Alpha AlphaCell HP User Manual

Page 1
AlphaCell HP
Users Guide
AlphaCell HP Battery
Effective: July 2011
Page 2
Alpha Technologies
Power
®
Page 3
AlphaCell
TM
HP Battery Users Guide
Storage, Maintenance and Deployment
745-680-C5-001, Rev. A
Effective Date: July, 2011
Copyright © 2011
Alpha Technologies, Inc.
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 powering system, 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
or
For general USA sales information and customer service (7 AM to 5 PM, Pacic Time), call
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
For Sales information and Technical Support in Canada, call
1 800 667 8743
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Table of Contents
Safety Notes ....................................................................................................................................................... 6
Battery Maintenance Guidelines......................................................................................................................... 7
Recycling and Disposal Instructions ................................................................................................................... 7
Important Storage Practices ............................................................................................................................... 8
Electrical Safety .................................................................................................................................................. 8
Chemical and Mechanical Safety ....................................................................................................................... 9
1.0 Introduction .......................................................................................................................................... 10
1.1 Description ...............................................................................................................................11
1.2 Operating Conditions .............................................................................................................. 12
1.3 Capacity .................................................................................................................................. 12
1.3.1 Ratings ......................................................................................................................... 13
2.0 Preparing for Maintenance .................................................................................................................. 14
2.1 Required Tools and Equipment .............................................................................................. 14
3.0 Periodic Maintenance Tasks and Schedule ......................................................................................... 15
3.1 Monthly Remote Status Monitoring ........................................................................................ 15
3.2 Quarterly Preventive Maintenance ......................................................................................... 16
TM
3.3 AlphaCell
3.4 Battery Evaluation Procedures ............................................................................................... 20
3.5 Battery Refurbishment Plan .................................................................................................... 21
4.0 Battery System Float Charging ............................................................................................................ 22
4.1 Alpha Power Supply Charging Prole .................................................................................... 23
5.0 Troubleshooting ................................................................................................................................... 24
6.0 Battery Parameters by Model Number ................................................................................................ 27
7.0 Warranty and Return Information ........................................................................................................ 28
7.1 AlphaCell
7.2 Battery Maintenance Report for Return Authorizations .......................................................... 30
Battery Maintenance Log .................................................................................... 18
TM
Limited Warranty.................................................................................................. 28
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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, Available Capacity vs. Ambient Temperature ........................................................................... 12
Fig. 5, Flow Chart, Monthly Status Monitoring ..................................................................................... 15
Fig. 6, Flow Chart, Quarterly Preventive Maintenance ........................................................................ 16
Fig. 7 Flow Chart for Battery Refurbishment Plan ............................................................................... 21
Fig. 8, Charger Modes ......................................................................................................................... 23
Table 1, Conductance values, new vs. suspect batteries .................................................................... 20
Table 2, Troubleshooting ..................................................................................................................... 24
Table 3, Battery Parameters, Current Models ..................................................................................... 27
Table 4, Warranty Periods for AlphaCellTM batteries ............................................................................ 28
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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.
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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 6 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 HP 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.
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Important Storage Practices
During storage please note:
All lead acid batteries experience self-discharge while in open circuit storage. This causes circuit
voltage and capacity to decrease.
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 77ºF (0ºC to 25ºC).
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.
NOTE:
The product warranty is void if the batteries are not stored and recharged in accordance with these guidelines.
24
100%
95%
90%
85%
80%
Percent State of Charge
75%
70%
2.17
2.16
2.15
2.14
2.13
OCV Per Cell
2.12
2.11
2.1 0
3
104°F/ 40°C
86°F/ 30°C
6
9 12
Storage Time (Months)
77°F/ 25°C
68°F/ 20°C
15
18 21
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.
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WARNING!
Chemical Hazards
Any 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.
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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 HP Thin Plate Pure Lead AGM battery.
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 HP batteries into Alpha Power systems.
Proper preventiative maintenance practices for AlphaCell HP batteries.
Replacement and recycling of AlphaCell HP batteries.
Warehousing, testing, and redeployment of reuseable AlphaCell HP batteries.
