AlphaCell OPzS Stationary Flooded Tubular Lead-acid Batteries Technical Manual AlphaCell OPzS Battery Effective: January 2008 Alpha Technologies
Alpha Technologies Power ®
AlphaCell OPzS Battery Installation and Operation Manual OPzS-BATTERY Effective Date: January 2008 Copyright© 2008 Alpha Technologies, Inc. A Member of the Alpha Group 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 .......................................................................................................................... 8 Battery Safety Notes.............................................................................................................. 9 Chemical Hazards ................................................................................................................. 9 Recycling and Disposal Instructions ......................................................
Table of Contents, continued 6.0 7.0 Unpacking and Handling for Installation ................................................................... 16 6.1 General .......................................................................................................... 16 6.2 Recommended Installation Equipment and Supplies .................................... 16 6.3 Cell Handling.................................................................................................. 16 System Installation....
Table of Contents, continued 12.0 13.0 Maintenance ............................................................................................................ 26 12.1 Battery Cleaning ............................................................................................ 26 12.2 12.1.1 Standard Cleaning .............................................................................. 26 12.1.2 Corrosion Cleaning ............................................................................. 26 12.1.
Figures and Tables Fig. 2-1, Safety Labels..........................................................................................................11 Fig. 16-1, Charged Battery Readings Before Discharge Begins Form ................................ 43 Fig. 16-2, After “Load Profile” Battery Form......................................................................... 44 Fig. 16-3, “Final Recharge” Battery Readings Form............................................................
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.
Battery Safety Notes WARNING! Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery installation, maintenance, service and replacement must be performed only by authorized personnel. Chemical Hazards Any liquid leakage from a flooded lead-acid battery contain dilute sulfuric acid, which is harmful to the skin and eyes. Emissions are electrolytic, and are electrically conductive and corrosive.
1.0 General Information 1.1 Introduction OpzS batteries are intended for telecommunication facilities, computers, emergency lighting, alarm, control and monitoring systems in power plants and distribution stations, railway stations, airports etc. Due to their extremely low self-discharge rate they are also suitable for plants supplied by solar cells. When properly handled and operated stationary OpzS batteries do not represent any danger or harm for the operators and environment.
2.0 Safety Follow Instructions Use Protective Goggle and Clothes Avoid Sparks, Flames, or Arcing Explosive Gases (Avoid Short Circuit Caustic Acid Danger Fig. 2-1, Safety Labels « CAUTION! If you have any questions concerning safety, contact your local manufacturer sales representative to clarify any of the noted safety precautions or call the Alpha Customer Service number listed on the back of this manual. 2.
2.0 Safety, continued 2.3 Safety Precautions, continued 2.3.1 Sulfuric Acid Burns, continued In case of eye contact with sulfuric acid, immediately: • • Flush thoroughly every few minutes with large amounts of water. Get medical attention. If acid is spilled it should be neutralized with a solution of 1 pound of baking soda to 1 gallon of water (1 kg NaHCO3 / 10 l water) and then washed off with water. 2.3.2 Explosive Gases and Fire Batteries generate explosive gases in all stages of operation.
3.0 Inspecting the Battery Shipment 3.1 General Precautions have been taken to pack the cells/battery units for shipment to ensure its safe arrival. However, upon receipt, you should inspect for evidence of damage that may have occurred during transit. WARNING! During inspections, take precautions against electrical shock. You are handling live batteries. 3.2 Visible External Damage Inventory all materials against the bill of lading and inspect for visible external damage.
4.0 Battery Storage Before Installation 4.1 General Batteries should be unpacked, installed and charged as soon as possible after receipt. However, if this is impractical, follow the instructions below for storing the battery before installation. Stationary battery cells can be filled with electrolyte and charged - flooded or dry-charged. Store batteries indoors in a clean, dry, cool and frost free location (10 °C – 30 °C).
5.0 Selection and Accommodation Considerations 5.1 General If you have any questions concerning the battery selection and installation considerations, contact your local manufacturer’s representative or Alpha Technologies Customer Service. 5.2 Battery Selection To correctly match your battery needs with the correct battery, please consider the following information: • • • • • • • • • 5.3 Type of consuming device (telephone plant, DC-AC converter, emergency lighting etc).
5.0 Selection and Accommodation Considerations, continued 5.3 Accommodation Considerations, continued Anchoring: Anchoring should meet national/local codes and industry standards. Floor anchoring and its design are the responsibility of the installer. Proximity to Electronic Equipment: Series flooded stationary batteries may be installed next to or under electronic equipment.
