AlphaCell HP English User Guide
Contents
1. 745 680 C5 002 Rev A 3 3 AlphaCell HP Battery Maintenance Log Node Location Power Supply Type Load kW xo oO R4 m Evaluation Procedure SrA ee d S cM on ON RE s QU d vd vd gt Q Q Ce e Eum Conductance Vdc24 Conductance Vdc 2 E C L3 RS ea RN c ES NE mhos Hour mhos 100A after Bt Lo Q Q ESI S Q amp Q oad TTE OCV 77 F 25 C 10 seconds OCV 745 680 C5 002 Rev A 19 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 defined as a faulty battery The battery will be replaced under the terms of the warranty if within the defined 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 initial2. 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 7 449 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 7 328 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 End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 1Ohr 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 8 745 680 C5 002 Rev A 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
3. Reduced life and RET Inadequate cabinet enter conditioning Elevated battery temp ventilation p Improve cabinet runaway Te Temperature Discharge charge ventilation Normal if not exceeding SES Checks cycle Limit recharge current 18 F increase High current recharge High charging voltage C Shorted cells Normal if not exceeding 18F 10C increase over ambient Limit recharge current Reduce within specifications Replace shorted cells and evaluate total string 745 680 C5 002 Rev A Table 2 Troubleshooting continued 25 5 0 Troubleshooting continued Type Symptom Possible Causes Possible Result Corrective Action Failure to support load If an RP internal arc occurs during A battery or connection in series SMS d SEE discharge can ignite gasses Replace battery with string is open Verify via the float Float current to j internal to cell open cell or repair Bon voltage check or AC ripple voltage string is zero Sedis If there is an open loose open loose external or impedance check of individual PNE f batteries connection in external con connection Float Charging ductive path can damage Current termination under load Checks Float current Batteries not fully recharged Not at 10096 capacity exceeds 3 0 Batteries above 77 F 25 C Conducive to thermal milliamperes per Potentially shorted cells in runaway D
4. member of The alp n Enl Group Users Guide AlphaCell HP Battery Effective July 2011 Alpha Technologies ani AlphaCell HP Battery Users Guide Storage Maintenance and Deployment 745 680 C5 001 Rev A Effective Date July 2011 Copyright 2011 Alpha Technologies Inc H member of The a n Group NOTE NE contained in this manual are for illustrative purposes only These photographs may not match your installation NOTE v 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 AS xs 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 Pacific Time call 1 800 863 3930 For complete technical support in the USA call 7 AM to 5 PM Pacific Time or 24 7 emergency support 1 800 863 3364 For Sales information and Technical Support in Canada call 1 800 667 8743 745 680 C5 002
5. During storage please note Alllead acid batteries experience self discharge while in open circuit storage This causes circuit voltage and capacity to decrease e 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 32 F to 77 F 0 C to 25 C e tis 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 v product warranty is void if the batteries are not stored and recharged in accordance with these guidelines 2 17 100 2 16 95 2 15 90 2 14 18596 OCV Per Cell Percent State of Charge 80 75 104 F 86 F e 68 F 40 C 30 C o 24 a 70 0 3 6 9 12 15 18 21 24 Storage Time Months Fig 1 Capacity vs Storage Time Electrical Safety Lethal voltages are present within the power supply and electric
6. Rev Table of Contents Satety NOfe5 oder nde ee T e tende etu necp ede ues de peer 6 Battery Maintenance Guideliries 12 2 core t ener Aaa c fee ee de Reda anne de 7 Recycling and Disposal Instructions sie 7 Important Storage Practices ED 8 Electrical Safe SR nieve Sa veo RUP b nera beue tinere Ure ein lex red oes 8 Chemical and Mechanical Safety etre tert aec e o an t da tu xe RR rdv 9 1 0 niece 10 1 1 BI Iegeep Rm 11 1 2 Operating Conditions sise 12 1 3 irri ee A td 12 LAS PURE CUT CR E E E fess ecdintesneca stints needa ieee 13 2 0 Preparing for Maintenance iii 14 2 1 Required Tools and Equipment ar tton oct t tro ed RE RR DOR RT HUS 14 3 0 Periodic Maintenance Tasks and Schedule 15 3 1 Monthly Remote Status Monitoring sessseeen A nnne nnne 15 3 2 Quarterly Preventive Maintenance ii 16 3 3 AlphaCell Battery Maintenance Log 18 3 4 Battery Evaluation Procedures edere seii ia eee tia e ea ee veau ved 20 3 5 Battery Refurbishment Plari rer n SER Een rure HER Pb ER eR XXE ERR XH EE Pax ERR S 21 4 0 Battery System Float Charglng i cce ede edt diede entre itl zt dfe ct cet er ads 22 4 1 Alpha Power Supply Charging Profile 444 23 5 0 relezrjeen mem c 24 6 0 Battery Parameters by Model Number conns e cedat cut a nlt amd ae 27 7 0 Warranty and Return