• How to keep proper maintenance records for troubleshooting and/or Warranty claims.
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1.1 Description
The AlphaCell HP battery is a lead acid battery that facilitates an oxygen recombination cycle.
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 (-)
to
3A
1A2A
inline fuse
inline
fuse
2B3B
1B
[Front]
Fig. 3, Parallel String of Batteries
upper tray
lower
tray
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1.0 Introduction, continued
1.2 Operating Conditions
AlphaCell HP batteries, which are valve regulated and virtually sealed, do not give off perceptible amounts of gas under normal operating conditions.
Acceptable ambient operating temperature: -40ºF to 131ºF (-40ºC to 55ºC)
Ideal ambient operating temperature: 68ºF to 77ºF (20ºC to 25ºC)
Ambient humidity: ≤ 95%
1.3 Capacity
The actual capacity is related to the utilization ratio of the active positive and negative
materials within the battery. The utilization ratio is inuenced by the depth of discharge, the
structure of the battery, and the manufacturing technology. During normal usage, the factors
that inuence the actual capacity are discharge rate, depth of discharge, end voltage, and
temperature.
The higher the discharge rate, the lower the available capacity.
As batteries get colder, the available capacity is reduced. This is related to the kinetics of the electrochemical reactions and the resistivity of the electrolyte (See Fig. 4).
NOTE:
Although the battery can be operated at temperatures below -4ºF (-20ºC), the capacity and ability to discharge will be dramatically decreased. Similarly, temperatures approaching 122ºF (50ºC) will increase
electrolyte loss and corrosion of the plates, resulting in a shorter battery life.
Eciency VS. Temperature AlphaCell 3.5HP and 4.0HP
100%
90%
80%
70%
60%
50%
40%
30%
20%
Percent Rated Capacity Available
10%
0%
-40°F/
-40°C
-22°F/
-30°C
-4°F/
-20°C
14°F/
-10°C
32F/ 0°C
50°F/ 10°C
68°F/ 20°C
4.0HP
3.5HP
Typical Gel
86°F/ 30°C
104°F/ 40°C
12
Fig. 4, Available Capacity vs. Ambient Temperature
Page 13
1.0 Introduction, continued
1.3 Capacity, continued
1.3.1 Ratings
3.5 HP Ratings
Amps
End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr
1.85 162.6 106.4 80.5 65.3 38 27.1 21.2 17.4 11.4 9.3 4.9
1.80 174.7 112.1 84.2 67.9 39.2 27.9 21.8 17.9 11.8 9.6 5.1
1.75 185.6 117.2 87.3 70.2 40.3 28.6 22.3 18.4 12.1 9.9 5.2
1.70 194.9 121.3 89.9 72 41.1 29.2 22.7 18.7 12.3 10 5.3
Power (Watts)
End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr
1.85 312.2 206 156.9 127.9 75.4 54.2 42.5 35.1 23.1 18.9 9.9
1.80 331 215.4 163.1 132.4 77.5 55.5 43.5 35.9 23.7 19.4 10.2
1.75 347.6 223.6 168.3 136.2 79.2 56.7 44.4 36.6 24.2 19.8 10.5
1.70 361.7 230.3 172.6 139.2 80.6 57.5 45 37.1 24.5 20.1 10.7
A/H Capacity
End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr
1.85 40.7 53.2 60.4 65.3 75.9 81.3 84.7 87.1 91.5 93.4 98.6
1.80 43.7 56.1 63.1 67.9 78.5 83.8 87.2 89.7 94.3 96.2 101.7
1.75 46.4 58.6 65.5 70.2 80.6 85.9 89.3 91.8 96.5 98.6 104.4
1.70 48.7 60.7 67.4 72 82.2 87.5 91 93.5 98.3 100.4 106.6
4.0 HP Ratings
Amps
End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr
1.85 198.7 128.3 95.9 77 43.7 30.8 24 19.4 12.5 10.1 5.4
1.80 212.8 134.6 99.7 79.7 44.9 31.6 24.5 19.8 12.8 10.4 5.6
1.75 225.2 139.9 102.9 81.9 45.9 32.2 25 20.2 13.1 10.6 5.7
