Alpha AlphaCell OPzS User Manual
AlphaCell OPzS
Stationary Flooded Tubular Lead-acid Batteries
Technical Manual
AlphaCell OPzS Battery
Effective: January 2008
Alpha Technologies
Alpha Technologies
Power
®
AlphaCell OPzS Battery
Installation and Operation Manual
OPzS-BATTERY
Effective Date: January 2008
Copyright© 2008
Alpha Technologies, Inc.
A Member of the Alpha Group
NOTE:
Photographs contained in this manual are for illustrative purposes only. These photographs may not match
your installation.
NOTE:
Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. 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 product information and customer service (7 AM to 5 PM, Pacifi c Time), call
1 800 863 3930
For complete technical support, call
OPzS-BATTERY
1 800 863 3364
7 AM to 5 PM, Pacifi c Time or 24/7 emergency support
3
Table of Contents
Safety Notes .......................................................................................................................... 8
Battery Safety Notes.............................................................................................................. 9
Chemical Hazards ................................................................................................................. 9
Recycling and Disposal Instructions ...................................................................................... 9
1.0 General Information .................................................................................................. 10
1.1 Introduction .................................................................................................... 10
1.2 Precautions .................................................................................................... 10
2.0 Safety.........................................................................................................................11
2.1 General ...........................................................................................................11
2.2 Safety Equipment and Clothing ......................................................................11
2.3 Safety Precautions ..........................................................................................11
2.3.1 Sulfuric Acid Burns ...............................................................................11
2.3.2 Explosive Gases and Fire ................................................................... 12
2.3.3 Electrical Shocks and Burns ............................................................... 12
3.0 Inspecting the Battery Shipment ............................................................................... 13
3.1 General .......................................................................................................... 13
3.2 Visible External Damage ................................................................................ 13
3.3 Concealed Damage ....................................................................................... 13
4.0 Battery Storage Before Installation ........................................................................... 14
4.1 General .......................................................................................................... 14
4.2 Storage Interval.............................................................................................. 14
4.2.1 Filled and charged cells ...................................................................... 14
4.2.2 Dry charged cells ................................................................................ 14
4.3 Advanced Preparation ................................................................................... 14
5.0 Selection and Accommodation Considerations ........................................................ 15
5.1 General .......................................................................................................... 15
5.2 Battery Selection ............................................................................................ 15
5.3 Accommodation Considerations .................................................................... 15
4
OPzS-BATTERY
Table of Contents, continued
6.0 Unpacking and Handling for Installation ................................................................... 16
6.1 General .......................................................................................................... 16
6.2 Recommended Installation Equipment and Supplies .................................... 16
6.3 Cell Handling.................................................................................................. 16
7.0 System Installation.................................................................................................... 17
7.1 General .......................................................................................................... 17
7.2 System Layout ............................................................................................... 17
7.3 Installation Considerations ............................................................................. 17
7.3.1 Arrangement ....................................................................................... 17
7.3.2 Spacing ............................................................................................... 18
7.4 Battery Installation ......................................................................................... 18
7.5 Preparing and Installing Connections ............................................................ 19
7.5.1 Terminal Posts ..................................................................................... 19
7.5.2 Intercell Connectors ............................................................................ 20
7.5.3 Terminal Plates .................................................................................... 20
8.0 Battery Taps .............................................................................................................. 21
9.0 Pilot Cell.................................................................................................................... 21
10.0 Freshening Charge .................................................................................................. 22
11.0 Operation ................................................................................................................. 23
11.1 Battery Charging and Operation Mode .......................................................... 23
11.1.1 Charging.............................................................................................. 23
11.1.2 Floating operation ............................................................................... 23
11.1.3 Switch mode operation........................................................................ 24
11.1.4 Battery charge/discharge operation .................................................... 24
