Alpha Lomain Ni-Cd Pocket Plate Battery User Manual
Alpha Lomain Ni-Cd Pocket Plate Battery
Technical Manual
Effective: July 2009
Alpha Technologies
Alpha Technologies
Power
®
Alpha Lomain Ni-Cd Pocket Plate Battery
Technical Manual
745-680-B10-001, Rev. A
Effective Date: July, 2009
Copyright© 2009
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 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.
TM
Contacting Alpha Technologies: www.alpha.com
or
For general product information and customer service (7 AM to 5 PM, Pacic Time), call
1-800-863-3930,
For complete technical support, call
1-800-863-3364
7 AM to 5 PM, Pacic Time or 24/7 emergency support
745-680-B10-001 Rev. A
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Table of Contents
Safety Notes .......................................................................................................................... 6
Battery Safety Precautions .................................................................................................... 7
1.0 Introduction ................................................................................................................. 9
1.1 Alpha Lomain Theory of Operation ......................................................................11
1.2 Safety terminal ................................................................................................... 14
1.3 Electrode Frame ................................................................................................. 14
1.4 Positive and negative electrode plate ................................................................ 14
1.5 Electrolyte .......................................................................................................... 15
2.0 Battery range and applications ..................................................................................... 16
3.0 Electrochemistry of Ni-Cd batteries .............................................................................. 16
4.0 Operating Features ....................................................................................................... 17
4.1 Capacity .............................................................................................................. 17
4.2 Cell voltage ........................................................................................................ 17
4.3 Internal resistance ............................................................................................. 17
4.4 Impact of temperature on cell performance and available capacity .................. 18
4.5 Impact of temperature on lifetime ...................................................................... 19
4.6 Short-circuit values ............................................................................................ 19
4.7 Open circuit loss ................................................................................................. 19
4.8 Cycling ............................................................................................................... 20
4.9 Topping up interval ............................................................................................. 21
5.0 Sizing the batteries for standby applications ................................................................. 22
5.1 Voltage window ................................................................................................... 22
5.2 Load prole ......................................................................................................... 22
5.3 Ambient temperature .......................................................................................... 22
5.4 Recharge time and state of charge..................................................................... 22
5.5 Aging ................................................................................................................... 22
5.6 Floating effect -Voltage depression .................................................................... 23
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745-680-B10-001 Rev. A
Table of Contents
6.0 Charging ....................................................................................................................... 24
6.1 Constant voltage charge ..................................................................................... 24
6.2 Charge acceptance............................................................................................. 25
6.3 Charge efciency ............................................................................................... 26
6.4 Temperature inuence ........................................................................................ 26
7.0 Commissioning ............................................................................................................. 27
7.1 Commissioning with constant current ................................................................ 27
7.2 Commissioning with constant voltage ................................................................ 27
8.0 Charging in operation ................................................................................................... 28
8.1. Two level charge ................................................................................................ 28
8.2. Single level charge ........................................................................................... 28
9.0 Periodic Maintenance .................................................................................................... 28
Figures and Tables
Fig. 1, Design of an Alpha Lomain Ni-Cd pocket plate cell ................................................................. 10
Fig. 2, Detail of plate design .................................................................................................................11
Fig. 3, Battery Vent .............................................................................................................................. 12
Fig. 4, Exploded view, Battery vent ..................................................................................................... 12
Fig. 5, Smaller Capacity Batteries ....................................................................................................... 13
Fig. 6, Larger Capacity Batteries ......................................................................................................... 13
Fig. 7, Terminal cross-section .............................................................................................................. 14
Fig. 8, Electrode Strip .......................................................................................................................... 14
Fig. 9, Strips connected ....................................................................................................................... 15
Fig. 10, NiCd vs. Lead-Acid performance as a function of temperature .............................................. 18
Fig. 11, Discharge curve of 45A x 4 KGL225P post-2224h Float Charge @ 50°C .............................. 18
Fig. 12, Battery life at higher temperatures as percentage of +25°C lifetime ...................................... 19
Fig. 13, Cycle life vs. depth of discharge as a percentage of rated capacity (20°C) ........................... 20
Fig. 14, Available 5-hour-capacity of 5 x KGM 140P after 15 hours charging at 1.43 V/pc at 30°C .... 25
Fig. 15, Total Discharge time 4:43h = 94% of nominal capacity .......................................................... 25
Fig. 16, Available 5-hour-capacity of 5 x KGL 665P after 15 hours charging at 1.43 V/pc at 30°C ..... 25
Fig. 17, Total Discharge time 4:15h = 85% of nominal capacity .......................................................... 25
745-680-B10-001 Rev. A
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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 this product, contact Alpha Technologies or the nearest Alpha
representative. Save this document for future reference.
