Alpha AlphaCell GelCell User Manual

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AlphaCell™ GelCell Series

AlphaCellTM GelCell Battery Users Guide

Storage, Maintenance, and Deployment

Effective: April, 2013

Alpha Technologies

Power

AlphaCell

Storage, Maintenance and Deployment

745-680-C0-002, Rev. B1

GelCell Battery Users Guide

Effective Date: April 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.

Contacting Alpha Technologies: www.alpha.com

For general USA sales information and customer service (7 AM to 5 PM, Pacic 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, Pacic Time or 24/7 emergency support

1 800 863 3364

1 800 667 8743

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 Prole .................................................................................... 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

Limited Warranty.................................................................................................. 27

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

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 specic regulatory/code requirements that may affect the placement of

equipment and installation procedures.

NOTE:

A NOTE provides additional information to help complete a specic 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.

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 specied in this document).

Signs of battery cable damage. Battery cable should be replaced immediately by

authorized personnel using replacement parts specied 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

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)

4ºF

(

6ºF (

0ºC

ºF

)

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 rectier 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.

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 specied 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

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

specications, 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.

745-680-C0-002, Rev.B1

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 specic gravity.

A 12V battery is made up of six 2V cells internally connected to provide 12 volts.

The battery system is a group of 12V batteries connected in a series string to provide a higher voltage system. In Fig. 2, three of the nominal 12V batteries are connected in series to provide an 18 cell system with a nominal voltage of 36V.

to power supply: red (+), black (-)

inline fuse

3A 1A2A

Fig. 2, Series String of Batteries

(For illustration purposes, a 36Volt string is shown. 48Volt strings are also available)

You can connect multiple strings of batteries in parallel. This provides a system whose capacity equals the sum capacity of all the strings. For example, in Fig. 3, two 36V 90Ah capacity strings are connected in parallel to provide a nominal 36V at 180Ah.

WARNING!

Alpha highly recommends fusing in single and parallel string congurations.

power supply: red (+), black (-)

1A2A

745-680-C0-002, Rev. B1

inline fuse

inline

fuse

2B3B

[Front]

Fig. 3, Parallel String of Batteries

upper tray

lower

tray

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 specications listed in the detailed procedures below. At a minimum each site needs to be

physically inspected every three months.

You do not have to measure the electrolyte specic gravity or add water to the cells.

All batteries in the string should be numbered to facilitate recording and analysis of data unique to each unit.

Notify anyone affected by the intended maintenance or troubleshooting activity. This should include but not be limited to anyone responsible for the status monitoring equipment at the head-end or NOC.

2.1 Required Tools and Equipment

Prior to beginning maintenance, ensure that all required tools and equipment, including safety

equipment, is available and functional.

The following is a list of the minimum equipment required to maintain and troubleshoot the

AlphaCell GelCell battery:

• Digital voltmeter

• Socket wrenches, insulated

• Box end wrenches, insulated

• Torque wrench calibrated in inch/lbs

• Rubber gloves

• Full face shield

• Safety Glasses

• Plastic apron

• Portable eyewash

• Spill kit, including sodium bicarbonate solution

• Fire extinguisher

• Optional equipment, depending on the type of maintenance being performed,

includes:

• True RMS Volt Meter with DC Amp Clamp

• Midtronics Conductance Meter

• 100 amp momentary load test set

• System load bank (DC if to be performed at the battery and AC if to be performed

by loading a power supply output— contact your Alpha Sales Representative for

purchasing information).

• NO-OX Corrosion Inhibitor

• Paper Towels and/or rags

745-680-C0-002, Rev.B1

3.0 Periodic Maintenance Tasks and Schedule

The following tasks are to be performed on a monthly and quarterly schedule.

The following maintenance procedure requires a fully functional status monitoring system capable of remotely measuring and recording the following data on a periodic basis:

• Battery Temperature

• Individual Battery Voltage

• Total Battery String Voltage

Please note: If status monitoring is not available these checks need to be made during the quarterly onsite visit and any batteries not meeting the minimum requirement must be addressed at such time.

3.1 Monthly Remote Status Monitoring

Review Status

Monitoring Data

Battery Voltage

>0.5V Above/Below

String Average

Yes

No No

RTS

Temperature >10C

above Ambient

Yes

Perform

Quarterly PM

Monitor as per PM

Program

Fig. 4, Flow Chart for Monthly Remote Status Monitoring

Procedure

1. If any individual battery voltage varies more than 0.5V above or below the average for the string then a site visit is required.

Example V1 = 13V, V2 = 13V, V3=14V

Average voltage = 13.3V

If V3 greater than average by 0.5V, then a site visit is required

2. If the RTS temperature is greater than 10 degrees C above the current regional ambient temperature then a site visit is required.

