temperatures will reduce the anticipated life expectancy of the battery
due to the increase in the corrosion rate of the cell plates. For example, an increase in
temperature of 8.4°C (15°F) over the 25°C (77°F) norm would double the corrosion rate,
thus this reduces battery life to 50% of the normal life expectancy. A further increase of
16.7°C (30°F) over the 25°C (77°F) norm would further reduce the service life to 25% of
the normal life expectancy.
NOTE: At no time should the cell electrolyte temperature ever exceed 55°C (131°F) as
permanent battery cell damage will result.
8.6 DISCHARGE CYCLE
A battery is discharged either when the discharge duty cycle is performed when the AC
voltage supply fails or when battery capacity tests are conducted on the system. When
setting up routine maintenance procedures that include in-service capacity tests, it should
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be noted that frequent boost charge/discharge cycles could reduce the service life of the
battery.
NOTE: It is important not to over discharge a storage battery. Reference the data sheet
or battery discharge table for the specific values. These values must not be
exceeded.
8.7 RECHARGING CYCLE
Fully discharged and/or partially discharged batteries must not be allowed to remain in a
discharged state for longer than 24 hrs, as damage may occur. Therefore, it is
necessary to begin recharging immediately after a battery has been discharged. If
sufficient time is available to re-charge, use the charger float mode set at 2.23 VPC.
The specific gravity when measured above the plates may not be an accurate indication
of battery state of charge after a discharge, as complete mixing of the electrolyte may
take up to 3 months. This will not affect the battery’s function so long as the individual
cell voltages are 2.23 V +.10/ -.05 volts and the battery charge current has returned to
normal float level.
If a complete recharge is to be accomplished within a shortened time period, it will be
necessary to charge at a higher voltage. (See equalization charging Section 8.2)
9.0 BATTERY MAINTENANCE
Proper maintenance will prolong the life of a battery and will aid in ensuring it is capable
of satisfying its performance requirements. A good battery maintenance program will also
serve as a valuable aid in determining the need for battery replacement.
9.1 CLEANING OF BATTERIES
Batteries should be kept clean and dry at all times. Cell containers and cell covers are
made of plastic materials and should be cleaned with water. No solvents or detergents
should be used. Use caution to avoid electrostatic discharges.
In certain circumstances, specific cleaners may be used. However, you must consult
with BAE USA or your local representative prior to use. If approved, after application of
the cleaner the cell should be rinsed with water and thoroughly dried with a clean damp
cloth.
9.2 ADDITION OF WATER
Water must be added to any cell when the electrolyte level has dropped to the minimum
level line. Add water to the maximum level line.
Under normal operating conditions, addition of water becomes necessary
typically at intervals of 2 to 5 years depending on the cell model.
If operating temperatures exceed 25°C (77°F) or the battery is subjected
to frequent recharging at high voltages, more frequent water additions
may be necessary.
NOTE: Use only approved purified or distilled water for topping off the cells.

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Required table of impurities for purified water for adding to cells:

No Impurity Max mg/L
1 Evaporation residue 10
2 Oxidable organic substances, calculated as KMnO4-consumption. 20
3 Metals of the hydrogen sulphide group (Pb, Sb, As, Sn, Bi, Cu, Cd)
Per element 0.1
Together 0.5
4 Metals of the ammonium sulphide group (Fe, Co, Ni, Mn, Cr)
Per element 0.1
Together 0.5
5 Halogens calculated as chloride 0.5
6 Nitrogen in the form of nitrate 2
7 Nitrogen in other form, e.g. ammonium 40