11.2 Hydrometer Readings - Specifi c Gravity ........................................................ 24
11.3 Equalizing Charge.......................................................................................... 24
11.3.1 Equalizing Charge Method .................................................................. 25
11.4 Operating Temperature .................................................................................. 25
OPzS-BATTERY
5
Table of Contents, continued
12.0 Maintenance ............................................................................................................ 26
12.1 Battery Cleaning ............................................................................................ 26
12.1.1 Standard Cleaning .............................................................................. 26
12.1.2 Corrosion Cleaning ............................................................................. 26
12.1.3 Heavy Corrosion Cleaning .................................................................. 27
12.1.4 Cleaning Flame Arrestors.................................................................... 27
12.1.5 Replacing or Isolating a Cell ............................................................... 27
12.2 Maintenance Records .................................................................................... 28
12.3 Corrective Actions .......................................................................................... 29
12.4 Adding Water ................................................................................................. 30
12.5 Quality of Water ............................................................................................. 30
12.6 Filling Dry-Charged Cells ............................................................................... 31
13.0 Test Procedures ....................................................................................................... 32
13.1 Procedure for Battery Capacity Tests ............................................................ 32
14.0 Specifi cations........................................................................................................... 33
15.0 Battery Room Ventilation Calculation ...................................................................... 42
16.0 Maintenance Records .............................................................................................. 43
6
OPzS-BATTERY
Figures and Tables
Fig. 2-1, Safety Labels..........................................................................................................11
Fig. 16-1, Charged Battery Readings Before Discharge Begins Form ................................ 43
Fig. 16-2, After “Load Profi le” Battery Form......................................................................... 44
Fig. 16-3, “Final Recharge” Battery Readings Form............................................................ 45
Table 14-1, OPzS Dimensions............................................................................................. 33
Table 14-2, OPzS General Specifi cations ........................................................................... 34
Table 14-3, OPzS Capacity ................................................................................................. 34
Table 14-4, Discharge Current (1.83Vpc End Voltage) ....................................................... 35
Table 14-5, Discharge Current (1.80Vpc End Voltage) ....................................................... 36
Table 14-6, Discharge Current (1.75Vpc End Voltage) ....................................................... 37
Table 14-7, Discharge Current (1.70Vpc End Voltage) ....................................................... 38
Table 14-8, Sulphuric Acid Impurities .................................................................................. 39
Table 14-9, Demineralized Water Impurities ........................................................................ 40
Table 14-10, List of Reference Standards ........................................................................... 40
Table 14-11, Total Gas Emission for OPzS Batteries after 10 years of Operation ............... 41
Table 14-12, Internal Resistance and Short Circuit Currents (2 Volts) ................................ 42
OPzS-BATTERY
7
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 specifi c regulatory/code requirements that may affect the placement of
equipment and installation procedures.
NOTE:
A NOTE provides additional information to help complete a specifi 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.
8
OPzS-BATTERY
Battery Safety Notes
WARNING!
Lead-acid batteries contain dangerous voltages, currents and corrosive material. Battery
installation, maintenance, service and replacement must be performed only by authorized
personnel.
Chemical Hazards
Any liquid leakage from a fl ooded lead-acid battery contain dilute sulfuric acid, which is harmful to the skin
and eyes. Emissions are electrolytic, and are electrically conductive and corrosive.
To avoid injury:
•
The servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel
knowledgeable of batteries and required safety precautions.
•
Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metallic
objects from hands and neck.
•
Batteries produce explosive gases. Keep all open fl ames and sparks away from batteries.
•
Use tools with insulated handles, do not rest any tools on top of batteries.
•
Lead-acid 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).
•
Wear protective clothing (insulated gloves, eye protection, etc.) when installing, maintaining, servicing, or replacing
batteries.
•
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 bicarbonate of soda to one gallon 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. Never install old or untested batteries.
•
Do not charge batteries in a sealed container. Each individual battery should have at least 0.5 inches of space
between it and all surrounding surfaces to allow for convection cooling.
•
All battery compartments must have adequate ventilation to prevent accumulation of potentially dangerous gas.
Ventilation should prevent trapped hydrogen gas pockets from exceeding a 1% concentration as per regulation 70E
of the National Fire Protection Agency (NFPA).
•
Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed
on your body.
•
Never use uninsulated tools or other conductive materials when installing, maintaining, servicing, or replacing
batteries.
•
Use special caution when connecting or adjusting battery cabling. An improperly connected or unconnected battery
cable can make contact with an unintended surface resulting in arcing, fi re, or 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.
Equipment Cautions
Do not operate NiCd and lead-acid batteries in the same room. NiCd emissions will neutralize the lead-acid solution,
•
rendering the battery useless.