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and
attention.
ATTENTION:
The use of ATTENTION indicates specic regulatory/code requirements that may affect the placement of
equipment and /or installation procedures.
NOTE:
A NOTE provide additional information to help complete a specic task or procedure.
CAUTION!
The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material
or equipment.
WARNING!
WARNING presents safety information to PREVENT INJURY OR DEATH to the
technician or user.
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745-680-B10-001 Rev. A
Battery Safety Precautions
WARNING!
Service personnel must always wear protective clothing (e.g., rubber gloves, safety goggles
with side guards, or a face shield) when working with electrolyte and on cells / batteries.
The battery pack, which provides backup power, contains dangerous voltages. Only •
qualied personnel should inspect, service or replace batteries.
If batteries are being stored prior to installation, charge at least once every six (6) •
months to ensure optimum performance and maximum battery service life.
Reduce the chance of spark and wear on the connectors; always switch the •
inverter’s battery circuit breaker off before connecting or disconnecting the battery
pack
Always use proper lifting techniques whenever handling batteries.•
In the event of a short-circuit, batteries present a risk of electrical shock and burns •
from high current. Observe proper safety precautions. Always carry a supply of
water, such as a water jug, to wash the eyes or skin in the event of exposure to
battery electrolyte.
The battery must be kept clean using only water. Do not use a wire brush or solvents •
of any kind.
NOTE:
Once the battery has been lled with the correct electrolyte at the factory there is no need to
periodically check the electrolyte density
Check regularly (appr. every year) that all connectors, nuts and screws are tightly •
fastened. All metal parts of the battery should be corrosion-protected by coating with
a thin layer of anti-corrosion grease. Do not coat any plastic part of the battery, for
example, the cell cases.
Check the charging voltage. If a battery is parallel connected it is important that •
the recommended charging voltage remains unchanged. The charging current in
the strings should also be checked to ensure it is equal. These checks has to be
carried out once a year. High water consumption of the battery is usually caused by
improper voltage setting of the charger.
745-680-B10-001 Rev. A
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Battery Safety Precautions, continued
Check the electrolyte temperature from time to time. The temperature of the •
electrolyte should never exceed 45 °C as higher temperatures have a detrimental
effect on the function and duration of the cells. In the course of charging an
electrolyte temperature of ≤ 35 °C should be aimed for. On exceeding 45 °C the
charging should be temporarily interrupted until the electrolyte temperature falls
down to 35 °C. The temperature measurements are to be made on one of the cells
in the middle of the battery. Low ambient or electrolyte temperatures down to –25
°C do not have any detrimental effect on the battery they just cause a temporary
reduction in capacity.
NiCd batteries must not be stored in the same room as lead acid batteries. Also, the •
charging gases from lead acid batteries must be kept away from Ni-Cd batteries by
suitable precautions such as ventilation or hermetic isolation of the rooms. Tools for
lead acid batteries must not be used for NiCd batteries
Do not place electrically conductive objects (e.g., tools) on the battery as this is a •
short circuit and re hazard.
Do not wear rings, metal bracelets, watches, or jewelry when working with the •
batteries and battery systems.
Provide sufcient ventilation (e.g., open the doors of the battery cabinet) during •
charging so any accumulated gases can escape. The charging gases from batteries
are explosive.
Do not allow open re or ember in the vicinity of the battery.•
Caustic potash solution is used as electrolyte, and is a highly corrosive liquid which •
can cause severe damage to health if it comes into contact with the eyes or the
skin (risk of blinding). If even small quantities are swallowed there is a possibility of
internal injuries.
Contact with the eyes: Flush out immediately with copious amounts of water for 10 •
to 15 minutes, and seek immediate medical attention.
Contact with the skin: Remove splashed clothing immediately and wash the affected •
skin areas with copious amounts of water, and seek immediate medical attention.
Swallowing: Rinse out the mouth immediately with large amounts of water and •
keep drinking large amounts of water. Do not induce vomiting, and seek immediate
medical attention.
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745-680-B10-001 Rev. A
1.0 Introduction
The Alpha Lomain Ni-Cd pocket plate battery is one of the most reliable batteries available and is
well-suited for operation under extreme environmental conditions. Features of the Alpha Lomain
Ni-Cd pocket plate battery include the following:
• Very good high power rating.
• Low internal resistance.
• Reduced loss of capacity at deep temperature.
• No ice formation at temperatures below 0 °C.
• Long lifetime at high temperatures.
• Resistant to the affects of repeated deep discharges.
• Long shelf life.
• No electrolyte stratication.
• Robust construction makes the battery well-suited for use in extreme conditions.
745-680-B10-001 Rev. A
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