Date: 06-28-13 DCR: 2336-S13 DCN: SES-544-02-09 Page 1 of 13

15DOC0020

NorthStar Battery (NSB) Telecom Installation and Operation Guide

Contents

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 ......................................................................................................................... 5

5 Commissioning ...................................................................................................................... 5

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 5.1 Discharge Rate ................................................................................................................. 6

6 Maintenance .......................................................................................................................... 6

6.1 Cleaning, Pesticides, and Chemicals ......................................................................... 6

7 Silver Star Technology® ............................................................................................ 7

7.1 Self Discharge During Storage .................................................................................... 7

7.2 Putting the Battery In Service ...................................................................................... 7 7.3 Charging Voltage ........................................................................................................... 7

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8 Blue Star Technology® .............................................................................................. 8

8.1 Self Discharge During Storage ........................................................................... 8

8.2 Charging the batteries prior to operation ............................................................ 8

8.3 Boost Charging .................................................................................................. 9

8.4 Float Charging Voltage ...................................................................................... 9

9 Blue+ ...................................................................................................................... 10

9.1 Self Discharge During Storage ......................................................................... 10

9.2 Putting the Battery In Service ........................................................................... 10

9.3 Boost Charging ................................................................................................ 11 9.4 Float Charging Voltage ............................................................................................... 11

10 Red Star Technology® ......................................................................................... 12

10.1 Self Discharge During Storage ..................................................................... 12

10.2 Putting the Battery In Service ....................................................................... 12

10.3 Charging Voltage .......................................................................................... 12

11 Contact ................................................................................................................ 13

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.

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1 Battery Safety

For full information please read the Material Safety Data Sheet (MSDS). The MSDS document may be downloaded from the Internet at: http://www.northstarbattery.com/MSD-430-01.pdf When dealing with Valve Regulated Lead Acid Batteries (VRLA) some additional safety information is required.

1.1 Old Batteries

Monoblocs which have reached their End of Life (EOL) should be removed from the application they are in and disposed of in accordance with federal, state, and local laws concerning the handling of hazardous materials and the environment. EOL is an industry defined term for VRLA batteries which indicates that the monobloc has only 80% of its original capacity left.

2 Determining Battery Manufacturing Date

The manufacturing codes for NorthStar are located in two places on the battery case.

1. On the front (the top picture in figure 1). 2. On the right hand side towards the rear

(the bottom picture in figure 1). Monoblocs manufactured prior to July 2005 are only marked on the right rear side of the battery case.

Figure 1 Location of manufacturing labels on NSB batteries

Please read and observe the installation and operation instructions.

When working on batteries wear appropriate Personal Protective Equipment (PPE). Refer to battery MSDS for complete list.

Do not expose the battery to an open flame or other ignition source. During operation an explosive mixture of hydrogen gas may accumulate.

Battery terminals are always energized and, if short-circuited, cause electrical arcing. Always use insulated tools.

Batteries are heavy objects. Use proper handling equipment safety gear during installation.

Inappropriate lead acid battery disposal can result in environmental contamination. Please dispose of batteries according to local regulations.

Battery may be returned, shipping pre-paid, to the manufacturer or any distributor for recycling.

Batteries contain concentrated sulfuric acid in water. Any fluid found outside the batteries should be regarded as acid.

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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.

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 NSB Plant 1 in 2009 (09), on the 78

th 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. The application into which the monobloc is to be installed may have a function, which precludes the monoblocs from being connected to the system if the OCV is too low.

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 monobloc.

Always use the packing from new monoblocs for transporting old monoblocs for proper disposal. 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.

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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 sulfuric acid 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 monobloc case. Doing so 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 monobloc’s 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.

Different ways to correctly store monoblocs

4.2 Shelf Life

NorthStar batteries have a two year shelf life at +25° C (+77°F).

5 Commissioning

Always use the installation instructions provided with the monoblocs and follow all outlines for safety and handling mentioned earlier in this document.

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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. If the monoblocs cannot be put into place 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, the monoblocs should be charged individually before being connected in series. 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

Make sure the monoblocs are all evenly spaced, aligned and rest on a flat surface. Resting the monoblocs on an acid resistant, electrically insulating surface is strongly recommended.

5.4 Connecting the Batteries

The monoblocs shall be connected into series using the cable and connectors designed for the particular layout of your delivery. We 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. 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 use 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:

5.1 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 sulfuric acid. If the monobloc needs to be cleaned, use water. Do not spray insecticides directly on the monoblocs.

Insulation Cover

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7 Silver Star Technology®

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. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals.

7.2 Putting the Battery In Service

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 Charge Time

>12.80 V 3 day charge @ 2.27 Volts / Cell

12.6-12.8 V 3 day charge @ 2.27 Volts / Cell

12.3-12.6 V 1 day charge @ 2.41 Volts / Cell

12.1-12.3 V 1 day charge @ 2.41 Volts / Cell

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 Volts / Cell (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 temperature please refer to our table below. If temperature varies strongly please consult the Telecom Application Manual. For UPS equipment multiply the voltage with the number of monoblocs.

T °C / °F V (float) 24 V 48 V

20 / 68 13.74 27.48 54.96

25 / 77 13.62 27.24 54.48

30 / 86 13.50 27.00 54.00

35 / 95 13.38 26.76 53.52

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8 Blue Star Technology®

8.1 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. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals.

8.2 Charging the batteries prior to operation

Blue Star Technology

® batteries must be fully

charged prior to operation. The following table gives the charging time required to reach full SOC.

Recharge Time

Current Limit (A)

Volts/Cell 1*I10 2*I0 4*I10 10*I10

2.27 V 2 Days 1 Day 1 Day 1 Day

2.35 V 12 hrs 12 hrs 6 hrs 6 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 Volts/Cell 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

®:

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 Volts/Cell 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:

Boost Float

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9 Blue+

9.1 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. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals.

9.2 Putting the Battery In Service

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 Charge Time

>12.80 V 3 day charge @ 2.27 Volts / Cell

12.6-12.8 V 3 day charge @ 2.27 Volts / Cell

12.3-12.6 V 1 day charge @ 2.41 Volts / Cell

12.1-12.3 V 1 day charge @ 2.41 Volts / Cell

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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.

9.4 Float Charging Voltage

The float charging voltage shall be 2.27 Volts/Cell 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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10 Red Star Technology®

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. The graph below shows that the rate of self discharge increases as the temperature increases, hence requiring shorter recharge intervals.

10.2 Putting the Battery In Service

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 Charge Time

>12.80 V 3 day charge @ 2.27 Volts / Cell

12.6-12.8 V 3 day charge @ 2.27 Volts / Cell

12.3-12.6 V 1 day charge @ 2.41 Volts / Cell

12.1-12.3 V 1 day charge @ 2.41 Volts / Cell

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 Volts / Cell (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 temperature please refer to our table below. If temperature varies strongly please consult the Telecom Application Manual. For UPS equipment multiply the voltage with the number of blocs.

T (°C / °F) V (float) 24 V 48 V

20 / 68 13.74 27.48 54.96

25 / 77 13.62 27.24 54.48

30 / 86 13.50 27.00 54.00

35 / 95 13.38 26.76 53.52

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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