Alpha OGi bloc User Manual

Nominal data:

Nominal voltage UN: 2.0 V x number of cells
Nominal capacity CN = C10: 10 hour dis­charge
(see type plate and technical data in these
instructions)
Nominal discharge current: IN = I10:
Final discharge voltage Us:
see technical data in these instructions
Nominal temperature TN: 20°C
"LA": antimony content < 2% in the grids
(earthcarriers) of the positive electrodes

Non-compliance with operating instruc­tions, repairsmade with other than original
parts, tamperingor use of additives for the
electrolyte (alleged"enhancing agents")
render the warrantynull and void.

1. Commissioning of filled and charged
batteries

Before commissioning all blocks must be
inspected
for mechanical damage, cells must be
connected with the correct polarity and con­nectors firmly seated. The following torques
apply for screw connectors:
M 10 with 17 Nm +/ _ 1 Nm
If necessary the terminal covers must be put
on.
Check the electrolyte level in all cells. If nec­essary
top up to maximum level with purified water
as under DIN 43530 Part 4.
With charger off and loads isolated connect
battery to the direct current power supply
maintaining correct polarity (positive terminal
to positive post).
Switch on the charger and charge as under
Section 2.2.

2. Operation

For the operation of stationary battery
installationsDIN VDE 0510 Part 1 (draft) and
DIN VDE 0510 Part 2 apply.

2.1 Discharging

Never allow the final discharge voltage of the
battery to drop below that assigned for the
discharge current. Unless the manufacturer
has specified otherwise, no more than the
nominal capacity is to be consumed. Charge
immediately after discharge as well as partial
discharge.

2.2 Charging

All charging procedures with their limit values
may be employed as under
DIN 41773 (IU characteristic)
DIN 41774 (W characteristic
DIN 41776 (I characteristic).
Depending on charger type and charging
characteristic alternating currents flow through
the battery superimposing onto the direct cur­rent.
These alternating currents and the reaction of
the loads lead to an additional warming of the
battery and strain on the electrodes with pos­sible resulting damage (see 2.5).
Depending on the system at hand charging
may be carried out under the following opera­tions:
a) S

tand-by parallel operation and floating
operation
Here the load, direct current and battery are
continuously connected in parallel.
Thereby the charging voltage is the operating
voltage of the battery and at the same time
the battery installation voltage.
With st

and-by parallel operation the direct cur­rent is at any time capable of supplying the
maximum load current and the battery charg­ing current. The battery only supplies current
when the direct current source fails. The
charge voltage should be set at 2.23 V +/_1%
x number of cells measured at the battery's
terminals. To reduce the recharging time a
charging stage canbe applied in which the
charging voltage is 2.33 to 2.4 V x number of
cells (stand-by parallelparallel
operation with recharging stage). Automatic
changeover to the charging voltage of 2.23 V

+/_ 1% x number of cells follows.
With the floating operation

the direct current
source is not able to supply the maximum
load current at all times. The load current
intermittent
Iy supercedes the nominal current of the
direct current source. During this period the
battery supplies power. It is not fully charged
at all times.
Therefore, depending on the load the charge
voltage must be set at 2.23 to 2.30 V x
number of cells.
b) Switch mode operation
When charging the battery is separated from
the load. Towards the end of the charging
process the charge voltage of the battery is

2.6 - 2.75 V/cell. The charging process must
be monitored (see Sections 2.4, 2.5 and 2.6)
On reaching a fully charged state the charging
process must be stopped or switched to float
chargeas under Section 2.3.
c) Battery operation (charge/discharge opera

­tion)
The load is supplied only by the battery.
Hereby the charge voltage of the battery
towards the end of the charging process is 2.6

- 2.75 V/ cell. The charging process must be
monitored (see Sections 2.4, 2.5 and 2.6). On
reaching a fully charged state the charging
process must be
switched off. The battery can be switched to
the load as necessary.

2.3 Maintaining the full charge

(float charge)
Devices complying with the stipulations under
DIN 41773 must be used. They are to be set
so that the average cell voltage is

2.23 V +/_ 1% and the electrolyte density
does not decrease over a protracted period.

2.4 Equalizing charge

Because it is possible to exceed the permitted
load voltages, appropriate measures must be
taken, e.g. switch off the load.
Equalizing charges are required after exhaus­tive discharges and after inadequate charges;
they can be carried out as follows:

- up to 72 hours at constant voltage of max.