7. 40 F 22 F 4 F 14 F 32F 50 F 68 F 86 F 104 F 40 C 30 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C Fig 4 Available Capacity vs Ambient Temperature 12 745 680 C5 002 Rev 1 0 Introduction continued 1 3 Capacity continued 1 3 1 Ratings 3 5 HP Ratings 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 54 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 End Voltage 15min 30min 45min 1hr 2hr 3hr 4hr 5hr 8hr 10hr 20hr 1 85 40 7 532 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
8. PP Battery with high AC ripple Voltage xdi Individual battery in voltage has proportionately eon Checks I Reduced operating time string exhibits AC higher impedance Evaluate a i Potential conditions could Verify battery condition ripple voltage twice for performance Subject MR be conducive to thermal Replace as required that of other typical battery could have deteriorating ilies batteries in string conductive path or dry shorted or y open cell 26 Table 2 Troubleshooting continued 745 680 C5 002 Rev A 6 0 Battery Parameters by Model Number Parameter Model Number 3 5 HP 4 0 HP Terminal Type Threaded Insert Threaded Insert Bolt Size 1 4 20 UNC Bolt 1 4 20 UNC Bolt Annual Retorque Inch Pounds N m 110In Ib 2 4Nem 110In Ib 2 4Nem Open Circuit Voltage 12 80 12 80 Average Float Voltage Range volts unit 12 6 to 14 1 12 6 to 14 1 Typical Impedance 60Hz ohms 2 7 2 2 Typical Conductance 7Hz mohms 1400 to 1850 1700 to 2500 Table 3 Battery Parameters Current Models 745 680 C5 002 Rev A 27 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
9. amps replace the battery string Measure and record the individual battery conductance and voltage on the Site Visit Record 4 Ifthe string float 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 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 Ensure the enclosure is clean and free of debris 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. can be replaced when it fails to deliver 7096 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 identified the User should promptly notify manufacturer Should manufacturer confirm 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 Abaseline Two Year Warranty applies to AlphaCell HP Batteries used in other applications not defined 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 ac
11. metallic objects such as rings or watches from your person Batteries produce explosive gases Keep all open flames 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 4549 bicarbonate of soda to one gallon 3 81 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 specified 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 fire or a possible ex
12. 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 float 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 float 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 2 40 Volts Per Cell So Charger Current 2 N w pm N Bulk Accept Float p Fig 8 Charger Modes dashed line indicates HV models 745 680 C5 002 Rev A 23 5 0 Troubleshooting Problem with Symptom Possible Causes Possible Result Corrective Actions Capacity Test Results Reduced operat ing time at 77 F 25 C with smooth voltage decline Normal life cycle Eventual failure to support the load followed by pot
13. 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 float voltage of each battery in the string that is on float 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 amp 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 float 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 Midtron
14. specifications 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 specific 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 4 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 14 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 e Midtronics Conductance Meter e 100 amp momentary load test set e 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 i
15. to support load Replace damaged unit and evaluate balance of string Burned area on Crack in container wicking electrolyte to grounded rack Could result in personal hazard due to conductive path to rack Clear the ground fault and replace defective unit Evalu container Ground fault smoke or battery fire ate balance of string thermal runaway Thermal runaway possible caused by high temp Could result in the emission of Replace the battery system Permanently P deformed environment overcharging hydrogen sulfide detectable asa and correct the items leading swollen container excessively high recharge current shorted cells ground fault or a combination rotten egg odor battery fire and inability to support the load to the theramal runaway condition Rotten egg odor Possible caused by high temperatuare environment overcharging excessively high recharge current shorted cells ground fault or a combination of these Odor is a product of thermal runaway Replace the battery system and correct items leading to thermal runaway condition Melted grease at terminals Hot connections due to excessive resistance caused by loose connections dirty contact surfaces or corrosion within connection 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 Cl