3. Prioritize site visits based on highest RTS temperatures and battery voltages

4. Visit the site within 30 days and remedy the problem by replacing the bad battery or batteries and reset quarterly maintenance.

745-680-C0-002, Rev. B1

3.2 Quarterly Preventive Maintenance

Yes

Replace the individual failed battery with

a battery that is within +/- .3 Volts of the string average.

Battery String

Float Current

>0.5A

Log each battery’s

conductance and

voltage

Disconnect

Batteries

Record Information

on Site Visit Record

Monitor as per PM

Program

Site Visit

Battery

Refurbishment

Plan

Return battery to

warehouse

Remote Status

Monitoring

Procedure

Ensure Power

Supply is in Float

Mode

Battery

> 0.5V

from the average

string voltage

Does the individual battery pass

the Evaluation Procedure #1

outlined in Section 3.4?

(see page 18)

Replace the string

Required Equipment

• True RMS Volt Meter with DC Amp Clamp

• Midtronics Conductance Battery Tester

Fig. 5, Flow Chart for Quarterly Preventive Maintenance

745-680-C0-002, Rev.B1

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 oat current.

3. If the individual string oat 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 oat current is less than 0.5 amps,

4.1 Disconnect the batteries from the system

4.2 Measure the battery conductance. If any reading is below the suspect level, refer to Table 1, page 18, for mhos values for battery models.

4.3 Measure the battery voltage. If any reading is less than 12.6V then replace all those batteries in the string.

4.4 If any individual battery voltage varies more than 0.5V above or below the average for the string then replace the string.

Example: V1 = 13V, V2 = 13V, V3=14V

Average voltage = 13.3V

If V3 is greater than average by 0.5V, then the batteries should be replaced. Batteries removed from the site should then be tested per Section 3.5, "Battery Refurbishment Plan".

4.5 Log the site location, battery location, model, manufacturer date codes, voltage and conductance readings for all batteries.

5. Record data on Battery Maintenance log.

6. Verify the spacing between the batteries from front to back is at least 1/2" or 13mm, and adjacent

batteries do not touch one another.

7. Ensure the enclosure is clean and free of debris.

8. Measure and record the top center battery's temperature. This is typically the warmest battery in the string.

9.Visually inspect the batteries for:

Cleanliness

Terminal damage or evidence of heating or overheating

Container or cover damage

10. Check terminal posts for signs of corrosion. If corrosion is present, neutralize with a solution of

1 lb (454g) sodium bicarbonate (baking soda) to 1 gallon (3.8l) of water. Rinse and dry.

11. Verify terminal posts are coated with NO-OX grease or a spray-on protectant. Reapply as needed.

12. Retorque all the interunit connecting hardware to the values noted in Table 3 on page 25.

745-680-C0-002, Rev. B1

3.3 AlphaCell

Node / Location

Power Supply Type

Load (kW)

Battery Maintenance Log

Follow this sample when lling out the maintenance log (following page).

Evaluation Procedure #1Evaluation Procedure #2Evaluation Procedure

Vdc

Conductance

Float

Battery

String

A 1 195GXL 4/08 3/08 .2 70° 13.4 1100

A 2 195GXL 4/08 3/08 .2 70° 13.5 1080

A 3 195GXL 4/08 3/08 .2 70° 13.4 1120

B 1 195GXL 4/08 3/08 .1 70° 13.4 1090

B 2 195GXL 4/08 3/08 .1 70° 13.4 1105

B 3 195GXL 4/08 3/08 .1 70° 13.6 1060

A 1 195GXL 4/08 3/08 7/8 .1 85° 13.3 1120

A 2 195GXL 3/08 7/8 .1 85° 13.3 1100

A 3 195GXL 3/08 7/8 .1 85° 13.4 1105

B 1 195GXL 3/08 7/8 .1 85° 13.2. 1070

B 2 195GXL 3/08 7/8 .1 85° 13.2 1100

B 3 195GXL 3/08 7/8 .1 85° 13.2 1080

Initial Install Date

Battery Type

Mfr. Date Code

PM Date

Float Current

Battery Temp

Load

mhos @

77°F

Vdc 24

Hour OCV

Conductance

mhos @

77°F/25°C

Vdc @

100A after

10 seconds

Vdc 24

Hour OCV

745-680-C0-002, Rev.B1

3.3 AlphaCell

Node / Location

Power Supply Type

Load (kW)

Battery Maintenance Log

String

Battery

Initial Install Date

Battery Type

Mfr. Date Code

PM Date

Float Current

Battery Temp

Evaluation Proce-

dure #1

Vdc

Conductance

Float

Load

mhos @

77°F

Evaluation Procedure #2Evaluation Procedure

Vdc 24

Conductance Hour OCV

mhos @

77°F/25°C

Vdc @

100A after

10 seconds

Vdc

24 Hour OCV

745-680-C0-002, Rev. B1

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 dened as a faulty battery. The battery will be replaced under the terms of the warranty if within the dened warranty period.

