AlphaCell™ GelCell Series AlphaCellTM GelCell Battery Users Guide Storage, Maintenance, and Deployment Effective: October, 2009 Alpha Technologies
Power Alpha Technologies ®
AlphaCellTM GelCell Battery Users Guide Storage, Maintenance and Deployment 745-680-C0-002, Rev. B Effective Date: October 2009 Copyright© 2009 Alpha Technologies, Inc. member of The GroupTM NOTE: Photographs contained in this manual are for illustrative purposes only. These photographs may not match your installation. NOTE: Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding.
Table of Contents Safety Notes........................................................................................................................................................ 6 Battery Maintenance Guidelines......................................................................................................................... 7 Recycling and Disposal Instructions.................................................................................................................... 7 Storage ...........
Figures and Tables Fig. 1, Capacity vs Storage Time............................................................................................................ 8 Fig. 2, Series Connected String of Batteries.........................................................................................11 Fig. 3, Parallel String of Batteries..........................................................................................................11 Fig. 4, Flow Chart, Monthly Status Monitoring........................
Safety Notes Review the drawings and illustrations contained in this manual before proceeding. If there are any questions regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha representative. Save this document for future reference. To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following symbols have been placed throughout this manual. Where these symbols appear, use extra care and attention.
WARNING! Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery installation, maintenance, service, and replacement must only be performed by authorized personnel. Battery Maintenance Guidelines • For optimal performance, inspect batteries every 3 months for: Signs of battery cracking, leaking or swelling.
Important Storage Practices All lead acid batteries experience self-discharge while in open circuit storage. This causes circuit voltage and capacity to decrease (see Fig.1). This is especially true if the batteries are stored for long periods of time at higher temperatures. Storage of the batteries in the shaded area of Figure 1 is not recommended, as higher temperatures combined with longer periods of storage will result in diminished residual capacity — hence a shorter battery lifespan.
WARNING! Chemical Hazards Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contains dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic and are electrically conductive and corrosive. To avoid injury: • Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel knowledgeable of batteries and the required safety precautions.
1.0 Introduction The purpose of this guide is to provide the user with the necessary information to maintain batteries in storage and deploy batteries in Alpha Powering systems, as well as perform battery testing, install replacements and recycling. This manual guides you through periodic maintenance checks and troubleshooting of the AlphaCell GelCell batteries of 50 through 107 ampere hours capacity.
1.1 Description The AlphaCell GelCell battery is a lead acid battery that facilitates an oxygen recombination cycle. The net result, under normal conditions, is minimal gas emission and water loss from the electrolyte. The electrolyte is immobilized in either a gel form or is absorbed within an absorbent separator between the plates. Consequently, there is no requirement to add water to the cells or to measure the electrolyte specific gravity.
2.0 Preparing for Maintenance The battery system should be remotely monitored monthly and physically inspected quarterly. If the battery system has an automatic monitoring system to gather the electrical and environmental data, the monthly checks should consist of evaluating the recorded data and visiting any site that does not meet the specifications listed in the detailed procedures below. At a minimum each site needs to be physically inspected every three months.
3.0 Periodic Maintenance Tasks and Schedule The following tasks are to be performed on a monthly and quarterly schedule.
3.2 Quarterly Preventive Maintenance Required Equipment • True RMS Volt Meter with DC Amp Clamp • Midtronics Conductance Battery Tester Remote Status Monitoring Procedure Site Visit Ensure Power Supply is in Float Mode Yes Battery String Float Current >0.5A Record Information on Site Visit Record No Disconnect Batteries Does the individual battery pass the Evaluation Procedure #1 outlined in Section 3.4? (see page 18) Monitor as per PM Program Yes Battery > 0.
3.2 Quarterly Preventive Maintenance, continued Procedure 1. Verify the power supply is in Float mode. 2. Use the DC Amp clamp to measure and record each individual battery string’s float current. 3. If the individual string float current is greater than 0.5 amps, replace the battery string. Measure and record the individual battery conductance and voltage on the Site Visit Record. 4. If the string float current is less than 0.5 amps, 4.1 Disconnect the batteries from the system 4.
3.3 AlphaCellTM Battery Maintenance Log Follow this sample when filling out the maintenance log (following page). 16 y Ba tte ry Ty pe Ini tia l In sta Mf ll D r. D ate ate Co PM de Da te Flo at Cu rre Ba nt tte ry Te mp tte r Ba St rin g Node / Location Power Supply Type Load (kW) Evaluation Procedure #1 Evaluation Procedure #2 Evaluation Procedure #3 Vdc Float No Load Vdc 24 Hour OCV Vdc @ 100A after 10 seconds Conductance mhos @ 77°F A 1 195GXL 4/08 3/08 .2 70° 13.