16. 10 Check terminal posts for signs of corrosion If corrosion is present neutralize with a solution of 1 Ib 454g sodium bicarbonate baking soda to 1 gallon 3 81 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 27 745 680 C5 002 Rev A 17 3 3 AlphaCell HP Battery Maintenance Log Follow this sample when filling out the maintenance log following page Node Location Power Supply Type Load kW xD o UD Evaluation Procedure 9 x CO e amp 3 V SD a S o LH QS S S D e S D A Vdc C xc aS Q Q Li Float Conductance Vdc 24 Conductance Vdc Vdc 24 XN QU x Xx se amp LY ne mhos Hour mhos 100A after Hour GO Qe LS Q amp g ne 77 F ocv 77 F 25 C 10seconds ocv A 1 40HP 4 11 3m 2 70 134 2100 A 2 40HP 4 11 3m 2 70 13 5 2087 A 3 40HP 4 11 3m 2 70 134 2100 B 1 40HP 4 11 3m 4 70 134 2087 B 2 40HP 4 11 3m 4 70 134 2100 B 3 40HP 4 11 3m 4 70 13 6 2087 A 1 40HP 4 11 3m 7 8 E 85 13 3 2100 A 2 4 0 HP 3m 7 8 4 85 13 3 2087 A 3 40 HP 3m 7 8 4 85 134 2100 B 1 4 0 HP 3m 7 8 4 85 132 2087 B 2 4 0 HP 3m 7 8 4 85 132 2100 B 3 4 0 HP 3m 7 8 4 85 132 2087
17. Information eee cceeeeenesc eee ttene nett R nana tnmen nnne ua 28 7 1 AlphaCell Limited Warranty siens 28 7 2 Battery Maintenance Report for Return Authorizations ses 30 745 680 C5 002 Rev A Figures and Tables Fig 1 Capacity VS Storage lime eene c dn eed bnt tubo dde Po nlt cde eot as 8 Fig 2 Series Connected String Of Batteries iei eerie et rendir ur e tede ya ER eL AREE RE E ERR Speed 11 Fig 3 Parallel String of Batteries cic neri na tee ete eec AEE L EE ER CR ERE E CEN ob E eR YER Pune 11 Fig 4 Available Capacity vs Ambient Temperature sssssssseee eene 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 me ME 23 Table 1 Conductance values new vs suspect batteries 20 Table 2 Troubleshooting scssi rrt rete ted E pee d I C E npe dvo o CH ed isa deed dae e ais 24 Table 3 Battery Parameters Current Models sssssssssssssssseeeee eene 27 Table 4 Warranty Periods for AlphaCell batteries ssssseeennennnnnns 28 745 680 C5 002 Rev A 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 th
18. Operating Conditions AlphaCell HP batteries which are valve regulated and virtually sealed do not give off perceptible amounts of gas under normal operating conditions e Acceptable ambient operating temperature 40 F to 131 F 40 C to 55 C e Ideal ambient operating temperature 68 F to 77 F 20 C to 25 C e Ambient humidity lt 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 influenced by the depth of discharge the structure of the battery and the manufacturing technology During normal usage the factors that influence 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 f NOTE Although the battery can be operated at temperatures below 4 F 20 C the capacity and ability to discharge will be dramatically decreased Similarly temperatures approaching 122 F 50 C will increase electrolyte loss and corrosion of the plates resulting in a shorter battery life Efficiency VS Temperature AlphaCell 3 5HP and 4 0HP 10096 90 80 70 60 50 40 E 30 En 20 Percent Rated Capacity Available 10 0
19. PA United Kingdom Tel 44 1279 501110 Fax 44 1279 659870 Alpha Technologies Suite 1903 19 F Tower 1 33 Canton Road Tsim Sha Tsui China Hong Kong City Kowloon Hong Kong Phone 852 2736 8663 Fax 852 2199 7988 Visit us at www alpha com Alpha Technologies Ltd 7700 Riverfront Gate Burnaby BC V5J 5M4 Canada Tel 1 604 436 5900 Fax 1 604 436 1233 Toll Free 1 800 667 8743 Alpha Technologies GmbH Hansastrasse 8 D 91126 Schwabach Germany Tel 49 9122 79889 0 Fax 49 9122 79889 21 Alphatec Ltd 339 St Andrews St Suite 101 Andrea Chambers P O Box 56468 3307 Limassol Cyprus Tel 357 25 375 675 Fax 357 25 359 595 Alpha Innovations Brasil Avenida lbirapuera 2120 Cj 76 Moema 04028 001 Santos SP Brazil Tel 55 11 2476 0150 Fax 55 11 2476 0150 Alpha Industrial Power Inc 1075 Satellite Blvd NW Suite 400 Suwanee GA 30024 United States Tel 1 678 475 3995 Fax 1 678 584 9259 Technologies Argus First de Mexico Anatole France Num 17 Colonia Polanco 11560 M xico D F Tel 52 55 5280 6990 Alpha TEK ooo Khokhlovskiy Pereulok 16 Stroenie 1 Office 403 Moscow 109028 Russia Tel 7 495 916 1854 Fax 7 495 916 1349 Alphatec Baltic S Konarskio Street 49 201 Vilnius LT 03123 Lithuania Tel 370 5 210 5291 Fax 370 5 210 5292 Due to continuing product development Alpha Technologies reserves the right to change specifications without no
20. age Practices on page 8 Does battery meet the minimum conductance values per Table 1 Does battery meet the minimum of 12 6 Volts for the 24 hour OCV Fig 7 Flow Chart for Battery Refurbishment Plan 745 680 C5 002 Rev A 21 4 0 Battery System Float Charging Battery System Float Charging Voltage Encountering temperature extremes When you encounter temperature extremes temperature compensate the float charging voltage The temperature compensation coefficient 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 float 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 VIC 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 float current corrosion of the plate grids and gassing and drying of the limited amount of electrolyte Severe overcharging over extended pe