Evaluation Procedure 1

Conductance/Impedance Test – Measure the conductance of each battery. Any battery that possesses a conductance

is taken (see Table 1 below). Use temperature compensation feature when using Midtronics meter.

AND

Float Voltage Test – Measure the oat voltage of each battery in the string that is on oat charge. Any battery in the string

measured at 13.2 volts or less is a suspect battery and should be further evaluated with the steps below. Any battery

below 12.6 volts should be replaced. The 13.2 & 12.6 voltage values are based on a 77˚F (25˚C) temperature. Adjust the

voltage for higher or lower temperatures by 0.0168 Volts per battery per degree Fahrenheit. The higher the temperature

above 77˚ F (25˚C) the lower the voltage will have to be adjusted and vice-versa for temperature below 77˚F (25˚C). (i.e.: at a temp of 89˚F (32˚C) would have a corresponding oat voltage of 13.0 volts).

Evaluation Procedure 2

Conductance/Impedance Test – Measure the conductance of each battery. Any battery that possesses a conductance

that is 50% less than the initial reading taken at the point of install can be considered suspect of being below 70% capacity and should be evaluated further. The battery temperature must be approximately the same each time this reading is taken. Consult table 1 below for guidance. Use temperature compensation feature when using Midtronics meter.

AND

24 Hour Open Circuit Test – Measure the open circuit voltage of the suspected battery 24 hours after the battery has

come off of oat charge. Care must be taken to ensure that the battery is at full state of charge when it is disconnected

from the power supply. The battery should exhibit a voltage about 12.60V. A battery below this voltage should be replaced. A fully charged battery below 12.6 volts is below 70% capacity, but a battery above 12.6 volts is not necessarily above 70% in capacity. Batteries that have been sitting for extended periods should be recharged after 6 months or when they

reach 12.48 volts (75% capacity), which ever comes rst depending on the storage temperature.

Evaluation Procedure 3

24 Hour Open Circuit Test – Measure the open circuit voltage of the suspected battery 24 hours after the battery has

come off of oat charge. Care must be taken to ensure that the battery is at full state of charge when it is disconnected

from the power supply. The battery should exhibit a voltage about 12.60 volts. A battery below this voltage should be replaced. A fully charged battery below 12.6 volts is below 70% capacity, but a battery above 12.6 volts is not necessarily above 80% in capacity. Batteries that have been sitting for extended periods should be recharged after 6 months or when

they reach 12.48 volts (75% capacity), which ever comes rst depending on the storage temperature.

AND

100A Load Test – Measure the voltage of each battery at the end of a 10 second 100-amp load test. Again, the

temperature must be equivalent to that of the original test performed at the point of installation. A signicant drop in

voltage versus the previous test will indicate deterioration of the battery. A 12-volt battery that falls below 10.80 volts should be considered faulty and should be replaced.

NOTE:

To maintain consistent test results, ensure the same Midtronics conductance tester is used for each test cycle.

Midtronics Conductance

Models 3200/micro CELLTRON

Approximate Conductance Values (mhos) Healthy Battery @ 77°F (25°C)

Suspect Battery @ 77°F (25°C) in mhos <520 <240 <450 <520 <400 <440 <400 <480 <440 <480

170XLT 85 GXL-HP 135 GXL 160 AGM 165 GXL 195 GXL 195 GXL 220 GXL 195 GOLD-HP 220 GOLD-HP

1040-1560 480-720 900-1350 1040-1560 800-1200 880-1320 800-1200 960-1400 880-1320 960-1400

Table 1, Conductance values, healthy vs. suspect batteries

745-680-C0-002, Rev.B1

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)

Does battery meet

Measure

Conductance

Yes

the minimum

conductance values

per Table 1?

Measure

Battery

Voltage

No Yes

Sort Batteries per

Conductance &

Properly recycle

batteries per EPA

requirements

Group re-deployable

batteries as indicated for

future deployment as

Batteries stored in

warehouses for

extended periods of

time refer to “Important

Storage Practices” on

Measure

Battery Voltage

Voltage

Does battery meet

the minimum of

12.6 Volts for the 24 hour OCV?

Group 1 – Voltage 12.6 to 12.9 and conductance 600 to 900 mhos. Group 2 – Voltage 12.6 to 12.9 and conductance 900 to 1200 mhos. Group 3 – Voltage 12.9 to 13.2+ and conductance 600 to 900 mhos. Group 4 – Voltage 12.9 to 13.2+ and conductance 900 to 1200 mhos. Manufacture date codes should be within

strings

page 8.