6.0 Unpacking and Handling for Installation, continued 6.3 Cell Handling, continued Lifting procedure: 1. Tilt the cell about 1 inch (25 mm) to position the lifting belt. 2. Slide belt underneath cell. 3. Bring the end rings of the belt together over the cover and engage the hook of the lifting device in both rings. Always lift vertically and balance the cell. 4. Lift cell into position. Exercise extreme care when initially lifting cells and when lowering them into their final position on the rack.
7.0 System Installation, continued 7.3 Installation Considerations, continued 7.3.2 Spacing Maintain proper spacing between cells on the rack to provide thermal management and to allow for the proper fit of hardware and connections. 7.4 Battery Installation Prior to installation ensure the following: • • • • • The floor is flat without bulges. In the event it is not, suitable brackets should be made and laid under the trays.
7.0 System Installation, continued 7.4 Battery Installation, continued 6. Lift the next cell to be installed and place it next to the previously installed unit. Be certain to allow proper spacing between cells as outlined in Section 7.3.2. Exercise extreme care when positioning cells. Bumping or scraping a cell against the adjacent cell or unit or rack member may damage the jar material. Do not use any kind of tool to pry cells into position.
7.0 System Installation, continued 7.5 Preparing and Installing Connections, continued 7.5.2 Intercell Connectors The connections are made by bolting the flexible copper intercell connectors to the cell posts of opposite polarity on adjacent cells. When more than one intercell connector per cell is furnished, bolt the connectors on opposite sides of the cell posts. See the assembly drawing, included with the shipment, for details. 1.
7.0 System Installation, continued 7.5 Preparing and Installing Connections, continued 7.5.3 Terminal Plates, continued 8. Before activating the charger: • • Inspect the cell connections of the system to ensure that all cells are connected correctly, POSITIVE (+) to NEGATIVE (-) according to the assembly drawing. Measure the voltage across the system terminals. Voltage of the battery should equal approximately 2.08 times the number of cells in the string.
10.0 Freshening Charge Refresh charging only applies to wet batteries in storage. Dry batteries may be stored for up to 2 years as long as environmental requirements are met. Batteries lose some initial charge during shipment and storage. A filled and charged cell should be recharged every 90 days to prevent failure. Use the date of battery shipment to determine freshening charge requirements.
11.0 Operation WARNING! Before connecting battery to charger, it is important to note that several hazards are associated with battery systems, particularly those used for large UPS applications where terminal voltages can approach several hundred volts and currents may exceed several thousand amperes. By exercising proper care and allowing only properly trained personnel to work on them, batteries should serve you well and perform without incident.
11.0 Operation, continued 11.1 Battery charging and operation mode, continued 11.1.3 Switch mode operation In the switch mode operation the battery is separated from the load. Towards the end of charging the charge voltage of the battery is 2.6 - 2.70 V/cell. The charging process must be monitored. On reaching a full charge state, charging should be terminated or switched to float operation mode. 11.1.
11.0 Operation, continued 11.3 Equalizing Charge, continued 11.3.1 Equalizing Charge Method Constant voltage charging is the method for giving an equalizing charge. Determine the equalizing voltage based on the maximum voltage allowed by the system equipment connected to the DC bus. NOTE: The voltage of a warm cell will be lower than the average. Its voltage can be corrected for temperature by adding 0.005 V/°C that the cell temperature is above the average temperature of the other cells.
12.0 Maintenance For OPzS batteries maintenance is reduced to a minimum and is required only from time to time. At normal operation, only some distilled water has to be added once in a 2-3 year period and, if necessary, the surface of cells has to be cleaned. All stated voltage values are valid for the temperature range from 15 °C to 25 °C. Out of this range the corrections given by the battery producer are necessary. 12.1 Battery Cleaning Check the battery for cleanliness at regular intervals.
12.0 Maintenance, continued 12.1 Battery Cleaning, continued 12.1.3 Heavy Corrosion Cleaning If the routine cleaning of bolted connections has been neglected, heavy post corrosion may occur. The performance of the battery under load could be adversely affected and this condition could present a safety hazard. To perform the heavy corrosion cleaning: 1. Unbolt and remove connectors. 2.
12.0 Maintenance, continued 12.2 Maintenance Records A complete recorded history of the battery operation is essential for obtaining satisfactory performance. Good record keeping will show when corrective action is required to eliminate possible charging, corrosion, maintenance or environmental problems.
12.0 Maintenance, continued 12.2 Maintenance Records, continued Quarterly Maintenance Schedule (Required) In addition to the monthly items listed above also measure and record the following: 1. Measure and record specific gravity of each cell. 2. Measure and record voltage of each cell. 3. Measure and record the total battery string voltage. 4. Measure and record the electrolyte temperature of one cell in each row of each rack. 5. Randomly select and check resistances of 10% of intercell connections.