Overcharging the battery can result in a loss of capacity and excess release of gas.
•
Recycling and Disposal Instructions
Spent or damaged batteries are considered environmentally unsafe. Always recycle used batteries or dispose of the
batteries in accordance with all federal, state and local regulations.
OPzS-BATTERY
9
1.0 General Information
1.1 Introduction
OpzS batteries are intended for telecommunication facilities, computers, emergency lighting,
alarm, control and monitoring systems in power plants and distribution stations, railway
stations, airports etc. Due to their extremely low self-discharge rate they are also suitable for
plants supplied by solar cells.
When properly handled and operated stationary OpzS batteries do not represent any danger
or harm for the operators and environment. When handling take into account all safety and
operating instructions.
1.2 Precautions
Before unpacking, storing, handling, installing, operating, or performing maintenance on the
battery system read the following information thoroughly.
It is important to read, understand and strictly follow the instructions in this manual.
If the following precautions are not fully understood, or if local conditions are not covered,
contact the manufacturer for clarifi cation or ask for technical advice.
Refer to all applicable state and local regulations and industry standards.
NOTE:
You should be trained in handling, installing, operating and maintaining batteries before you work on any
battery system.
10
.
OPzS-BATTERY
2.0 Safety
Follow
Instructions
CAUTION!
If you have any questions concerning safety, contact your local manufacturer sales representative to clarify
any of the noted safety precautions or call the Alpha Customer Service number listed on the back of this
manual.
Use Protective
Goggle and
Clothes
Avoid Sparks,
Flames, or
Arcing
Fig. 2-1, Safety Labels «
Explosive
Gases
(Avoid Short
Circuit
Caustic Acid Danger
2.1 General
Like all other fl ooded, lead-acid batteries, OPzS stationary batteries may leak, release
hydrogen gas or cause acid misting. Always follow the generally accepted safety procedures
for handling batteries. In addition, it is very important that the precautions recommended in
this manual are observed.
You must understand the risk of working with batteries and be prepared to take the necessary
safety precautions.
2.2 Safety Equipment and Clothing
When working with any battery system, be sure you have the necessary tools and safety
equipment, including but not limited to: insulated tools, face shield and protective goggles,
rubber apron or acid resistant cloth, rubber gloves, emergency eye wash and shower, fi re
extinguisher and acid spill cleanup kit.
Always:
Remove all jewelry (i.e., rings, watches, chains, etc.).
•
Keep sparks, fl ames and smoking materials away from the battery.
•
Never lay tools or other metallic objects on the battery cell. Using the correct tools and
wearing proper safety equipment will help prevent injury should an accident occur.
NOTE:
In case of a sulfuric acid spill, bicarbonate of soda or an emergency spill kit should be within the battery room.
2.3 Safety Precautions
2.3.1 Sulfuric Acid Burns
Stationary batteries are safe when operated and handled properly. However, they do
contain sulfuric acid, which can cause burns and other serious injuries. Always wear
protective clothing.
In case of contact with skin or cloth, immediately:
Remove contaminated clothing.
•
Flush the area thoroughly with water.
•
Get medical attention, if required.
•
OPzS-BATTERY
11
2.0 Safety, continued
2.3 Safety Precautions, continued
2.3.1 Sulfuric Acid Burns, continued
In case of eye contact with sulfuric acid, immediately:
•
•
If acid is spilled it should be neutralized with a solution of 1 pound of baking soda to 1
gallon of water (1 kg NaHCO3 / 10 l water) and then washed off with water.
2.3.2 Explosive Gases and Fire
Batteries generate explosive gases in all stages of operation. Under extreme
conditions these gases can explode, causing blindness and other serious personal
injury. Consider the following:
•
•
•
•
In case of fi re:
Flush thoroughly every few minutes with large amounts of water.
Get medical attention.
Always wear protective clothing and use the correct safety tools.
Eliminate any potential of sparks, fl ames or arcing.
Before working on the battery, be sure to discharge static electricity that can build
up on tools or the technician by touching a grounded surface in the vicinity of the
battery but far enough from the cells and fl ame arresters to avoid ignition of any
hydrogen gas present.
Provide adequate ventilation of the battery room.
If batteries are connected to a charger, shut off power.