1.70 235.7 144.3 105.5 83.7 46.7 32.8 25.4 20.5 13.3 10.8 5.8
Power (Watts)
End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr
1.85 383.9 251.6 189.4 152.7 87.5 61.9 48.2 39 25.3 20.5 11
1.80 406.8 261.8 195.7 157.2 89.6 63.3 49.3 39.9 25.9 21 11.3
1.75 426.7 270.5 200.9 160.9 91.3 64.5 50.1 40.6 26.4 21.3 11.5
1.70 443.1 277.4 205.1 163.8 92.6 65.4 50.8 41.2 26.7 21.6 11.6
A/H Capacity
End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr
1.85 49.7 64.2 72 77 87.5 92.5 95.8 96.9 100.3 101.3 108.8
1.80 53.2 67.3 74.8 79.7 89.8 94.8 98.1 99.2 102.7 103.8 111.7
1.75 56.3 70 77.2 81.9 91.8 96.7 100 101.1 104.7 105.9 114
1.70 58.9 72.1 79.1 83.7 93.3 98.2 101.5 102.6 106.3 107.5 115.8
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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 HP 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
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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 >10°C
above Ambient
Yes
Perform
Quarterly PM
Monitor as per PM
Program
Fig. 5, 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.
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Page 16
3.2 Quarterly Preventive Maintenance
Yes
No
Yes
Yes
No
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
No
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
16
Fig. 6, Flow Chart for Quarterly Preventive Maintenance
Page 17
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 20, 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 27.
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3.3 AlphaCell HP Battery Maintenance Log
Node / Location
Power Supply Type
Load (kW)
Follow this sample when lling out the maintenance log (following page).
Evaluation Procedure #1Evaluation Procedure #2Evaluation Procedure
Vdc
Conductance
Float
No
Battery
String
A 1 4.0 HP 4/11 3/11 .2 70° 13.4 2100
A 2 4.0 HP 4/11 3/11 .2 70° 13.5 2087
A 3 4.0 HP 4/11 3/11 .2 70° 13.4 2100
B 1 4.0 HP 4/11 3/11 .1 70° 13.4 2087
B 2 4.0 HP 4/11 3/11 .1 70° 13.4 2100
B 3 4.0 HP 4/11 3/11 .1 70° 13.6 2087
A 1 4.0 HP 4/11 3/11 7/8 .1 85° 13.3 2100
A 2 4.0 HP 3/11 7/8 .1 85° 13.3 2087
A 3 4.0 HP 3/11 7/8 .1 85° 13.4 2100
B 1 4.0 HP 3/11 7/8 .1 85° 13.2. 2087
B 2 4.0 HP 3/11 7/8 .1 85° 13.2 2100
B 3 4.0 HP 3/11 7/8 .1 85° 13.2 2087
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
#3
Vdc 24
Hour OCV
18
Page 19
3.3 AlphaCell™ HP Battery Maintenance Log
Node / Location
Power Supply Type
Load (kW)
String
Battery
Initial Install Date
Battery Type
Mfr. Date Code
PM Date
Float Current
Battery Temp
Evaluation Proce-
dure #1
Vdc
Conductance
Float
No
Load
mhos @
77°F
Evaluation Procedure #2Evaluation Procedure
Vdc 24
Conductance Hour OCV
mhos @
77°F/25°C
Vdc @
100A after
10 seconds
#3
Vdc
24 Hour OCV
19
Page 20
3.4 Battery Evaluation procedures for AlphaCell™ HP
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
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 (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.
20
Midtronics Conductance
Models 3200/micro CELLTRON
Approximate Conductance Values (mhos) Healthy Battery @ 77°F (25°C)
Suspect Battery @ 77°F (25°C) in mhos <680 <840
Table 1, Conductance values, healthy vs. suspect batteries
3.5 HP 4.0 HP
1400-1850 1700-2500
Page 21
3.5 Battery Refurbishment Plan
Battery
Refurbishment
Batteries Returned
from Site. Measure
and document 24
hour Open Circuit
Voltage (OCV).