18 months for batteries in string

Fig. 6, Flow Chart for Battery Refurbishment Plan

745-680-C0-002, Rev. B1

4.0 Battery System Float Charging

Battery System Float Charging Voltage

Encountering temperature extremes

When you encounter temperature extremes, temperature compensate the oat charging voltage. The temperature compensation coefcient 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 oat 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. For an 18 cell battery this is 39.78 to 40.86 VDC.

This helps reduce the potential for thermal runaway at elevated temperatures.

If the battery operates at cold temperatures, (60°F, 17° below 77°F, for example), you

can increase the charging voltage to improve recharging time.

For example, increase the charging voltage range by -17° x -0.0028 V/C per degree or 0.048 V/C. For the 180 cell string this is 41.36 to 42.26 Vdc.

Under or overcharging

If the battery is undercharged for a period of time during which there are multiple discharges, the battery does not fully recharge after each discharge and provides progressively lower capacity.

Excessive overcharging causes premature aging of the battery and loss of capacity,

noted by excessive oat current, corrosion of the plate grids, and gassing and drying

of the limited amount of electrolyte.

Severe overcharging over extended periods of time can induce a thermal runaway condition. This requires replacing the battery system.

NOTE:

The following set points are recommended for AlphaCell Batteries when used with the XM Series 2 or GMX Power Supply.

AlphaCellTM GelCell Batteries

Bulk / Float 2.27 V/C

Accept 2.40 V/C

Temp Comp -5mV/C/C

AlphaCellTM 195GXL FT

Bulk / Float 2.26 V/C

Accept 2.35 V/C

Temp Comp -4mV/C/C

AlphaCellTM IGL Series

Bulk / Float 2.25 V/C

Accept 2.32 V/C

Temp Comp -3mV/C/C

745-680-C0-002, Rev.B1

4.0 Battery System Float Charging, continued

NOTE:

The following information specically pertains to Alpha XM Series 2 Power Supplies.

4.1 AlphaPowerSupplyChargingProle

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 specic threshold (2.27VDC per cell).

The BULK charger mode generally returns the battery charge state to 80 percent of rated battery capacity. Bulk mode is not temperature compensated. The charger then automatically switches to ACCEPT mode.

ACCEPT charge is a “Constant Voltage” charge. This voltage, 2.40VDC per cell (14.40VDC),

is manually adjustable if needed and temperature-compensated to ensure longer battery life and proper completion of the charge cycle.

This cycle is complete when the charging current into the batteries becomes less than 0.5A, or approximately six hours elapses from the time ACCEPT mode was entered. When the batteries are fully recharged the charger switches to the FLOAT mode of operation.

FLOAT charge is a temperature-compensated charge, averaging about 2.27VDC (adjustable)

per cell. During FLOAT mode, the batteries are fully charged and ready to provide backup power.

During ACCEPT and FLOAT modes, the cell voltage is temperature-compensated at -

0.005VDC per cell per degree C (adjustable) to ensure a safe battery cell voltage and to

maximize battery life.

For AlphaCell GelCell batteries, the recommended battery system oat charge voltage is

equal to the number of cells in the system multipled by the range of 2.25 to 2.30 volts per cell

at 77°F(25°C).

For example, oat charge a string of 3 each 12 volt (6 cell) batteries within a range of 40.5 to

41.4 VDC (18 cells x 2.25 V/C minimum and 18 x 2.30 V/C maximum) at 77°F(25°C).

Severe overcharging over extended periods of time can induce a thermal runaway condition. This requires replacing the battery system.

745-680-C0-002, Rev. B1

Fig. 7, Charger Modes (dashed line indicates HV models)

5.0 Battery Symptoms and Solutions

Problem with Symptom Possible Causes Possible Result Corrective Actions

Reduced operat-

Capacity Test Results

Visual Battery Checks

ing time at 77°F

(25°C) with

smooth voltage decline

Reduced operating time at 77°F

(25°C) with steep

voltage decline or voltage plateaus

Excessive initial voltage drop even to the point of dropping load in

the rst several

seconds

Cover or container crack

Cover or container explosion

Burned area on container

Permanently deformed

(swollen) container

Rotten egg odor

Melted grease at terminals

Corrosion at terminals

Normal life cycle

Individual low capacity cells

• Battery is extremely cold

• Cabling is too small

gauge

• High resistance

connections

• Battery is undersized

• Shorted cells

Handling or impact damage

Ignition of cell internal gasses due to external source, fusing, or internal conductive path or internal spark due to shorting. Potential exists for ill-maintained batteries or those left in service beyond useful life.