21. al 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 e Observe circuit polarities e 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 e 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 rectifier 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 8 745 680 C5 002 Rev A ass 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
22. cordance 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 fire 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 11 Field Batteries replaced through limited warranty terms and conditions will receive the balance of original warranty 12 All defective and replacement Batteries if returned become property of manufacturer 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
23. e 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 significant 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 Sx maintain consistent test results ensure the same Midtronics conductance tester is used for each test cycle Midtronics Conductance 3 5 HP 4 0 HP Models 3200 micro CELLTRON Approximate Conductance Values mhos 1400 1850 1700 2500 Healthy Battery 77 F 25 C Suspect Battery 77 F 25 C in mhos lt 680 lt 840 Table 1 Conductance values healthy vs suspect batteries 20 745 680 C5 002 Rev A 3 5 Battery Refurbishment Plan Battery Refurbishment Plan s Batteries Returned from Site Measure and document 24 hour Open Circuit Voltage OCV Must occur within 24 hours of removal from charger Measure Conductance Measure Battery Voltage Measure Battery Voltage Sort Batteries per Conductance amp Voltage Properly recycle batteries per EPA requirements Group re deployable batteries as indicated for future deployment as strings Batteries stored in warehouses for extended periods of time refer to Important Stor
24. ean and reassemble connection if damaged Replace batteries with damaged terminals Corrosion at terminals Possibly electrolyte leaking from battery terminal seal attacking the interunit container Increased connection resistance and resulting increase in the connection heating and voltage drop at high rate discharge 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 745 680 C5 002 Rev A 5 0 Troubleshooting continued Problem with Symptom Possible Causes Possible Result Corrective Actions System float voltage gt 2 3VIC average 77 F 25 C Charger output set incorrectly Overcharging causes excessive gassing and drying out of electrolyte and contributes to potential thermal runaway Reset the charger output voltage to recommended value System float voltage lt 2 25VIC average 77 F 25 C Charger output set incorrectly 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 Reset the charger output voltage to recommended value Equalize battery system from 48 to 72 hours and perform ca
25. ection hardware Refer to documentation for the correct torque and connection hardware for the application Donotattempt 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 e 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 e Always recycle used batteries in accordance with federal state provincial and local regulations The Alpha Group provides recycling services Call 800 863 3930 or contact your local Alpha representative 745 680 C5 002 Rev A Important Storage Practices
26. ential for shorted cells Replace battery system when at 70 of rated capacity or before Reduced operat ing time at 77 F 25 C with steep voltage decline or voltage plateaus Individual low capacity cells Reversed cells during discharge Reversed cells will become very hot and will not fully recharge Replace the isolated low capacity batteries Excessive initial voltage drop even to the point of dropping load in the first several seconds Battery is extremely cold Cabling is too small gauge High resistance connections Battery is undersized Shorted cells Excessive voltage drop Cells will become hot could develop thermal runaway internal arcing could result in an explosion 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 Visual Battery Checks Cover or container crack Handling or impact damage Cell dryout or ground fault Potential internal gas ignition Replace damaged unit Cover or container explosion 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 Personal injury and equip ment damage at time of explosion Failure
27. es 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 745 680 C5 002 Rev A 1 4 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 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 configurations TO POWER SUPPLY RED BLACK UPPER TRAY INLINE FUSE LOWER TRAY INLINE FUSE Front Fig 3 Parallel String of Batteries 745 680 C5 002 Rev A 11 1 0 Introduction continued 1 2
