Alpha AlphaCell GelCell User Manual
AlphaCell™ GelCell Series
AlphaCellTM GelCell Battery Users Guide
Storage, Maintenance, and Deployment
Effective: April, 2013
Alpha Technologies
Alpha Technologies
Power
®
AlphaCell
Storage, Maintenance and Deployment
745-680-C0-002, Rev. B1
TM
GelCell Battery Users Guide
Effective Date: April 2013
Copyright© 2013
Alpha Technologies, Inc.
member of The 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. If
there are questions regarding the safe operation of this product, please contact Alpha Technologies or your
nearest Alpha representative.
NOTE:
Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,
batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with
its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.
TM
Contacting Alpha Technologies: www.alpha.com
or
For general USA sales information and customer service (7 AM to 5 PM, Pacic Time), call
For Sales information and Technical Support in Canada, call
745-680-C0-002, Rev. B1
1 800 863 3930
For complete technical support in the USA, call
7 AM to 5 PM, Pacic Time or 24/7 emergency support
1 800 863 3364
1 800 667 8743
3
Table of Contents
Safety Notes ....................................................................................................................................................... 6
Battery Maintenance Guidelines......................................................................................................................... 7
Recycling and Disposal Instructions ................................................................................................................... 7
Storage ............................................................................................................................................................... 8
Electrical Safety .................................................................................................................................................. 8
Chemical and Mechanical Safety ....................................................................................................................... 9
1.0 Introduction .......................................................................................................................................... 10
1.1 Description ..............................................................................................................................11
2.0 Preparing for Maintenance .................................................................................................................. 12
2.1 Required Tools and Equipment .............................................................................................. 12
3.0 Periodic Maintenance Tasks and Schedule ......................................................................................... 13
3.1 Monthly Remote Status Monitoring ........................................................................................ 13
3.2 Quarterly Preventive Maintenance ......................................................................................... 14
3.3 AlphaCellTM Battery Maintenance Log .................................................................................... 16
3.4 Battery Evaluation Procedures ............................................................................................... 18
3.5 Battery Refurbishment Plan .................................................................................................... 19
4.0 Battery System Float Charging ............................................................................................................ 20
4.1 Alpha Power Supply Charging Prole .................................................................................... 21
5.0 Battery Symptoms and Solutions ........................................................................................................ 22
6.0 Battery Parameters by Model Number ................................................................................................ 25
7.0 Warranty and Return Information ........................................................................................................ 27
7.1 AlphaCell
7.2 Battery Maintenance Report for Return Authorizations .......................................................... 29
TM
Limited Warranty.................................................................................................. 27
4
745-680-C0-002, Rev.B1
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 ..................................................................................... 13
Fig. 5, Flow Chart, Quarterly Preventive Maintenance ........................................................................ 14
Fig. 6 Flow Chart for Battery Refurbishment Plan ............................................................................... 19
Fig. 7, Charger Modes ......................................................................................................................... 21
Table 1, Conductance values, new vs. suspect batteries .................................................................... 18
Table 2, Battery Symptoms and Solutions ........................................................................................... 22
Table 3, Battery Parameters, Current Models (threaded insert terminals) .......................................... 25
Table 4, Battery Parameters, Legacy Models (threaded insert terminals) ........................................... 26
Table 5, Battery Parameters, Legacy Models, (Lead ag insert terminals) ......................................... 26
Table 6, Warranty Periods for AlphaCellTM batteries ............................................................................ 28
745-680-C0-002, Rev. B1
5
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.
ATTENTION:
The use of ATTENTION indicates specic regulatory/code requirements that may affect the placement of
equipment and installation procedures.
NOTE:
A NOTE provides additional information to help complete a specic task or procedure.
CAUTION!
The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment.
WARNING!
A WARNING presents safety information to PREVENT INJURY OR DEATH to the
technician or user.
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745-680-C0-002, Rev.B1
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. The battery should be replaced immediately
by authorized personnel using a battery of the identical type and rating (match conductance,
voltages, and date codes as specied in this document).
Signs of battery cable damage. Battery cable should be replaced immediately by
authorized personnel using replacement parts specied by vendor.
Loose battery connection hardware. Refer to documentation for the correct torque and
connection hardware for the application.
• Do not attempt to remove the vents (valves) from the AlphaCell GelCell battery or add water. This is a
safety hazard and voids the warranty.
• Apply NO-OX grease on all exposed connections.
• When necessary, clean up any spilled electrolyte in accordance with all federal, state, and local
regulations or codes.
• Follow approved storage instructions.