•
Extinguish a fi re in a battery room containing lead acid batteries, using CO2,
•
foam, or dry chemical extinguishing media. Do NOT discharge the extinguisher
directly onto the battery. The resulting thermal shock may cause cracking of the
battery case/cover.
Leave the area as soon as possible if toxic fumes are present.
•
Wear breathing apparatus if it is required to remain in the area.
•
2.3.3 Electrical Shocks and Burns
Multi-cell battery systems can attain high voltage and/or currents, therefore, do not
touch un-insulated battery connectors or terminals. To prevent serious electrical
shock and burns, use extreme caution when working with the system.
Always wear protective clothing and use nonconductive or insulated tools when
working with any battery system.
Remove any jewelry or clothing that could produce a short circuit between the
positive and negative terminal of a battery or battery string.
Before working on the system:
Disconnect all loads and power sources to the battery.
•
If working on an assembled battery system, sectionalize (interrupt the battery
•
sections) into safe working voltage levels.
Check the battery system grounding. Grounding of the battery system is not
•
recommended. However, grounding of the rack is recommended.
Should you be required to work on a grounded battery system, make absolutely sure
you use the correct safety precautions, equipment and clothing.
12
OPzS-BATTERY
3.0 Inspecting the Battery Shipment
3.1 General
Precautions have been taken to pack the cells/battery units for shipment to ensure its safe
arrival. However, upon receipt, you should inspect for evidence of damage that may have
occurred during transit.
WARNING!
During inspections, take precautions against electrical shock. You are handling live
batteries.
3.2 Visible External Damage
Inventory all materials against the bill of lading and inspect for visible external damage.
Check material quantities received including the number of battery pallets and the number of
accessory boxes.
Note any damage to packing material and wetness or stains, indicating electrolyte leakage
and contact the manufacturer.
3.3 Concealed Damage
Within 15 days of receipt (or as soon as practical), unpack the cells. Check the received
materials against the detailed packing list to verify receipt of all materials in the quantities
specifi ed and check for concealed damage.
Examine the electrolyte level to ensure that none has been spilled. If electrolyte has been lost
in transit and no damage is established which can cause leak add sulfuric acid electrolyte of
the nominal operating specifi c gravity indicated on the cell nameplate, and bring to the low
level line on open circuit.
If damage is noted fi le a claim for concealed damage.
If cells are shipped charged and dry with separate electrolyte, fi ll only when ready to place in
service.
DELAY IN NOTIFYING MAY RESULT IN LOSS OF YOUR RIGHT TO REFUND FOR
DAMAGES.
If you have questions concerning potential damages, contact the manufacturer’s sales
representative or Alpha Technologies Customer Service.
OPzS-BATTERY
13
4.0 Battery Storage Before Installation
4.1 General
Batteries should be unpacked, installed and charged as soon as possible after receipt.
However, if this is impractical, follow the instructions below for storing the battery before
installation.
Stationary battery cells can be fi lled with electrolyte and charged - fl ooded or dry-charged.
Store batteries indoors in a clean, dry, cool and frost free location (10 °C – 30 °C). Storage
at higher temperatures will result in accelerated rates of self-discharge and possible
deterioration of battery performance and life.
Do not stack pallets. Damage may occur and the warranty will be voided.
4.2 Storage Interval
4.2.1 Filled and charged cells
Filled and charged cells should be recharged every 90 days to prevent their failure.
Use the date of battery shipment to determine freshening charge requirements.
Storage times exceeding the above may result in plate sulfation, which may
adversely affect electrical performance and expected life.
4.2.2 Dry charged cells
Dry charged cells may stand for a longer time as long as they are sealed and stored
with as little temperature variations as possible within 24 hours (< 30 °C, < 50 % H).
In the winter the storage room should be safe from freezing.
Maximum total storage time before installation is 2 years from the date of shipment
from the factory to the customer.
4.3 Advanced Preparation
If storage time is likely to be exceeded, make advanced preparation to have an adequate
charger available and adjacent to an appropriate AC supply voltage. Positioning of the cells
to accept the temporary intercell connectors is another consideration of advance planning.
Make every effort to get the battery connected to the charger before the expiration of the
storage period.
NOTE:
Failure to charge as noted voids the battery warranty.
14
OPzS-BATTERY
Loading...