RS02046

Installation and Operating Procedures

For C&D Technologies TRUE Front Access TEL Series Batteries

FOLLOW MANUFACTURER’S PUBLISHED INSTRUCTIONS WHEN

INSTALLING, CHARGING AND SERVICING BATTERIES.

For additional information: www.cdtechno.com

Technical-Warranty Assistance, contact:
C&D Technologies, Inc.
1400 Union Meeting Road / PO Box 3053 / Blue Bell, PA 19422-0858
800-543-8630 or 215-619-2700
Fax 215-619-7899

Before handling cells or storing cell for future installation take time to read this manual. It contains
information that could avoid irreparable damage to the battery and/or void product warranty.
 General:
The purpose of this manual is to inform installers how to receive, install and maintain C&D Technologies front
access batteries.
Battery Description:
The Valve Regulated Lead Acid (VRLA) battery is a minimal maintenance system utilizing an oxygen
recombination cycle to minimize gassing and eliminate electrolyte maintenance. The dilute sulfuric acid
electrolyte is immobilized by absorbent glass mat (AGM) separators. Each of the 2 VDC cells (6 cells per
unit) in each unit has a unique self resealing one way valve to relieve any excess pressure generated
during overcharging conditions. Four six cell units in series make up a 24 cell 48VDC battery, two six cell
units in series for a 12 cell 24VDC applications.

Table 1 - Installation Tools (minimum) required to be supplied by Installer

Safety Glasses for each installer*
Insulated gloves (1 pair for each installer)*
Digital Voltmeter*
Terminal Prep Supplies (water, baking soda, cloth rag, brass bristle brush or scotch brite type pad, NO-OX-
ID terminal grease)*
Insulated Inch Pound Torque Wrench (up to 160 in lb)*
Insulated 7/16” socket wrench for TEL12-105FS, TEL12-160F, TEL12-160FW & TEL12-180F models*
Insulated 10mm socket wrench for TEL12-115FNG model*
Insulated 13mm socket wrench for TEL12-105FNSG,TEL12-170FG,TEL12-210FG models*
Utility knife or diagonal cutter (for trimming protective covers and gas collection tubing if used)*
Battery Numbers and String Letters/Numbers*
6mm id or ¼ id clear PVC tubing (3 ft length) when using gas collection tube features on any TEL models
with the ‘G’ suffix - not provided unless ordered as an option with the battery order (P/N 15028596)
Optional plastic apron, portable eyewash, spill kit and fire extinguisher (Class C)*
* Not provided with battery shipment
See Section IV. Installation Instructions-for further descriptions.

Table 2 - Installation Hardware Included with each 12 Volt Battery along with Proper Torque Values
Model Bus Bar Hardware Torque Protective
Connector Package (two SS Terminal
Bolts & two SS Cover
washers)
TEL12-105FS (1) 30042987 1/4-20 x 7/8 110 in-lbs (1) 15016827
(1) 15015928
TEL12-105FNSG (1) 15028536 8mm x 16 160 in-lbs (1) 15028540
(1) 15028538
TEL12-115FNG (1) 15028537 6mm x 16 110 in-lbs (1) 15028540
(1) 15028539
TEL12-160F (1) 30046800 1/4-20 x 3/4 110 in-lbs (1) 15029218
(1) 15028506
TEL12-160FW (1) 30046795 ¼-20 x 3/4 110 in-lbs (1) 15029218
(1) 15028506
TEL12-170FG (1) 15028593 8mm x 16 160 in-lbs (1) 15028594
(1) 15028538
TEL12-180F (1)30046800 ¼-20 x 3/4 110 in-lbs (1) 15029218
(1) 15028506
TEL12-210FG (1) 15028593 8mm x 16 160 in-lbs (1) 15028594
(1) 15028538
Hardware, terminal protector, and bus bar indicated above is individually packaged within the insert
on the top of the battery, inside the shipping carton of each 12 volt battery unit.

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I. Safety
Installation and servicing of batteries should be performed or supervised by personnel knowledgeable of
lead acid batteries standard safety practices i.e., personal and equipment safety precautions.