3.3 AlphaCellTM Battery Maintenance Log Ty pe Ini tia l In sta Mf ll D r. D ate ate C PM od e Da te Flo at Cu rre Ba nt tte ry Te mp tte ry Ba tte r Ba St rin g y Node / Location Power Supply Type Load (kW) 745-680-C0-002, Rev.
3.4 Battery Evaluation procedures for AlphaCell™ GXL, GXL-HP and Gold-HP batteries To help identify batteries approaching end of life in an operating power system, test #1 should be performed at each maintenance interval. For batteries not installed in an operating power system, test #2 or #3 may be performed. For accuracy, tests must be performed on fully charged batteries. A battery failing any of the following combined tests is defined as a faulty battery.
3.5 Battery Refurbishment Plan Battery Refurbishment Plan Batteries Returned from Site. Measure and document 24 hour Open Circuit Voltage (OCV). (Must occur within 24 hours of removal from charger) No Measure Conductance Does battery meet the minimum conductance values per Table 1? Yes Measure Battery Voltage No Measure Battery Voltage Does battery meet the minimum of 12.
4.0 Battery System Float Charging Battery System Float Charging Voltage Encountering temperature extremes When you encounter temperature extremes, temperature compensate the float charging voltage. The temperature compensation coefficient is -0.0028 V/C per °F (-0.005 V/C per °C). For example if the normal battery temperature is 90°F (13° above 77°F) you should reduce the average float charging voltage range by 0.036 V/C (13° x -0.0028 V/C per °F) to between 2.21 and 2.26 V/C.
4.0 Battery System Float Charging, continued NOTE: The following information specifically pertains to Alpha XM Series 2 Power Supplies. 4.1 Alpha Power Supply Charging Profile BULK charge is a “Constant Current” charge. This current is the maximum the charger is capable of delivering: 10A for 615, 906/915/915HV, and 922/922HV. As the charge is returned to the batteries, their voltage increases to a specific threshold (2.27VDC per cell).
5.
5.0 Battery Symptoms and Solutions, continued Problem with Symptom Possible Causes System float voltage > 2.3V/C average 77°F (25°C) System float voltage < 2.25V/C average 77°F (25°C) DC Voltage Checks Charger output set incorrectly • Individual battery float voltage > 13.3 VDC Individual battery float voltage 14.5 VDC for 6 cell DC voltage measured between battery system output terminals and ground (rack) or a ground fault indicated by automatic monitoring equipment.
5.0 Battery Symptoms and Solutions, continued Type Symptom Possible Causes A battery or connection in series string is open. Verify via the float voltage check or AC ripple voltage or impedance check of individual batteries. Float current to string is zero Float Charging Current Checks High Rate 10 Second Load Test Battery Impedance/ Conductance Test Float current exceeds 3.0 milliamperes per ampere hour of rated capacity at 77°F(25°C) at float voltage.
6.0 Battery Parameters by Model Number Parameter Model Number 220 Gold-HP 220GXL 195 Gold-HP 195GXL Terminal Type Threaded Insert Threaded Insert Threaded Insert Threaded Insert Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 10-32 UNC Bolt Annual Retorque Inch-Pounds / N•m 110In-lb / 2.4N•m 110In-lb / 2.4N•m 110In-lb / 2.4N•m 25In-lb / .8N•m Open Circuit Voltage 12.84 12.84 12.84 12.84 Average Float Voltage Range (volts/unit) 13.5 to 13.8 13.5 to 13.8 13.5 to 13.
6.0 Battery Parameters by Model Number, continued Parameter Model Number 215 Gold HP 210GXL 190 Gold HP 180GXL Terminal Type Threaded Insert Threaded Insert Threaded Insert Threaded Insert Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt Annual Retorque Inch-Pounds / N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m Open Circuit Voltage 12.84 12.84 12.84 12.84 Average Float Voltage Range (volts/unit) 13.5 to 13.8 13.
7.0 Warranty and Return Information 7.1 AlphaCell™ Limited Warranty Float Service Outdoor VRLA Batteries This limited warranty applies only to the original purchaser (“User”) of the Product supplied under the Supply Agreement. A Battery will be considered defective, and can be replaced, when it fails to deliver 70% of its rated capacity during stated warranty period provided that it has been used in accordance with the conditions listed below. Standard Warranty periods are outlined in Table 6.
7.1 AlphaCell™ Standard Limited Warranty, continued The table below indicates the warranty periods for AlphaCellTM Batteries used with Alpha approved power supplies and enclosures.
7.2 Battery Maintenance Report for Return Authorizations Contact your Alpha Customer Service representative for assistance in processing your AlphaCellTM warranty claim. Alpha Customer Service (800) 421-8089, or fax# (360) 671-4936 This form, in conjunction with Alpha's Battery Evaluation Procedure is intended as a method of collecting data critical to the efficient processing of your warranty battery claims. Record battery float voltage while the battery is still connected to the system.
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