28. etermine specific ampere hour of battery Thermal runaway results in cause take corrective rated capacity at Depending on degree bat eventual meltdown of battery action 77 F 25 C at float tery entering or in thermal and potential of hydrogen voltage runaway sulfide emissions and fire Terminal voltage marginally below Battery perhaps not fully charged minimum voltage or is older in service battery and Perhaps reduced operating time Fully recharge battery specified for 10 has somewhat lower capacity second point high Rate 10 Battery discharged of Second Load Terminal voltage battery conductive path er Test CERES Reduced operating time significantly below plate grid or active material ES Conducive to thermal Charge retest battery minimum voltage or electrolyte volume ga AEA runaway or replace as required specified for 10 deterioration Will mot support load second point Shorted pp Open cells Imp dance Battery discharged or battery resistance increase Battery E conductive path plate grid or Reduced operating time by 50 from Charge and retest Impedance sa active material or electrolyte Conducive to thermal original values Se battery or replace as Conductance volume deterioration runaway or conductance 3 required Test Shorted cells Will not support load decline to 5096 of Open cells the value when new Retorque Repetitive cycles results A con
29. expressly authorized by manufacturer in writing and returned prepaid to its plant ALPHA SHALL NOT BE LIABLE FOR AND USER SHALL INDEMNIFY AND SAVE ALPHA HARMLESS FROM ANY CLAIMS AND LIABILITIES ARISING OUT OF THE USE MAINTENANCE TRANSPORTATION OR INSTALLATION OF ANY EQUIPMENT WARRANTED HEREUNDER THE FOREGOING LIMITED WARRANTY IS IN LIEU OF ALL WARRANTIES EXPRESSED OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE THE SOLE LIABILITY OF IS SET FORTH UNDER THE CLAIMS PARAGRAPH ABOVE SHALL NOT HAVE ANY LIABILITY FOR ANY SPECIAL INCIDENTAL INDIRECT OR CONSEQUENTIAL DAMAGES THIS LIMITED WARRANTY APPLIES ONLY TO THE ORIGINAL PURCHASER USER OF THE EQUIPMENT AND IS NON TRANSFERABLE 745 680 C5 002 Rev A 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 745 680 C5 002 Rev A 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 faxit 360 671 4936 This form in conjunction with Al
30. ics 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 float 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 7096 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 7596 capacity which ever comes first 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 float 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 7096 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 7596 capacity which ever comes first depending on the storage temperature AND 100A Load Test Measure th
31. is 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 specific regulatory code requirements that may affect the placement of equipment and installation procedures f NOTE A NOTE provides additional information to help complete a specific task or procedure A caution The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or equipment a WaRnina A WARNING presents safety information to PREVENT INJURY OR DEATH to the technician or user 6 745 680 C5 002 Rev A iss 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 e 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 specified in this document Signs of battery cable damage Battery cable should be replaced immediately by authorized personnel using replacement parts specified by vendor Loose battery conn
32. nection as Loose connections result d in heating and cooling of required NA in heat damaged or melted connection resulting in 5 Correct source Connection f terminals during high rate SCR relaxation of torque increase of contamination resistance increase discharge in connection resistance E clean contact Connection 20 or more from ups e Excessive voltage drop i Contamination within surface areas Hardware original value 3 during high rate discharge 3 the connection results in grease contact Resistance 5 2 and resulting reduced 2 corrosion and high terminal PRUNUS surfaces with anti Tightness 5 operating time resistance oxidant grease Check reassemble Connection t 3 Repetitive cycles results in heat hardware tightness Loose connections result in heat ing and cooling of connection re Retorque the is less than the enr s damaged or melted terminals d ae Sulting in relaxation of torque and connection as required specified retorque during high rate discharge walle increase in connection resistance AC ripple p p Excessive AC ripple could cause the battery to cycle at the ripple voltage on system Improve the charger 6 Poor filtering of charger output frequency and result in heating ON lt 4 of the value of Due output filtering and deterioration of the plate ac the DC float voltage AC Ripple tive material
33. nformation e NO OX Corrosion Inhibitor e Paper Towels and or rags 745 680 C5 002 Rev A 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 e 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 Monitor as per PM Monitoring Data Program RTS Temperature gt 10 C above Ambient Battery Voltage gt 0 5V Above Below String Average No Perform gt Quarterly PM 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 Ifthe RTS temperature is greater than 10 degrees C above the current regional ambient temperature then a site visit is required Prioritize site visits ba