Safety Concerns (Please reference C&D Material Safety Data Sheet document L-84 for additional
information which is available directly from www.cdtechno.com)

 Electrical Hazards
Battery systems present a risk of electrical shock and high short circuit current. Remove any metal
objects (e.g. watches and rings), use properly insulated tools, and wear eye protection and rubber gloves.
Observe circuit polarities, use a voltmeter to check potentials before making connections and do not
make or break live circuits without following all proper safety precautions.
 Disposal
Lead Acid Batteries are to be recycled. Batteries contain lead and immobilized dilute sulfuric acid.
Dispose of in accordance with Federal, State and local regulations. Do not dispose of in a landfill,
lake or other unauthorized location. For assistance contact C&D at www.cdtechno.com
 Chemical Hazards
Any liquid emission from a battery may be electrolyte which contains dilute sulfuric acid this is
harmful to the skin and eyes, is electrically conductive and is corrosive. If electrolyte contacts the
skin, wash immediately and thoroughly. If electrolyte enters the eyes, promptly flush eyes with water
and seek medical attention. Neutralize spilled electrolyte with a solution of 1 lb. bicarbonate of soda
(baking soda) to 1 gallon of water.
 Fire, Explosion and Heat Hazards
Batteries can contain an explosive mixture of hydrogen gas which can vent under overcharging
conditions. Do not smoke or cause sparks in the vicinity of the battery. Do not install and charge
batteries in a sealed container. Mount the individual batteries with a minimum of 0.5'' between units.
If contained, assure the container or cabinet and room have adequate ventilation to prevent
accumulation of potentially explosive vented gas. Refer to the current issue of the National Electric
Code (NEC). Please note that for sealed cabinets with VRLA gas removal provisions, the C&D TEL
Series batteries with gas collection (G suffix) and the optional tubing kit can be utilized (see Diagram
in Section V of this document)

 Caution
Do not attempt to remove battery vents or add water as this presents a safety hazard and voids the
warranty. Wash hands after any contact with the battery lead terminals.

II. Receiving Instructions

Upon receipt, inspect the batteries for physical damage to the containers and terminals. If found, a claim must
be filed with the carrier within 10 days. Also check the packing slip to make sure all material has arrived. The
batteries are shipped fully charged. Their Open Circuit Voltage (OCV) should not be below 12.48 volts per
12 volt unit.

III. Storage Instructions

Store batteries in a clean, dry, cool area away from radiant heat sources. Recharge batteries in storage every 6
months or before their OCV declines to 12.48 VDC. Follow instructions as outlined in Section VI. Freshening
Charge.

IV. Installation Instructions-Required Installation Tools & Room

Equipment
At a minimum, the following tools and equipment are required to install VRLA batteries. A digital voltmeter,
insulated 7/16”, 10mm or 13mm socket wrench (depending on product model), inch pound torque wrench (160
in. lb. maximum ), rubber gloves, safety glasses for normal maintenance, full face shield for load testing,
optional plastic apron, portable eyewash, spill kit and fire extinguisher (Class C). If gas collection tubing is
connected, a knife or diagonal cutter will be needed to cut the inter-battery tubing to length.

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Optional test equipment, depending on the type of checkout to be performed includes; micro-ohm meter,
ohmic test set, 100 amp momentary load test set or system load bank.

Typically for Telecom applications, four individual batteries are connected in series to form a higher voltage
string of batteries (e.g. 4 each 12 volt batteries connected in series form a 48VDC battery system). Refer to
Figure 3 for a 48 VDC series connected battery string using 12 volt front access batteries.

Two or more strings may be connected in parallel to increase the total capacity of the
system (e.g. two strings of 48 volt 75 ampere-hour batteries connected in parallel make a 48 volts 150
Amp hour battery. Refer to Figure 4 for parallel connected front access batteries.

Warranty Date Code C&D’s front access batteries date code is located on the front panel of the battery
as a four digit number, MM-YY

Front access batteries are heavy, typically over 100 pounds each. Make sure proper lifting and moving
arrangements are in place to safely handle this weight and have been considered before traveling to the
site.

Figure 3 – Single -48 volt string configuration (typical)

Series -48VDC connection of individual front access batteries

Step 1. If installing in a multiple tier rack or cabinet arrangement, always begin with the lowest shelf,
string A, place each the individual front access batteries on the shelf (typically 4 per level) with
approximately 1/2 inch spacing between the individual units. All the batteries should be placed with
terminals to the front of the rack / shelf. Remove and save terminal protectors.

Step 2. C&D recommends, prior to connection of inter-unit bus bars and lugged cables, the battery
terminals and all contact surfaces should be neutralized, cleaned, lightly brushed with a brass bristle brush
or scotch brite type pad and lightly coated with protective No-Ox-Id terminal grease.