10.0 PERIODIC INSPECTIONS

The inspections described below should be performed and will serve as a means of
checking the reliability of the battery system. The periodic inspections listed below are
the minimum required. For additional guidance on recommended battery maintenance,
reference IEEE 450.
To be measured and recorded Quarterly:
• Battery System Voltage & Current (Section 10.1)
• Visual inspections:
o General Appearance & Cleanliness
o Electrolyte Level
o Visible Cell damage
• Charger output and voltage
• Ambient temperature and condition of ventilation equipment
• Monitoring equipment operation if installed.
To be measured and recorded every 6 months:
• Quarterly Inspections & Measurements, plus the following
o Pilot individual cell/block voltages (Section 10.2)
o Pilot cell temperatures (Section 10.3)
o Float Current (Section 10.4) or Pilot cell Specific Gravity (Section 10.5)

To be measured and recorded every 12 months (Annually):

• Quarterly Inspections & Measurements, plus the following:
o Individual cell/block voltages (Section 10.2)
o Individual cell/block temperatures of all cells/blocks (Section 10.3)
o Float Current (Section 10.4) or Individual cell Specific Gravity (Section 10.5)
o Connection resistance readings (Section 10.6)
o Rack condition and integrity
10.1 TOTAL SYSTEM VOLTAGE AND CURRENT
The total battery voltage at the terminal posts (positive and negative) during float charge
should be 2.23 VPC times the number of cells.

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Example: 2.23 VPC X 60 cells = 133.8 Total Battery Voltage
Check and record this overall voltage every quarter. If a deviation in voltage greater
than +/- 1% is found, then check the charger and make necessary adjustments.
Also, check and record the input current to the batteries every quarter. Consult the
specific battery product data sheet for acceptable values.
10.2 INDIVIDUAL CELL VOLTAGES
Pilot cell voltages must be taken and recorded on a 6 month basis. All of the individual
cell voltages must be checked and recorded at least once per year.
Single Cell Voltage Tolerance is +0.1 or -0.05V as compared to the nominal voltage
of 2.23; this gives us a range of 2.18 to 2.33 volts
If the individual cell voltages are not within the allowable tolerances, measure and
record the specific gravity readings of those cells and contact BAE USA or your local
representative.
10.3 CELL TEMPERATURE
Cell temperatures must be measured and recorded either off the battery post or with the
specific gravity (Section 10.5).
10.4 FLOAT CURRENT
If float current is used to determine state of charge in lieu of specific gravity, it is
important that this value be measured accurately. Float current of a fully charged cell
under normal conditions is typically 15 to 30 mA per 100 Ah of capacity therefore the
measuring device used must be capable of that level of accuracy.
10.5 SPECIFIC GRAVITY (ELECTROLYTE DENSITY)
If accurate float current cannot be measured, then specific gravities must be measured
and recorded per above periodic maintenance schedule (Section 10.0)
NOTE: Proper operation of BAE Stationary lead-acid batteries requires a fully charged
condition. The following are the nominal electrolyte densities (Specific Gravity) at the
maximum electrolyte level in a fully charged condition:
Single Cell Nominal Specific Gravity and Tolerance for the BAE OGi and OPzS Cells:
1.240 ±0.01 kg/l at 25°C (77°F); yielding a range of 1.230 to 1.250 kg/l
For the correct evaluation of the measured electrolyte density, it should be noted that
specific gravity is greatly affected by service conditions, including:
• Temperature: Extreme high temperatures reduce electrolyte density; low
temperatures increase the density. The change in density is 0.006 kg/l for every
10°C (18°F).
• Electrolyte Level: Electrolyte densities increase proportionally to the water
consumption and the lowering of the electrolyte level.
• Insufficient mixing: If water is added to the cells, this will result in lower specific
gravity readings above the plates. If the battery is discharged, significant time may
be required for full mixing to occur.