12.0 Maintenance, continued 12.4 Adding Water Cells on charge normally show a very gradual lowering of the electrolyte level over a period of time, due to a loss of water from the electrolyte. Hydrogen and oxygen gasses are liberated by electrolysis as a result of charging current. Cells also lose water from normal evaporation, at a rate relative to the cell temperature and the humidity.
12.0 Maintenance, continued 12.6 Filling Dry-Charged Cells Cells may be received dry-charged. Dry-charged cells should be activated (filled with electrolyte and charged) only when ready to be placed in service. Dry-charged cells may be stored for up to 2 years without deterioration in cool, low-humidity locations (<30°C, <50% H).
13.0 Test Procedures 13.1 Procedure for Battery Capacity Tests 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 11.3. 1. Make sure all battery connections are clean, tight, and free of corrosion. 2. While the battery is on float, read and record the specific gravity and voltage of each cell, the temperature of at least every 6th cell, and battery terminal float voltage. 3.
14.0 Specifications Specifications and data are subject to change without notice. TYPE L (in/mm) W (in/mm) H (in/mm) Filled Weight (lbs/kg) 12V 1 OPzS 50 10.5/272 8.0/205 15.0/388 80/37 12V 2 OPzS 100 10.5/272 8.0/205 15.0/388 117/53 12V 3 OPzS 150 15/380 8.0/205 15.0/388 167/76 6V 4 OPzS 200 10.5/272 8.0/205 15.0/388 108/48 6V 5 OPzS 250 15/380 8.0/205 15.0/388 143/65 6V6 OPzS 300 15/380 8.0/205 15.0/388 160/73 3 OPzS 150 4.0/103 8.0/206 14.5/375 35/16 4 OPzS 200 4.
14.0 Specifications, continued Specifications and data are subject to change without notice.
14.0 Specifications, continued Specifications and data are subject to change without notice. Cell Type 10 Min 30 Min 1 Hr 3 Hr 4 Hr 5 Hr 8 Hr 10 Hr 24 Hr 12V 1 OPzS 50 38.4 32 24 12 9.7 9 6 5 2.3 12V 2 OPzS 100 66.0 55 42.7 24 18.4 17 11.4 10.2 4.6 12V 3 OPzS 150 99.0 82.5 64.1 36 27.6 25.5 17.1 15.3 6.9 6V 4 OPzS 200 132.0 110 85.4 48 36.8 34 22.8 20.4 9.2 6V 5 OPzS 250 165.0 137.5 106.8 60 46 42.5 28.5 25.5 11.5 6V 6 OPzS 300 198.0 165 128.
14.0 Specifications, continued Specifications and data are subject to change without notice. Cell Type 1 Min 10 Min 30 Min 1 Hr 3 Hr 4 Hr 5 Hr 8 Hr 10 Hr 12V 1 OPzS 50 58.6 42 35 25 13 9.6 9 7 6 24 Hr 2.7 12V 2 OPzS 100 125.6 90 75 51 25 19.3 18 12 10.5 4.7 12V 3 OPzS 150 188.3 135 112.5 76.5 37.5 29 27 18 15.8 7.1 6V 4 OPzS 200 251.1 180 150 102 50 38.6 35 24 21 9.5 6V 5 OPzS 250 313.9 225.5 187.5 127.5 62.5 48.3 45 30 26.3 11.
14.0 Specifications, continued Specifications and data are subject to change without notice. Cell Type 1 Min 10 Min 30 Min 1 Hr 3 Hr 4 Hr 5 Hr 8 Hr 10 Hr 12V 1 OPzS 50 - 46.8 39 26 13 9.7 9 7 - 24 Hr - 12V 2 OPzS 100 - 94.9 79.1 54 26.1 20.4 19 12.6 - - 12V 3 OPzS 150 - 142.4 118.7 81 39.2 30.6 28.5 18.9 - - 6V 4 OPzS 200 - 189.8 158.2 108 52.2 40.8 38 25.2 - - 6V 5 OPzS 250 - 237.4 197.8 135 65.3 51 47.5 31.5 - - 6V 6 OPzS 300 - 284.
14.0 Specifications, continued Specifications and data are subject to change without notice. Cell Type 10 Min 30 Min 1 Hr 3 Hr 4 Hr 5 Hr 8 Hr 10 Hr 24 Hr 12V 1 OPzS 50 49.2 41 27 13 9.5 9 - - - 12V 2 OPzS 100 102.0 85 58 27 21.2 20 - - - 12V 3 OPzS 150 153.0 127.5 87 40.5 31.8 30 - - - 6V 4 OPzS 200 204.0 170 116 54 42.4 40 - - - 6V 5 OPzS 250 255.0 212.5 145 67.5 53 50 - - - 6V 6 OPzS 300 306.0 255 174 81 63.6 60 - - - 2 OPzS 100 102.