Step 3a. Starting at the battery on the right, which is to be the positive (+) output, label it as number 1 and
then label the adjacent batteries (right to left) in ascending numerical order 2, 3 & 4.

Step 3b. If more than one 48 VDC string is within the enclosure, number the additional batteries the same
way. Identify the bottom string as string A with the string above if present as string B and soon.

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Step 4. Using the provided inter-unit bus bar and hardware (bolt and washer), connect between battery 1’s
negative (-) terminal to battery 2’s positive (+) terminal as shown in Figure 3. Tighten bolt washer
assembly hand tight.

Step 5. Repeat, using the provided inter-unit bus bar and hardware (bolt and washer), connect between
battery 2’s negative (-) terminal to battery 3’s positive (+) terminal. Tighten bolt washer assembly hand
tight.

Step 6. Repeat, using the provided inter-unit bus bar and hardware (bolt and washer), connect between
battery 3’s negative (-) terminal to battery 4’s positive (+) terminal. Tighten bolt washer assembly hand
tight.

Step 7. Torque each of the above bolt washer assemblies as per the inch-pound specifications in Table 1
for the appropriate product.

Step 8.Following the rack or cabinet manufacturers cabling guidelines perform the lugged power lead
connections to positive (+) of battery 1 and negative (-) battery 4 terminals verifying proper polarities are
observed.

Step 9. Torque all remaining bolt washer assemblies as per the inch-pound specifications in Table 1 for the
appropriate product.

Step 10. Repeat for additional battery string if multiple strings are present.

Step 11. Install all protective terminal covers and use a utility knife or diagonal cutter to trim the cover as
needed allowing for proper cable routing.

Step 12. Verify charging equipment is set for proper float voltage of 2.25 to 2.30 volt per cell at 77F at the
battery terminals (54 to 55.2Vdc for a nominal 48 volt battery).

Figure 4 – Series +24 volt string configuration (typical) 2 strings to be in parallel shown
Series +24VDC connection of individual front access batteries

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 Series +24VDC connection of individual front access batteries
Step 1. If installing in a multiple tier rack or cabinet arrangement, always begin with the lowest shelf,
string A & B, place each the individual front access batteries on the shelf (typically 4 per level) with
approximately 1/2 inch spacing between the individual units. All the batteries should be placed with
terminals to the front of the rack / shelf. Remove and save terminal protectors.

Step 2. If supplied by the rack / cabinet manufacturer, place a safety shield in the center of the tray
between adjacent 24 volt battery strings.

Step 3. C&D recommends, prior to connection of inter-unit bus bars and lugged cables, the battery
terminals and all contact surfaces should be neutralized, cleaned, lightly brushed with a brass bristle brush
or scotch brite type pad and lightly coated with protective No-Ox-Id terminal grease.

Step 4a. Starting at the battery on the far right of the tray/shelf, which is to be the positive (+) output,
label it as number 1 and then label the adjacent battery to the left as battery number two, string A. Repeat
the numbering procedure for the adjacent string (next two batteries to the left), string B.

Step 4b. If more than two 24 VDC strings is within the enclosure, number these batteries the same way.
Identify the bottom tray as string A and B with the strings above as string C and D and so on

Step5. Using the provided inter-unit bus bar and hardware (bolt and washer), connect between String A,
battery 1’s negative (-) terminal to String A, battery 2’s positive (+) terminal as shown in Figure 4.
Tighten bolt washer assembly hand tight.

Step 6. Torque each of the above bolt washer assemblies as per the inch-pound specifications in Table 1
for the appropriate product.

Step 7. Following the rack or cabinet manufacturers cabling guidelines to perform the lugged power lead
connections to positive (+) of String A, battery 1 and negative (-) of String A, battery 2 terminals
verifying proper polarities are observed.

Step 8. Torque each of the above bolt washer assemblies as per the inch-pound specifications in Table 1
for the appropriate product.

Step 9. Repeat above steps for String B and each of any remaining battery strings.

Step 11. Install all protective terminal covers and use a utility knife or diagonal cutter to trim the cover as
needed allowing for proper cable routing.

Step 12. Verify charging equipment is set for proper float voltage of 2.25 to 2.30 volt per cell at 77F at the
battery terminals (27 to 27.6 Vdc for a nominal 24 volt battery).
.