2.4 V/cell - as under Table 1 with I and W
characteristic.
On exceeding the maximum temperature of
55°C charging must either be stopped or pro­ceed with reduced current or be switched to
float charge to allow the temperature to drop.
The equalizing charge is completed when the
electrolyte densities and cell voltages no
longer increase within 2 hours.

2.5 Alternating currents with periodic
deviations

On recharging up to 2.4 V/cell as under oper­ation modes a) to c) the actual value of the
alternating current is ocassionally permitted to
reach max. 20 Aper 100 Ah nominal capacity.
Above 2.4 V/cells 10 Aper 100 Ah nominal
capacity may not be
exceeded.
In a fully charged state with a charge voltage
of 2.23 to 2.30 V/cell the actual value of the
alternating current may not exceed 5 Aper
100 Ah nominal capacity.

Observe operating instructions
and affix close within sight of the
battery!
Work on batteries only under
instrustions of skilled personnel!

Smoking prohibitet! Do not
expose battery to open flame
glowing fire or sparks as explo­sion and fire hazard exists!

When working on batteries wear
protective glasses and
clothing!Observe the accident
prevention rules as well as DIN
VDE 0510, VDE 0105 part 1 !

Explosion and fire hazard, avoid
short circuits!
Caution! Metal parts of the battery
cells are always live, therefore do
not place items or tools on the
battery!

Electrolyte is strongly corrosive!

Monobloc batteries/cells are very
heavy! Ensure secure installation!
Only use suitable transport equip­ment!

Dangerous voltage!

Acid splashes in the eyes or on
the skin must be washed out or
off with plenty of water.Then see
a doctor immediately. Acid on
clothing should be washed out
with water!

Assembled by:____________________________
on:______________________________________
Start-up by:_______________________________
on:______________________________________
Safety marking
affixed by:________________________________
on:______________________________________

OPERATING INSTRUCTIONS

Stationary vented lead-acid batteries OGi bloc

Ue (V/cell) 1.80 1.75 1.75 1.70 1.65 1.65 1.60 Dimensions Masse/Weight

C10 C5 C3 C1 C1/2 C1/6 C1/12 L W Hmax Bat.+el. el. Ri Ik

TYPE C (Ah) (mm) (mm) (mm) (kg) (kg) (mΩ/bl.) (kA)

12V 1 OGi 25 29.0 25.5 22.5 16.8 14.3 9.2 6.7 272 205 375 33 11 16.97 0.72
12V 2 OGi 50 55.0 49.5 44.7 32.8 28.0 18.0 13.1 272 205 375 41 10.9 8.91 1.41
12V 3 OGi 75 80.0 74.5 67.5 49.6 42.2 27.3 19.8 272 205 375 49 10.8 5.94 2.11
12V 4 OGi 100 105.0 98.5 89.4 65.7 56.1 36.1 26.1 272 205 375 58 10.7 4.46 2.81
12V 5 OGi 125 135.0 123.0 111.3 81.6 69.0 44.3 31.7 380 205 375 78 15.7 3.57 3.52
12V 6 OGi 150 165.0 148.5 133.8 98.2 82.5 52.7 37.1 380 205 375 86 15.5 2.97 4.22
6V 7 OGi 175 193.0 172.5 156.0 114.1 94.0 58.7 40.8 272 205 375 49 11.3 1.27 4.93
6V 8 OGi 200 228.0 197.5 178.8 130.0 108.0 67.3 46.8 272 205 375 53 11.1 1.11 5.63
6V 9 OGi 225 254.0 221.5 200.7 145.8 121.5 75.5 52.6 380 205 375 68 16.4 0.99 6.36
6V 10 OGi 250 270.0 247.0 223.5 161.7 133.0 80.5 55.3 380 205 375 72 16.3 0.89 7.04
6V 11 OGi 275 304.0 271.5 245.1 177.6 146.0 88.5 60.7 380 205 375 75 16.2 0.81 7.78
6V 12 OGi 300 320.0 296.0 268.2 194.4 159.5 96.5 66.3 380 205 375 79 16 0.74 8.44
2V 24 OGi 600 684.0 592.5 536.4 390.0 324.0 201.9 140.4 205 272 375 53 11.1 0.13 16.42
2V 30 OGi 750 810.0 741.0 670.5 485.1 399.0 241.5 165.9 205 380 375 72 16.3 0.10 21.89
2V 36 OGi 900 960.0 888.0 804.6 583.2 478.5 289.5 198.9 205 380 375 79 16 0.08 24.63

2.6 Charging currents

The charging currents are not limited to

2.4 V/ cell. When exceeding the charging
voltage of 2.4 V/cell greater water decompo­sition occurs.
The charging currents per 100 Ah nominal
capacity shown in Table 1 may not be
exceeded.