Crack in container wicking electrolyte to grounded rack. Ground fault

Thermal runaway possible caused by high temp., environment, overcharging, excessively high recharge current, shorted cells, ground fault, or a combination Possible caused by high temperatuare environment, overcharging, excessively high recharge current, shorted cells, ground fault, or a combination of these.

Hot connections due to excessive resistance caused by loose connections, dirty contact surfaces or corrosion within connection

Possibly electrolyte leaking from battery terminal seal attacking the interunit container

Eventual failure to support the load followed by potential for shorted cells

Reversed cells during discharge Reversed cells will become very hot and will not fully recharge

• Excessive voltage drop

• Cells will become hot, could

develop thermal runaway; internal arcing could result in an explosion

Cell dryout or ground fault. Potential internal gas ignition

• Personal injury and equip-

ment damage at time of explosion.

• Failure to support load.

Could result in

• personal hazard due to

conductive path to rack

• smoke or battery re

• thermal runaway

Could result in the emission of

hydrogen sulde, detectable as a rotten egg odor, battery re, and

inability to support the load

Odor is a product of thermal runaway

• Excessive voltage drop

perhaps leading to short operating time or damaged terminals

• In extreme case could lead

to melted terminal and ignition of the battery cover

Increased connection resistance and resulting increase in the connection heating and voltage drop at high rate discharge.

Replace battery system when at 70% of rated capacity or before

Replace the isolated low capacity batteries

• Heat the battery

• Run parallel cables

or increase gauge of cables

• Clean and reassemble

connections

• Add required parallel

strings

• Replace isolated

units with shorts and evaluate entire string

Replace damaged unit.

Replace damaged unit and evaluate balance of string.

Clear the ground fault and replace defective unit. Evaluate balance of string.

Replace the battery system and correct the items leading to the theramal runaway condition

Replace the battery system and correct items leading to thermal runaway condition

• Clean and reassemble

connection if damaged

• Replace batteries with

damaged terminals

Disassemble connection, clean, coat connecting surfaces and terminal area, seal with anti-oxidation grease, reassemble the connection. If leakage about terminal area is obvious, the battery should be replaced.

Table 2, Battery Symptoms and Solutions

745-680-C0-002, Rev.B1

5.0 Battery Symptoms and Solutions, continued

Problem with Symptom Possible Causes Possible Result Corrective Actions

Overcharging causes excessive gassing and drying out of electrolyte and contributes to potential thermal runaway.

Undercharging results in gradual loss of operating time and capacity with successive discharge cycles. If persistant, an irreversible level of lead sulfate develops on the plates resulting in a permanent capacity loss

Reduced operating time

under load. Increased oat

current. Heating of cell during discharge. Contributes to potential thermal runaway.

Failure to support load. Could result in an internal arc, could ignite gasses within the cell.

• Personnel shock hazard

resulting in serious injury or electrocution.

• Potential burning of

container at damaged

area or battery re.

Reduced battery life

• Reduced battery life

• Reduced life and

potential thermal runaway

• Normal if not exceeding

18°F increase

Normal if not exceeding

18F/10C increase over

ambient

Reset the charger output voltage to recommended value.

• Reset the charger

output voltage to recommended value.

• Equalize battery system

from 48 to 72 hours and perform capacity test. If capacity loss is permanent, replace the total battery system.

Replace individual battery.

Determine the source of ground fault and replace battery.

Cool room or accept reduced battery life

• Improve room air

conditioning

• Improve cabinet

ventilation

• Limit recharge current

• Reduce within specications

• Replace shorted cells

and evaluate total string.

DC Voltage Checks

Temperature Checks

System oat voltage >

2.3V/C average 77°F (25°C)

System oat voltage <

2.25V/C average 77°F (25°C)

Individual battery oat voltage > 13.3 VDC

Individual battery oat

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. Elevated room temperature

Elevated battery temp.

High current recharge

Charger output set incorrectly

• Potentially the

individual battery has shorted cell

• Verify with impedance

or conductance check

Potentially open cells in

individual battery. Conrm by checking for zero oat

current or check for very high impedance of the battery.

Damaged container allowing electrolyte to wick out

to grounded surface (rack).

Lack of adequate air conditioning or ventilation

• Elevated room temp.

• Inadequate cabinet

ventilation

• Discharge - charge

cycle

• High charging voltage

• Shorted cells

745-680-C0-002, Rev. B1

Table 2, Battery Symptoms and Solutions, continued

5.0 Battery Symptoms and Solutions, continued

Type Symptom Possible Causes Possible Result Corrective Action

• Failure to support load. If an

internal arc occurs during discharge, can ignite gasses internal to cell.

• If there is an open/loose

connection in external conductive path, can damage termination under load.

• Not at 100% capacity

• Conducive to thermal

runaway

• Thermal runaway results in

eventual meltdown of battery and potential of hydrogen

sulde emissions and re.