Parallel Connection of individual strings of batteries

C&D recommends each individual battery string be cabled separately to a common junction point or box.
Each string may also contain a separate fuse or disconnect switch to facilitate maintenance. The parallel
connections should be completed only when the charger and load are not connected to the battery output
circuit or battery string voltage should be matched to within 0.5 volts before the connection is made and
should be performed only by qualified technicians familiar with live battery connections. The battery
strings must not be ''daisy chained'' in parallel.

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V. Optional Gas Collection System Installation (tubing kit PN 15028596)
TELSeries Models with ‘G’ in the product suffix (i.e. TEL12-105FNSG) include a gas collection system
feature which allows the hydrogen and oxygen gases that may vent from the battery to be directed to a
specific cabinet exit location by the installation of 6mm or ¼” ID PVC tubing. This tubing daisy chains
from one battery to the next in the string with the first battery in the string requiring a ‘plug’ in the hose
barb port above the positive terminal Short tubes
of the battery (shown in Figure 5). plug
(Note that each battery ships with a
plug in this right side port. Installer
should remove any remaining plugs
to allow for tubing connection)
Individual tubes are cut by the Tube to
installer (each short tubing piece is cabinet
approx 5” in length) and are routed exit port
from battery to battery as shown in
Figure 5 (please make sure that the
tubing is not kinked so gases can flow
in the tubing). A final system Figure 5 – Optional Gas Collection
collection tube, which varies in System Installation (if required by
length, is connected to the hose barb cabinet manufacturer)
port above the negative terminal on
the left most battery unit. This tube should be routed per the cabinet manufacturer’s instructions.

Special Note: if the gas collection system is not required and/or utilized, the factory installed
plug in the right port of each 12 volt battery can be removed or can remain in place. NEVER
install a plug in both battery ports or the left side port since this will not allow the battery to vent
any excess pressure and could cause an UNSAFE CONDITION.

VI. Freshening Charge

When the batteries have been in storage or transit for an extended period, over 6 months or if OCV’s are
below 12.48 volts or when the number of cells in series is greater than 24, it is recommended the battery
system be given a freshening charge at 2.4 volts average per cell for 24 hours prior to final installation.
This will assure higher initial performance and will reduce the time period required for the cells to achieve
proper voltage balance between the individual units. Normally freshening charges are only necessary if batteries
were in a warehouse at 77F in excess of 6 months or the open circuit voltage of the unit has declined to less than
12.48 Vdc.

VII. Float Charging

Following the freshening charge (if necessary) the battery system should be placed on “float“ charge at
between 2.25 v/c and 2.30 v/c average (approximately 13.5 to 13.8 volts/unit average for 12 volt units at
77°F).

VIII. Periodic Maintenance

These VRLA batteries are maintenance free with respect to the electrolyte. However, the charging voltage,
temperature, performance and connection resistances must be periodically monitored and any necessary
corrective actions taken if irregular values are observed to assure reliable standby power when required.

Quarterly Inspection
 Measure and record the system total float charging voltage at the battery terminals
 Record the charger on charge output current and voltage
 Record the ambient temperature and condition of ventilation equipment
 Visually inspect the batteries and rack for; general appearance, cleanliness or any irregularity.
 If gas tubing provisions are utilized, check for any obstructions in the tubing which would prevent
the free flow of gases thru the exit point.

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Semiannual Inspection
 Repeat the quarterly checks
 Record the on charge voltage of each unit
 Optionally perform and record Ohmic checks for trending purposes

Yearly and Initial Inspection

 Repeat the semiannual checks
 Inspect all connections to ensure integrity.

Any data, descriptions or specifications presented herein are subject to revision by

C&D Technologies, Inc.without notice. While such information is believed to be accurate
as indicated herein, C&D Technologies, Inc. makes no warranty and hereby disclaims all
warranties, express or implied, with regard to the accuracy or completeness of
1400 Union Meeting Road such information. Further, because the product(s) featured herein may be used under
P.O. Box 3053 • Blue Bell, PA 19422-0858 conditions beyond its control, C&D Technologies, Inc. hereby disclaims all warranties,
(215) 619-2700 • Fax (215) 619-7899 • (800) 543-8630 either express or implied, concerning the fitness or suitability of such product(s) for any
customersvc@cdtechno.com particular use or in any specific application or arising from any course of dealing or usage
of trade. The user is solely responsible for determining the suitability of the product(s)
www.cdtechno.com featured herein for user’s intended purpose and in user’s specific application.

Copyright 2011 C&D TECHNOLOGIES, INC. Printed in U.S.A. RS02046 0311/CD

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