34. pacity test If capacity loss is permanent replace the total battery system Potentially the Reduced operating time DC Voltage T individual battery has under load Increased float Individual battery float E Checks shorted cell current Heating of cell during Replace individual battery voltage 13 3 Vdc Sos Verify with impedance discharge Contributes to or conductance check potential thermal runaway Potentially open cells in Individual battery float navigus battery Contirm Failure to support load Could by checking for zero float one voltage 14 5 Vdc for result in an internal arc could Replace individual battery current or check for very ae ise 6 cell men ignite gasses within the cell high impedance of the battery DU voliage measured Personnel shock hazard between battery system es resulting in serious output terminals and Damaged container allow P Determine the source of f injury or electrocution ground rack or a ing electrolyte to wick out ground fault and replace ds Potential burning of ground fault indicated to grounded surface rack gt battery ien container at damaged by automatic monitoring area or battery fire equipment Elevated room tem Lack of adequate air condi a Cool room or accept reduced DENS epe Reduced battery life perature tioning or ventilation battery life Reduced battery life Elevated room temp 3 Improve room air
35. pha s Battery Evaluation Procedure is intended as a method of collecting data critical to the efficient processing of your warranty battery claims Record battery float 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 Evaluation Procedure Initial Mfr P Install Date PM Float Battery History Current Temperature Date Code Conductance Conductance Vdc 100A Conductance Vdc Float Vdc 24 No Load mhos Hour OCV mhos after 10 mhos p Ws E MITES seconds WIRES 745 680 C5 002 Rev A This page intentionally blank Alpha Technologies Inc 3767 Alpha Way Bellingham WA 98226 United States Tel 1 360 647 2360 Fax 1 360 671 4936 Alpha Energy 1628 W Williams Drive Phoenix AZ 85027 United States Tel 1 602 997 1007 Fax 1 623 249 7833 Alpha Technologies Europe Ltd Twyford House Thorley Bishop s Stortford Hertfordshire CM22 7
36. plosion A battery showing signs of cracking leaking or swelling should be replaced immediately by authorized personnel using a battery of identical type and rating Mechanical Safety Keep hands and tools clear of fans Fans are thermostatically controlled and will turn on automatically Power supplies can reach extreme temperatures under load Use caution around sheet metal components especially sharp edges Depending on the model batteries can weigh anywhere from 25 to 100 pounds 11kg to 45kg Exercise care when handling and moving batteries Use proper handling equipment 745 680 C5 002 Rev A 10 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 specifications 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 practic
37. riods of time can induce a thermal runaway condition This requires replacing the battery system NOTE v i following set points are recommended for AlphaCell HP Batteries when used with the XM Series 2 or GMX Power Supply AlphaCell HP Batteries Accept 2 35 VIC Float 2 25 VIC Temp Comp 4mV C C 745 680 C5 002 Rev 4 0 Battery System Float Charging continued NOTE v following information specifically pertains to Alpha XM Series 2 and HP Power Supplies 4 14 Alpha Power Supply Charging Profile 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 specific 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
38. sed on highest RTS temperatures and battery voltages Visit the site within 30 days and remedy the problem by replacing the bad battery or batteries and reset quarterly maintenance 745 680 C5 002 Rev A 15 16 3 2 Quarterly Preventive Maintenance Required Equipment e True RMS Volt Meter with DC Amp Clamp Midtronics Conductance Battery Tester Remote Status Monitoring Procedure Site Visit Ensure Power Supply is in Float Mode Battery String Float Current Yes gt 0 5A Disconnect Batteries Program Does the individual battery pass No the Evaluation Procedure 1 outlined in Section 3 4 see page 18 No from the average string voltage Replace the individual failed battery with a battery that is within 3 Volts of the string average Log each battery s conductance and voltage Replace the string Return battery to warehouse Fig 6 Flow Chart for Quarterly Preventive Maintenance Battery Refurbishment Plan Record Information on Site Visit Record Ll Monitor as per PM 745 680 C5 002 Rev A 3 2 Quarterly Preventive Maintenance continued Procedure Verify the power supply is in Float mode Use the DC Amp clamp to measure and record each individual battery string s float current If the individual string float current is greater than 0 5
39. tice 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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