Perhaps reduced operating time. Fully recharge battery.

• Reduced operating time.

• Conducive to thermal

runaway

• Will not support load

• Reduced operating time

• Conducive to thermal

runaway

• Will not support load

• Loose connections result

in heat damaged or melted terminals during high rate discharge.

• Excessive voltage drop

during high rate discharge and resulting reduced operating time

Loose connections result in heat damaged or melted terminals during high rate discharge

Excessive AC ripple could cause the battery to cycle at the ripple frequency and result in heating and deterioration of the plate active material

• Reduced operating time.

• Potential conditions could

be conducive to thermal runaway.

Replace battery with open cell or repair

open/loose external

connection.

Determine specic

cause; take corrective action.

Charge, retest battery or replace as required.

Charge and retest battery or replace as required.

• Retorque

connection as required

• Correct source

of contamination, clean contact surface areas, grease contact surfaces with antioxidant grease, reassemble.

Retorque the connection as required

Improve the charger

output ltering.

Verify battery condition. Replace as required.

Float Charging Current Checks

High Rate 10 Second Load Test

Battery

Impedance/

Conductance Test

Connection Hardware Resistance

/ Tightness

Check

AC Ripple Voltage Checks

Float current to string is zero

Float current exceeds 3.0 milliamperes per ampere hour of rated capacity at

77°F(25°C) at oat

voltage. Terminal voltage marginally below minimum voltage

specied for 10

second point.

Terminal voltage

signicantly below

minimum voltage

specied for 10

second point.

Impedance /

resistance increase by 50% from original values or conductance decline to 50% of the value when new.

Connection resistance increase 20% or more from original value.

Connection hardware tightness is less than the

specied "retorque"

value.

AC ripple (p-p)

voltage on system <4% of the value of

the DC oat voltage

Individual battery in string exhibits AC ripple voltage twice that of other typical batteries in string.

A battery or connection in series

string is open. Verify via the oat

voltage check or AC ripple voltage or impedance check of individual batteries.

• Batteries not fully recharged.

• Batteries above 77°F(25°C)

• Potentially shorted cells in

battery

• Depending on degree, bat-

tery entering or in thermal runaway

Battery perhaps not fully charged or is older, in service battery and has somewhat lower capacity.

• Battery discharged of

battery conductive path, plate grid, or active material or electrolyte volume deterioration.

• Shorted.

• Open cells.

• Battery discharged or battery

conductive path, plate grid or active material, or electrolyte volume deterioration.

• Shorted cells

• Open cells

• Repetitive cycles results

in heating and cooling of connection, resulting in relaxation of torque, increase in connection resistance.

• Contamination within

the connection results in corrosion and high terminal resistance.

Repetitive cycles results in heating and cooling of connection resulting in relaxation of torque and increase in connection resistance.

Poor ltering of charger output.

Battery with high AC ripple voltage has proportionately higher impedance. Evaluate for performance. Subject battery could have deteriorating conductive path or dry, shorted or open cell.

Table 2, Battery Symptoms and Solutions, continued

745-680-C0-002, Rev.B1

6.0 Battery Parameters by Model Number

Parameter

Terminal Type

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-Lb / 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)

20-Hour Ampere Rate to 1.75 V/C 5.45 5.45 5.00 5.00

Typical Impedance @ 60Hz ohms 0.0050 0.0050 0.0050 0.0050

Typical Conductance 7Hz mohms 960 to 1400 960 to 1400 880 to 1320 880 to 1320

Typical 10 Sec. Voltage @ 100 amp 11.4 11.4 11.3 11.3

Parameter

Terminal Type 16mm Insert Threaded Insert Threaded Insert Threaded Insert

Bolt Size M6 thread 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 10-32 UNC Bolt

Annual Retorque Inch-Pounds / N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m 25In-lb / 2.8N•m

Open Circuit Voltage 12.84 12.84 12.84 12.84

Average Float Voltage Range (volts/unit)

20-Hour Ampere Rate to 1.75 V/C 5.50 4.30 3.75 2.50

Typical Impedance @ 60Hz ohms 0.0050 0.0055 0.0055 0.0040

Typical Conductance 7Hz mohms 800 to 1200 800 to 1200 900 to 1350 480 to 720

Typical 10 Sec. Voltage @ 100 amp 10.8 11.2 11.2 11.6

220 GOLD-HP 220GXL 195 GOLD-HP 195GXL

Threaded Insert Threaded Insert Threaded Insert Threaded Insert

13.5 to 13.8 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8

195GXL FT 165GXL 135AGM-P 85GXL-HP

13.5 to 13.8 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8

Model Number

Table 3, Battery Parameters, Current Models (threaded insert terminals)