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If the specific gravity of one cell or if isolated cells are below the specified tolerance,
please contact BAE USA or your local representative.
10.6 CONNECTION RESISTANCE MAINTENANCE READINGS
It is very important that the procedure for taking connection resistance readings be
consistent for each periodic reading so as to detect upward changes that could be
caused by corrosion or loose connections. Variations in taking the readings will cause
discrepancies in the results. Increased resistance is a cause for concern and may
require corrective action.
Normal connection resistance varies with the cell size and connection type. The
following methods should be used to establish a connection resistance limit, which
should initiate corrective action prior to the next inspection:
• Baseline values are established by measuring the connections after initial installation
or after cleaning the connections (see Section 6.4).
o A 20% increase from the established baseline value for any connection type (i.e.,
inter-cell, inter-tier, inter-rack) serves as the criteria for initiating corrective action
prior to going onto the next inspection.
• Baseline average values are specific to each connection (inter-cell, inter-tier, or inter-
rack) and not an average of all connections.
• The timing of the corrective action for increased connection resistance should be
determined by an analysis of the effects of the increased resistance. Consult BAE
USA or your local representative if there are questions.
• Whenever all battery connections are cleaned and reassembled, a new baseline
should be established.
• If the baseline information for an installed battery is unknown, then a baseline should
be established when all connections are cleaned and reassembled. When
establishing a new baseline, refer to IEEE 450 for guidance.
Please note that no regular re-torque is recommended or required. If regular re-torque
is part of your standard maintenance program, consult BAE USA or your local
representative.
11.0 IN-SERVICE CAPACITY TESTS
Regularly scheduled capacity tests are not necessary for healthy batteries. However,
for batteries approaching end of life or for other specific reasons, capacity tests may
desired. These capacity tests should be conducted in the following manner.
At least 3 days but not more than 7 days before a battery capacity test, give the battery
an equalizing charge as described in Section 8.2.
11.0.1 Discharge should be performed with a constant current or constant power type
load unit. In the determining the correct current or power rate for the capacity test,
it is helpful to take into account operating conditions and specific site
requirements. From this, select a discharge time and current or power that best
fits the requirements. These values are obtained from the BAE discharge sheets
for the given battery model.

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11.0.2 Prior to starting the discharge test, care must be taken to ensure that the battery
is in a fully charged condition. The recommended battery temperature per IEEE
450 should be between 18°C (64°F) and 32°C (90°F).
11.0.3 The capacity test may be performed after the battery has been taken off of float
charge. During the discharge the current must not fluctuate more than ±1% on an
average from the nominal value. Short-term deviations up to ±5% from the
nominal value are allowable for a maximum of 20 seconds.
11.0.4 Voltages at the terminals of all individual cells must be checked after 10%, 25%,
50%, 80% and 100% of the specific discharge period. These should be recorded
into a time versus voltage chart; making sure that the final discharge voltages are
recorded.
11.0.5 The final discharge voltage of a battery is obtained by multiplying the final
discharge voltage of the individual cells by the total number cells. The minimum
allowable final discharge voltage is dependent on the discharge current. The
rated discharge current values to a specific end point voltage per cell can be
obtained from the BAE data sheets.
Example: 1.75 VPC X 60 cells = 105 Total Battery Voltage
11.0.6 The capacity test must be terminated when the discharged time assigned to the
specific current has been reached or when the final discharge voltage at the end
terminals has been reached. During this operation, the individual cell voltages
may be 0.2V below the allowable final discharge voltage.
11.0.7 The measured capacity is the product of the discharge current and the discharge
time. If the initial temperature was not 25°C (77°F) the measured capacity must
be corrected to compensate, please reference IEEE 450 or contact BAE USA or
your local representative.
11.0.8 If the target capacity is not achieved, we request that you contact BAE USA or
your local representative. It is generally recommended that if the measured
capacity of the battery is less than 80% the battery should be considered for
replacement.
11.0.9 Recharge the battery in accordance with the charging procedure as previously
stated in the operating instructions immediately after the capacity test.
Please reference IEEE 450 for additional guidance
For any situation not covered in these instructions, please contact BAE Batteries USA or your
local representative immediately for guidance.
Any data, descriptions or specifications presented herein are subject to revision by BAE
Batteries USA without notice.

BAE Batteries USA

484 County Road V V
Somerset WI 54025
TEL (715) 247-2262
FAX (715) 247-5741
www.baebatteriesusa.com

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