• Always replace batteries with those of an identical type and rating. Never install untested batteries.
• Do not charge batteries in a sealed container. Each individual battery should have at least 1/2 inch of
space between it and all surrounding surfaces to allow for convection cooling.
• All battery compartments must have adequate ventilation to prevent an accumulation of potentially
dangerous gas. Never place batteries in a sealed enclosure. Extreme caution should be used when
maintaining and collecting data on the battery system.
Recycling and Disposal Instructions
• Spent or damaged batteries are considered environmentally unsafe as they contain lead and dilute
sulfuric acid. They should not be "thrown away" with common refuse.
• Always recycle used batteries in accordance with federal, state, provincial, and local regulations. The
Alpha Group provides recycling services. Call 800 863 3930 or contact your local Alpha representative.
745-680-C0-002, Rev. B1
7
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.
NOTE:
The product warranty is void if the batteries are not stored and recharged in accordance with these guidelines.
During storage please note:
• The self-discharge rate is related to ambient temperature. The lower the temperature, the less
the discharge. Batteries should be stored in a clean, ventilated, and dry location with an ambient
temperature of 32ºF to 68ºF (0ºC to 20ºC).
• It is important to track open circuit voltage which is related to the density of the electrolyte. If
the open circuit voltage is lower than 12.6V or the batteries have been stored beyond the limits
shown in Figure 1, the batteries should be charged to avoid damage caused by self-discharge.
• All batteries should be fully charged before storage. Record the storage date and next
supplemental charge date in a maintenance record and on the battery.
• Upon battery deployment, verify all batteries within each string measure in the range of
+/- 0.3Vdc of the string average.
Residual Capacity (%)
32ºF (0ºC)
50ºF (10ºC)
1
0
4ºF
(
40
8
6ºF (
3
º
C)
0ºC
68
ºF
(2
0
º
C
)
)
Storage Time (Months)
Fig. 1, Capacity vs. Storage Time
Electrical Safety
• Lethal voltages are present within the power supply and electrical enclosures. Never assume that
an electrical connection or conductor is not energized. Check circuits with a volt meter prior to any
installation or removal procedure.
• Observe circuit polarities.
• Always use the buddy system when working under hazardous conditions.
• Ensure no liquids or wet clothes contact internal components.
• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input
power is disconnected.
• Use an insulated blanket to cover exposed portions of the battery system when performing extended
maintenance that could result in personal or equipment contact with the energized conductors.
• Certain types of rectier circuits used in charging the battery may not include a line isolating transformer.
In these cases extreme caution should be used when maintaining and collecting data on the battery
system.
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745-680-C0-002, Rev.B1
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.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. To avoid
battery contact, remove all metallic objects, (such as rings or watches), from your person.
• Batteries produce explosive gases. Keep all open ames and sparks away from batteries.
• Use tools with insulated handles, do not rest any tools on top of batteries.
• Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects
or other reproductive harm. Battery post terminals and related accessories contain lead and lead
compounds. Wash hands after handling (California Proposition 65).
• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your
company’s approved chemical exposure procedures.
• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with
a solution of one pound (454g) bicarbonate of soda to one gallon (3.8l) of water. Report a chemical spill
using your company’s spill reporting structure and seek medical attention if necessary.
• Always replace batteries with those of an identical type and rating (match conductance, voltages, and
date codes as specied in this document).
• Never install old or untested batteries.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have
developed on your body.
• Use special caution when connecting or adjusting battery cabling. An improperly or unconnected battery
cable can make contact with an unintended surface that can result in arcing, re, or a possible explosion.
• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by authorized
personnel using a battery of identical type and rating.
Mechanical Safety
• Keep hands and tools clear of fans.
• Fans are thermostatically controlled and will turn on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components, especially sharp edges.
• Depending on the model, batteries can weigh anywhere from 25 to 100 pounds (11kg to 45kg). Exercise
care when handling and moving batteries. Use proper handling equipment.
745-680-C0-002, Rev. B1
9
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.
Adherence to the procedures and practices detailed in this guide will not only insure the battery operates per
specications, but also provides the proper backup for the Alpha Powering system in which it is installed.
To achieve these goals, this guide will address the following topics:
• The storage and maintenance of new battery inventory.
• Deployment of AlphaCell batteries into Alpha Power systems.
• Proper preventiative maintenance practices for AlphaCell batteries.
• Replacement and recycling of AlphaCell batteries.
• Warehousing, testing, and redeployment of reuseable AlphaCell assets.
• How to keep proper maintenance records for troubleshooting and/or Warranty claims.
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745-680-C0-002, Rev.B1
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