14.0 Specifications, continued Specifications and data are subject to change without notice. Electrolyte Quality (Dilute Sulfuric Acid H2SO4) - Maximum Impurities (% by Weight) Organic Matter Platinum (Pt) Sulfurous Acid (SO2) 1.250 - 1.300 1.170 - 1.215 None None None None 0.0016 0.0013 Iron (Fe) 0.0020 0.0016 Copper (Cu) 0.0001 0.00008 Zinc (Zn) 0.0016 0.0013 Arsenic (As) 0.00004 0.00003 Antimony (Sb) 0.00004 0.00003 Selenium (Se) 0.0008 0.0006 Nickel (Ni) 0.00004 0.
14.0 Specifications, continued Specifications and data are subject to change without notice. Battery Water Quality Maximum Impurities (Parts per Million (PPM)) Requirements Maximum Allowable Limits Total Solids 350.0 Fixed Solids 200.0 Organic and Volatile 150.0 Iron 4.0 Chloride 25.0 Ammonium (NH4) 4.0 Nitrates (NO2) 10.0 Nitrates (NO3) 10.0 Manganese 0.07 Calcium and Magnesium 40.
14.0 Specifications, continued Specifications and data are subject to change without notice. Voltage is 2.23 Float for 60 cells Type of cell ml/cell,month ml gas/cell,h ml H2/cell,h lH2/cell,min cu.ftH2/cell,min 3OPzS150 24750 33 22 0.0003 0.0000130 1.126 4OPzS200 33000 44 30 0.00049 0.0000174 1.502 5OPzS250 41250 55 37 0.00062 0.0000217 1.877 6OPzS300 49500 67 44 0.00074 0.0000261 2.252 5OPzS350 57750 78 52 0.00086 0.0000304 2.628 6OPzS420 69300 93 62 0.
14.0 Specifications, continued Specifications and data are subject to change without notice. OPzS Cell Type RI(mΩ)/CELL Short Circuit Current (amps) 3 OPzS 150 1.15 1739 4 OPzS 200 0.74 2703 5 OPzS 250 0.63 3175 6 OPzS 300 0.52 3846 5 OPzS 350 0.58 3448 6 OPzS 420 0.53 3774 7 OPzS 490 0.48 4167 6 OPzS 600 0.47 4255 8 OPzS 800 0.40 5000 10 OPzS 1000 0.30 6667 12 OPzS 1200 0.29 6897 12 OPzS 1500 0.29 6897 16 OPzS 2000 0.18 11111 20 OPzS 2500 0.
16.0 Maintenance Records CHARGED BATTERY READINGS BEFORE DISCHARGE BEGINS BATTERY TYPE _____________ DATE____________ ROOM TEMP___________UNITS_____ VENDOR_________________________________________________________________________ BATTERY VOLTAGE : ____________ VDC AT FLOAT _____________ VDC OPEN CIRCUIT COMMENTS: Cell No. Volts+2.000 Elect. Temp. Sp.Gr.+1.000 Electrolyte Level* CellNo.
16.0 Maintenance Records, continued AFTER “LOAD PROFILE” BATTERY BATTERY TYPE _____________ DATE____________ ROOM TEMP___________UNITS_____ VENDOR_________________________________________________________________________ BATTERY VOLTAGE : ____________ VDC AT FLOAT _____________ VDC OPEN CIRCUIT COMMENTS: Cell No.. Volts+2.000 Elect. Temp. Sp.Gr.+1.000 Electrolyte Level* Cell No..
16.0 Maintenance Records, continued ““FINAL RECHARGE” BATTERY READINGS BATTERY TYPE _____________ DATE____________ ROOM TEMP___________UNITS_____ VENDOR_________________________________________________________________________ BATTERY VOLTAGE : ____________ VDC AT FLOAT _____________ VDC OPEN CIRCUIT COMMENTS: Cell No.. Volts+2.000 Elect. Temp. Sp.Gr.+1.000 Electrolyte Level* Cell No..
Power Alpha Technologies ® Alpha Technologies 3767 Alpha Way Bellingham, WA 98226 USA Tel: +1 360 647 2360 Fax: +1 360 671 4936 Web: www.alpha.com Alpha Technologies Inc. G.B. Enterprises Inc. Alpha Industrial Power Inc. 1075 Satellite Blvd NW, Suite 400 Suwanee, GA 30024 United States Tel: +1 678 475 3995 Fax: +1 678 584 9259 USA Tel: +1 360 647 2360 Fax: +1 360 671 4936 Web: www.alpha.com Alpha Technologies Ltd.