(
Must occur within 24
hours of removal from
charger)
No
Measure
Conductance
Plan
Does battery meet
the minimum
conductance values
per Table 1?
Yes
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
Fig. 7, Flow Chart for Battery Refurbishment Plan
Measure
Battery
Voltage
Voltage
strings
page 8.
Does battery meet
the minimum of
12.6 Volts for the 24 hour OCV?
21
Page 22
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 -0.0022 V/C per °F (-0.004 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 0.028 V/C (13° x -0.0022 V/C per °F) to between 2.21 and 2.26 V/C.
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 -0.0022 V/C per degree or 0.037 V/C.
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 HP Batteries when used with the XM Series 2 or GMX Power Supply.
AlphaCellTM HP Batteries
Accept 2.35 V/C
Float 2.25 V/C
Temp Comp -4mV/C/C
22
Page 23
1
2
3
4
5
6
7
8
9
10
2.15
2.25
2.05
2.40
0
Volts Per Cell
Charger Current
Bulk Accept Float
4.0 Battery System Float Charging, continued
NOTE:
The following information specically pertains to Alpha XM Series 2 and HP 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, 2.2-2.45Vdc per cell, 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 2.1-2.35Vdc
(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
-0.004Vdc per cell per degree C (adjustable) to ensure a safe battery cell voltage and to
maximize battery life.
For AlphaCell HP batteries, the recommended battery system oat charge voltage is equal
to the number of cells in the system multipled by the range of 2.1 to 2.35 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 37.8 to
42.3 Vdc (18 cells x 2.1 V/C minimum and 18 x 2.35 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.
Fig. 8, Charger Modes (dashed line indicates HV models)
23
Page 24
5.0 Troubleshooting
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.
24
Table 2, Troubleshooting
Page 25
5.0 Troubleshooting, 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.
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
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
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
Table 2, Troubleshooting, continued
25
Page 26
5.0 Troubleshooting, 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.
26
Table 2, Troubleshooting, continued
Page 27
6.0 Battery Parameters by Model Number
Parameter
Terminal Type
Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt
Annual Retorque Inch-Pounds / N•m 110In-lb / 2.4N•m 110In-lb / 2.4N•m
Open Circuit Voltage 12.80 12.80
Average Float Voltage Range (volts/unit)
Typical Impedance @ 60Hz ohms 2.7 2.2
Typical Conductance 7Hz mohms 1400 to 1850 1700 to 2500
Threaded Insert Threaded Insert
12.6 to 14.1 12.6 to 14.1
Model Number
3.5 HP 4.0 HP
Table 3, Battery Parameters, Current Models
27
Page 28
7.0 Warranty and Return Information
7.1 AlphaCell HP 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 4.
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 4 of this section.
3) The standard warranty shown in Table 4 applies to AlphaCell HP Batteries used in Alpha enclosures in
conjunction with Alpha Power Supplies.
4) A baseline Two Year Warranty applies to AlphaCell HP Batteries used in other applications not dened in item
#3 shown above. AlphaCell HP 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 HP 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 HP 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 HP Warranty requires a minimum semiannual preventive maintenance schedule with records
as outlined in the AlphaCell HP owners manual and user's guide.
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.
28
Page 29
7.1 AlphaCell HP Standard Limited Warranty, continued
The table below indicates the warranty periods for AlphaCell HP Batteries used with Alpha approved power supplies and enclosures.
Battery Model Description Warranty (US/Canada) Warranty (International
3.5 HP Pure Lead 5 Years 4 Years
4.0 HP Pure Lead 5 Years 4 Years
Table 4, Warranty periods for AlphaCell HP batteries
29
Page 30
7.2 Battery Maintenance Report for Return Authorizations
Contact your Alpha Customer Service representative for assistance in processing your AlphaCell HP 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
PM
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
#3
Conductance
mhos @
77°F
30
Page 31
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Page 32
Alpha Technologies Inc.
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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 © 2011 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies. 745-680-C5-001 Rev. A (7/2011)
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