745-680-C0-002, Rev. B1

6.0 Battery Parameters by Model Number, continued

Parameter

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

Open Circuit Voltage 12.84 12.84 12.84 12.84

Average Float Voltage Range (volts/unit)

20-Hour Ampere Rate to 1.75 V/C 5.35 5.30 4.75 4.68

Typical Impedance @ 60Hz ohms 0.0050 0.0050 0.0050 0.0050

Typical Conductance 7Hz mohms 960 to 1400 960 to 1400 880 to 1320 880 to 1320

Typical 10 Sec. Voltage @ 100 amp 11.4 11.4 11.3 11.3

215 GOLD HP 210GXL 190 GOLD HP 180GXL

110In-lb / 12.4N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m

13.5 to 13.8 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8

Model Number

110In-lb / 12.4N•m

Table 4, Battery Parameters, Legacy Models (threaded insert terminals)

Parameter

Terminal Type Lead Flag Lead Flag Lead Flag Lead Flag

Bolt Size 1/4"-20 1/4"-20 1/4"-20 1/4"-20

Annual Retorque Inch-Pounds / N•m 65 in-lb / 7.3N•m 65 in-lb / 7.3N•m 65 in-lb / 7.3N•m 65 in-lb / 7.3N•m

Open Circuit Voltage 12.84 12.84 12.84 12.84

Average Float Voltage Range (volts/unit)

20-Hour Ampere Rate to 1.75 V/C 5.30 4.68 4.30 4.40

Typical Impedance @ 60Hz ohms 0.0050 0.0050 0.0055 0.0040

Typical Conductance 7Hz mohms 960 to 1400 880 to 1320 800 to 1200 1040 to 1560

Typical 10 Sec. Voltage @ 100 amp 11.4 11.3 11.2 11.6

210GXL-HP/GXL 180GXL-HP/GXL 165GXL 160A

13.5 to 13.8 13.5 to 13.8 13.5 to 13.8 13.5 to 13.8

Model Number

Table 5, Battery Parameters, Legacy Models, (Lead ag insert terminals)

745-680-C0-002, Rev.B1

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.

When a defective battery is identied the User should promptly notify manufacturer. Should manufacturer conrm the

Batteries to be defective they will replace the material found to be defective F.O.B. its Factory without charge except for freight.

CONDITIONS AND LIMITATIONS: (all claims are subject)

1) Warranty date is based on Ship Date code stamped on battery.

2) Warranty applies in accordance with Table 6 of this section.

3) The standard warranty shown in Table 6 applies to AlphaCell Batteries used in Alpha enclosures in

conjunction with Alpha Power Supplies.

4) A baseline Two Year Warranty applies to AlphaCell Batteries used in other applications not dened in item #3

shown above. AlphaCell batteries are not recommended for solar applications so please consult Alpha Applications Engineering for an alternative battery solution for solar applications. Extended warranties beyond two years may

be available for unique enclosure/charger applications based on preapproval by Alpha Engineering. Consult your

salesperson for details.

5) Each Battery must be of proper size, design and capacity for its application in order for the warranty to apply.

6) Each Battery must be charged, discharged, stored and serviced in accordance with the AlphaCell owners manual

and user's guide.

7) Warranty is void if Battery is subject to misuse, abuse or physical damage or if Battery becomes unserviceable due to re, wreckage, freezing, or any act of God.

8) Battery must be used with a temperature compensation charger having characteristic charging curves (voltage and current) acceptable with standard manufacturer’s charging practices as outlined in the AlphaCell owners manual

and user's guide.

9) User agrees that manufacturer’s representative shall have access to equipment furnished hereunder for purpose of

inspection at reasonable hours and intervals in order for the warranty to apply.

10) All defective and replacement Batteries, if returned, become property of manufacturer.

11) Field Batteries replaced through limited warranty terms and conditions will receive the balance of original warranty.

12) Standard AlphaCell

outlined in the AlphaCell owners manual and user's guide.

Warranty requires a minimum semiannual preventive maintenance schedule with records as

CLAIMS:

1) Contact original point of purchase for instructions on applicable warranty claim procedures.

2) Upon satisfactory proof of claim as determined by manufacturer, manufacturer shall repair or replace, at its option,

any defective Battery based upon the purchase price, exclusive of freight and labor.

3) Manufacturer does not accept any product for return, credit or exchange unless expressly authorized by

manufacturer in writing and returned prepaid to its plant.