2.7 Temperature

The recommended operating temperature for
lead-acid batteries is 10°C to 30°C. The tech­nical data apply for the nominal temperature
20°C. The ideal operating temperature is
20°C +/_ 5 K. Higher temperatures shorten
the service life. Lower temperatures reduce
the available capacity. The maximum temper­ature of 55°C may not be exceeded.

2.8 Temperature-related charge voltage

A temperature-related adjustment of the
charge voltage within the operating tempera­ture of 10°C to 30°C is not necessary.
Should the temperature range be lower than
10°C and/or higher than 30°C a temperature
related adjustment of the charge voltage
should be made. The temperature correction
factor is (-0.004 V/C per K).
Should the temperature constantly rise above
40°C, then the factor is (0.003 V/C per K).

2.9 Electrolyte

The electrolyte is diluted sulphuric acid. The
nominal electrolyte density is based on 20°C
and the nominal electrolyte level when fully
charged maximum +/ _ 0.01 kg/l.
Higher temperatures reduce the electrolyte
density, lower temperatures increase the
electrolyte density. The associated correction
factor is 0.0007 kg/l per K.

Example: electrolyte density of 1.23 kg/l at
35°C corresponds to a density of 1.24 kg/l at
20°C or electrolyte density of 1.25 kg/l at 5°C
corresponds to a density of 1.24 kg/l at 20°C.

3. Battery maintenance and control

The electrolyte level must be checked regu­larly. If it has dropped to the lowest elec­trolyte level mark, purified water must be
added as under DIN 43530 Part 4, maximum
conducting capacity 30 _S/cm.To avoid leak­age currents keep the battery
clean and dry. Cleaning the battery should
be carried out as specified in the ZVEI pam­phlet on battery cleaning.
Plastic battery components, in particular the
vent caps, must only be cleaned with water
containing no additives. At least every 6
months the following must be measured and
recorded:

- battery voltage

- voltage of a few selected cells/monobloc
batteries

- electrolyte density of a few selected
monobloc batteries

- electrolyte temperature of a few selected
monobloc batteries
The following must be measured and record­ed annually:

- voltage of all bloc batteries

-electrolyte density of all bloc batteries

- electrolyte temperature of a few selected
bloc batteries
Should the float charge voltage in one cell
deviate more than + 0.1 V or - 0.05 V from
the average value (see 2.3), customer serv­ices must be called in.
Annual visual checks:

- on bolted connectors, check that unsecured
bolt connectors are firmly seated

- on battery installation or arrangement

- on ventilation.

4. Tests

Tests must be conducted according to DIN
43539 Part 1 and 4. In addition, special test
instructions such as under DIN VDE 0107
and DIN VDE 0108 must be observed.

5. Faults

Should faults be detected in the battery or
the
charging device, customer services should
be
called in immediately. Measurement data
under
Section 3 simplify fault detection and
removal.
A service contract with us facilitates the time­ly detection of faults.

6. Storage and taking out of operation

Should cells/batteries be stored or taken out
of operation for a longer period of time they
mustbe placed, fully charged, in a dry, frost­free room.
To avoid damage the following-charging
methods can be chosen:

1. Equalizing charges on a quarterly basis as
under Section 2.4. In average ambient tem­peratures of more than 30°C monthly equal­izing charges may be necessary.

2. Float charging as under Section 2.3.

7. Transport

Batteries which show no damage of any kind
are not treated as dangerous goods under
the road and railway transport regulations
(GGVS and GGVE) if they are secured
against short circuits, sliding, overturning or
damage and stacked and secured appropri­ately on palettes
(GGV's margin No. 2801 a). The batteries
ready for dispatch must not show any exter­nal dangerous traces of acid.
For all sealed batteries and cells whose ele­ments are leaking or damaged the exception­al regulation No. 69 applies.

8. Technical data

The nominal voltage, the number of blocks,
the nominal capacity (C10 = CN) and the
battery type are obtained from the type plate.
Other capacities (Cn) at different discharge
voltages (In) with the corresponding dis­charge times (tn)can be obtained from the
OGi tables.

Charging Monobloc battery Cell
procedure OGi bloc, OGi voltage

I-charact. 5,0 A 2,6-2,75 V
W-charac- 7,0 A at 2,4 V

teristic 3,5 A at 2,65 V

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Alpha Industrial Power

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