ALPHA SHALL NOT BE LIABLE FOR, AND USER SHALL INDEMNIFY AND SAVE ALPHA HARMLESS FROM ANY CLAIMS AND LIABILITIES ARISING OUT OF THE USE, MAINTENANCE, TRANSPORTATION, OR INSTALLATION OF ANY EQUIPMENT WARRANTED HEREUNDER. THE FOREGOING LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THE SOLE LIABILITY OF IS SET FORTH UNDER THE CLAIMS PARAGRAPH ABOVE. SHALL NOT HAVE ANY LIABILITY FOR ANY SPECIAL INCIDENTAL INDIRECT OR CONSEQUENTIAL DAMAGES. THIS LIMITED WARRANTY APPLIES ONLY TO THE ORIGINAL

PURCHASER (USER) OF THE EQUIPMENT, AND IS NON-TRANSFERABLE.

745-680-C0-002, Rev. B1

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.

Battery Model Description Mfg Date Warranty Warranty Warranty

US/Canada International

220GOLD -HP Threaded Insert Gel Silver Alloy Post June 2009 6 Years 2 Years 5 Years

220GXL Threaded Insert Gel Silver Alloy Post June 2009 4 or 5 Years 2 Years 5 Years

195GOLD-HP Threaded Insert Gel Silver Alloy Post July 2009 6 Years 2 Years 5 Years

195GXL Threaded Insert Gel Silver Alloy Post July 2009 4 or 5 Years 2 Years 5 Years

165GXL Threaded Insert Gel Silver Alloy Post Jan 2007 4 or 5 Years 2 Years 5 Years

215GOLD-HP Threaded Insert Gel Silver Alloy Pre Jan 2007 6 Years 2 Years 5 Years

190GOLD-HP Threaded Insert Gel Silver Alloy Pre Jan 2007 6 Years 2 Years 5 Years

210GXL Threaded Insert Gel Silver Alloy Pre July 2009 4 or 5 Years 2 Years 5 Years

180GXL Threaded Insert Gel Silver Alloy Pre July 2009 4 or 5 Years 2 Years 5 Years

210GXL-HP Lead Flag Gel Silver Alloy Pre Dec 2006 5 Years 1.5 Years 4 Years

180GXL-HP Lead Flag Gel Silver Alloy Pre Dec 2006 5 Years 1.5 Years 4 Years

180/165 GXL Lead Flag Gel Silver Alloy Pre Oct 2005 N/A 1.5 Years 3 Years

180/165 G Lead Flag Gel Pre Oct 2005 N/A 1 Year 1 Year

Standard

International Northern Climates

210/180/165 GXL-5 Lead Flag Gel Pre Dec 2006 5 Years N/A N/A

210/180/165 GXL-4 Lead Flag Gel Pre Dec 2006 4 Years N/A N/A

210/180/165 GXL-3 Lead Flag Gel Pre Dec 2006 3 Years N/A N/A

85GXL-HP Threaded Insert Gel Silver Alloy Post Jan 2007 5 Years 2 Years 5 Years

85GXL-HP Threaded Insert Gel Silver Alloy Pre Dec 2006 5 Years 1.5 Years 4 Years

160 A/AGM/AGM-P Lead Flag AGM All 1 Year 1 Year 1 Year

170XLT Lead Flag AGM - North of 38th parallel Post Aug 2007 4 Years N/A 4 Years

135 AGM-P Threaded Insert AGM Silver Alloy Post Jan 2007 4 Years N/A N/A

135 GXL-5 Threaded Insert AGM Silver Alloy Pre Dec 2006 5 Years N/A N/A

135 GXL-4 Threaded Insert AGM Silver Alloy Pre Dec 2006 4 Years N/A N/A

195GXL-FT FT Gel north of 38th parallel All 3 2 2

195GXL-FT FT Gel south of 38th parallel All 3 2 2

Table 6, Warranty periods for AlphaCellTM batteries

745-680-C0-002, Rev.B1

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 efcient processing of your warranty battery claims. Record battery oat voltage while the battery is still connected to the system. Record battery open circuit voltage (OCV) 24 hours

following removal from the system. Describe the problem encountered with the battery as compared to the remaining batteries in the battery string. The ZRE# will be provided after you submit your request to Alpha for processing.

Original Purchase Order (if available)

Company Name

Address

CSZ

Contact Name

Phone

Email address

Replacement Units Address

CSZ

Contact Name

Phone

Email address

Initial

Install

Date

Mfr.

Date

Code

History

Float

Current

Battery

Temperature

Evaluation Procedure #1Evaluation Procedure #2Evaluation Procedure

Vdc Float No Load

Conductance

mhos @

77°F

Vdc 24

Hour OCV

Conductance

mhos @

77°F

Vdc @ 100A

after 10

seconds

Conductance

mhos @

77°F

745-680-C0-002, Rev. B1

This page intentionally blank

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Power

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Visit us at www.alpha.com

Due to continuing product development, Alpha Technologies reserves the right to change specications without notice. Copyright © 2013 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies.

745-680-C0-002 Rev. B1 (04/2013)

Alpha AlphaCell GelCell User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual