Fiamm FLB Battery Installation & Operating Instructions
Contents
1. lco 45 ko Industrial Batteries mE amp C 4 E m EA A 3 MI MI a3 r ch 2 1 5 FIAMM Standby Batteries 9 gt 9 gt gt gt SS 9 This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication TABLE OF CONTENTS INTRODUCTION ku CONSTRUCTION FEATURES 4 Plates Containers Separators Electrolyte Vent Plugs Terminal post OPERATING FEATURES Capacity Se Capacity in relation to discharge rate Capacity range of FIAMM Flooded Lead Acid Batteries Capacity in relation to the temperature ste Internal impedance and short circuit current Storage of filled and charged cells Storage of dry charged cells Service life Gassing Operation of batteries in parallel Electrolyte Specific Gravity State of charge COMMISSIONING CHARGE FIRST CHARGE Dry charge cells Filled and Charged Cells CHARGING Floating charge Boost charge Recharge following a discharge Equalize voltage BATTERY INSTALLATION Installation Battery room requirements Installation amp Operating Instruction Technical Manual Edition 06 2013 EMEA SAFETY Protective Equipment Battery disposal MAINTENANCE Battery care Cleaning V2. Methods of tests e IEC 60896 Part 22 S Stationary lead acid battery Valve Regulated Type Requirements e EN 50272 2 Safety requirements for secondary batteries and battery installations Part 2 Stationary batteries e BS 6290 4 Lead acid stationary cells and batteries Specification for classifying valve regulated types e BS 6290 1 Lead acid stationary cells and batteries Specification for general requirements Page 9 of 9 Edition 06 2013 EMEA FIAMM Standby Batteries MAINTENANCE Battery care GASES GIVEN OFF BY BATTERIES ON CHARGE ARE EXPLOSIVE DO NOT SMOKE OR PERMIT OPEN FLAMES OR DO ANYTHING TO CAUSE SPARKS NEAR BATTERIES 1 Keep the battery and surroundings clean and dry 2 Make sure that bolted connections are properly tightened see table in INSTALLATION paragrapf 3 Usually it 1s not necessary to apply greese on the bolts and connectors in any case No oxide grease increase the protection against corrosion 4 Should any corrosion of the connections occur because of spilled acid etc carefully remove corrosion materials thoroughly clean and neutralize with diluted ammonia or baking soda 5 Keep the battery at the recommended charge voltage see CHARGING section 6 The room in which the battery is installed should be well ventilated and its temperature as close as possible to 20 C 7 Do not try to open the cover valve Cleaning When necessary batteries could be cleaned
3. o a Fig 1 Typical discharge curves for FIAMM AGM batteries FIT range Capacity in relation to discharge rate The available capacity of all lead acid batteries depend on discharge rate discharge current this is due to internal electrochemical process and type of construction 1 e type of positive plate available capacity 96 hours Fig 2 Average available capacity versus discharge rates for FIAMM AGM batteries This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual Capacity range of FIAMM AGM Lead Acid Batteries FIAMM Capacity range Battery range Ah UMTB from 60 to 160 FIT from 40 to 180 SLA from 25 to 2000 FLB from 26 to 235 from 26 to 235 Capacity in relation to the temperature The capacity available from a battery at any particular discharge rate varies with temperature Batteries which have to operate at temperatures different from the nominal 20 C need a higher or lower capacity as per the factor indicated in the following graph required capacity has to be multiply by the correction factor stated in the graph 1 0 0 9 0 8 15 30 min discharge rate 1 10 hours discha
4. Port Road 02 04 CWT Distripark SINGAPORE 619097 Tel 65 6867 6152 Fax 65 68626550 info standby asia fiamm com CHINA FIAMM ENERTECH CO LTD Hannan Road 458 Shamao Town Hannan District Wuhan City Hubei Province P R CHINA P C 430090 Tel 86 27 84782000 Fax 86 27 84782888 info standby asia fiamm com General brochure EMEA 2012 02
5. UMTB range RVS top side used for SLA FLB SP FIT UMTB range TOP TERMINAL CONNECTION is mainly used for FIAMM battery range SLA FLB SP as well Front Terminal Connections Suitable solid connectors made of copper thin or lead plated and covers made of ABS are provided to make a propper installation between blocs Designed for FIAMM front terminal range UMTB FIT using a special L clamp a SOLID CONNECTOR 85 cover o CLAMP Page 4 of 4 This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication FIAMM Standby Batteries OPERATING FEATURES Capacity The battery capacity is rated in ampere hours Ah and is the quantity of electricity which it can supply during discharge The capacity depends on the quantity of the active materials contained in the battery thus on dimensions and weight as well as the discharge rate and temperature and minimum voltage The nominal capacity of FIAMM batteries refers to the 10 hrs discharge rate indicated with Cio with constant current at 20 C to 1 80 volt per cell eer 12 5 MT RET 77 a 120 088 C10 120 1 C10 Bloc Voltage Volt o o 120 15 C10 120 27 C10 o 120 5 C10 120 85 C10
6. air it basically consists of 80 90 hydrogen is very low and thus it is clear that FIAMM VRLA batteries can be installed in rooms containing electric equipment with no explosion danger or corrosion problems under normal conditions In any case these rooms or cabinets must have a natural or forced ventilation and not be fully sealed Please refer to VENTILATION for information on required air exchange Fig 5 Approximate state of Charge versus Open circuit cell voltage Operation of batteries in parallel When the required capacity exceeds the capacity of a single string of batteries it 1s possible to connect more strings in parallel paying attention to the following guidelines This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication FIAMM Standby Batteries Installation amp Operating Instruction Technical Manual Edition 06 2013 EMEA RECHARGING limited to no more than once per month to ensure the maximum service life of the battery In order to ensure the best protection against power failures in any moment it 1s necessary that batteries are kept in the following conditions 120 e in float charging throughout all their standby period 100 e fully recharged soon after a discharge e completely recharged af
7. dispersion of explosive gas depends on the gas release rate and the ventilation close to the source of release For calculation of the safety distance d from the source of release the following formula applies assuming a hemispherical dispersal of gas The safety distance d is given from the following formula d 28 8 X N x AJ Tgas X A Crt where N depends on the number of cells per monoblock battery N or vents openings per cell involved 1 N For further information please refer to EN50272 Standard or contact FIAMM at infostandby fiamm com Note A calculation program is available on request Page 13 of 13 Edition 06 2013 EMEA Industrial Batteries SALES OFFICES EUROPE FIAMM S p A Viale Europa 63 Montecchio Maggiore 36075 VI ITALY Tel 39 0444 709311 Fax 39 0444 694178 info standby fiamm com MIDDLE EAST amp AFRICA FIAMM S p A Viale Europa 63 Montecchio Maggiore 36075 VI ITALY Tel 39 0444 709311 Fax 39 0444 694178 info standby fiamm com www fiamm com NORTH AMERICA FIAMM Energy LLC Battery Division 1 Fiamm Way Waynesboro GA 30830 USA Tel 1 706 437 3220 Fax 1 706 437 3300 info standby america fiamm com LATIN AMERICA FIAMM Latin America Ltda Av Piraporinha 121 CEP 09891 0000 Sao Bernardo do Campo SP Brasil Tel 55 11 3737 6137 Fax 55 11 3737 6116 baterias industriais fiamm com ASIA PACIFIC FIAMM ASIA PACIFIC Pte Ltd 24 Jurong
8. kept clean e Elevated temperatures direct and indirect sunshine have to be avoided e Optimum storage temperature rang is 10 C to 30 C e Avoid storage in ambient with a relative humidity greater than 90 e Battery cells must be protected from harsh weather moisture and flooding e Storage on a pallet wrapped in plastic material is permitted in principle However it is not recommended in rooms where temperature fluctuates significantly or if high relative humidity can cause condensation under the plastic cover e With time this condensation can cause a whitish hydration on the poles and lead to high self discharge by leakage current e Atmospheres with chemical contaminants have to avoid e Do not load other merchandise on top of unprotected batteries e Battery cells must be protected from dropping objects from falling down and falling over e Battery cells must be protected from short circuits by metallic parts or conductive contaminations This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual avallable capacity 6 e Avoid storing of unpacked battery cells on sharp edged supports e Stacking of pallets is not permitted unless otherwise speci
9. test battery SHOULD NOT BE ABLE TO SUPPLY ENERGY IN CASE OF MAIN FAILURE Dummy load is usually necessary to provide the request discharge current Test is usually carried out to verify the battery capacity to a specify end voltage and discharge rate usually 1 3 or 10 hours Test must be conducted in accordance with EN 60896 21 22 Please refer to prescription indicated in the above standard Record at regular intervals every half an hour at the beginning every 10 minutes the last half an hour cell bloc voltage battery temperature on pilot cell discharge current total battery voltage in any case voltage reading has to be made at least at 25 50 and 80 of the discharge time Accordin IEC60896 21 the discharge shall be terminated when one of the following values fj whichever comes first has been recorded l tgisch the elapsed time of discharge of the string with n cells to a voltage of n x Using V 2 1 the elapsed time when the first of the unit in the string reached a voltage of unit voltage U Unna 3 x 02 At the end of discharging test batteries have to be recharged immediately The following formula determinates the battery capacity C discharge current X tgiscn where taisen 1s indicated in hours For temperatures different from the nominal 20 C and discharge rates between 3 to 10 hours the battery capacity shall be corrected as follows B C Where Cn C T33 8 20 9 ini
10. using a soft dry antistatic cloth or water moistened soft antistatic cloth paying attention not to cause any ground faults No detergent nor solvent based cleaning agents nor abrasive cleaners should be used as they may cause a permanent damage to the battery plastic container and lid Voltage checks All voltage measurements should be made when the whole battery has stabilized on floating at least 7 days after battery installation or after a discharge charge cycle To facilitate voltage reading in the correspondence of each block terminal protection covers are designed with a safe and proper hole Measure and record individual block voltages on float once a year It is normal to have a spread of block voltages at 20 C up to 2 27 eon V 13 62 9 29 for a 12 volt battery particularly in the first year of operation No corrective action is required in this case Maintaining a correct battery charging voltage is extremely important for the reliability and life of the battery So it is advisable to carry out a periodical checking of the overall float voltage to verify any possible defect of charger or connections Cell Appearance Any cells showing corrosion container bulging high temperature than the other cells should be regarded as suspect Such cells should be carefully examined and expert advice should be obtained immediately from FIAMM This document and the confidential information it contains shall be distribut
11. 1 Record the floating voltage of each cell as well as the total system voltage 2 Check the actual load A or W as well as the minimum admissible voltage of the system 3 On FIAMM discharge tables you can approx determinate the discharge rate minutes of discharge Please note that battery performances change decrease with battery age After switching off the rectifier discharge the battery for a time of 20 of that calculated discharge rate 4 During the discharge record at regular intervals cell block voltage battery temperature discharge current total battery voltage 5 For safety reason during the test assure that the total battery voltage remains above the minimum depending on discharging rate in order to avoid any failure to the system please note that approaching to the final voltage the voltage curve decreases rapidly 6 For particular comments on test s data please refer to FIAMM technical offices Capacity test This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual Edition 06 2013 EMEA Please carry out this test only when complete information on the quantity of energy inside the battery is requested Take precautions because after this
12. 72 2 During normal operating conditions lead acid batteries emits low quantity of gases which can reach an explosive mixture when hydrogen concentration is higher than Lower Explosion Limit LEL threshold which is 4 vol The purpose of ventilating a battery location or enclosure by natural or forced artificial ventilation is to maintain the hydrogen concentration below the above stated limit Battery locations and enclosures are to be considered as safe from explosions when the concentration of hydrogen is kept below this safe limit The minimum air flow rate for ventilation of a battery location or compartment shall be in accordance with European Standard EN 50272 calculated by the following formula Q 0 05 x Nx Teas X Citx X 10 where Q ventilation air flow in m h N number of cells each 2 Volt Cy capacity Clo Ah at 1 80 volt cell at 20 C The current lpas mA Ah producing gas as indicated in the table of the above mentioned standard con be assumed as Izas 1 For batteries on float Teas 5 For batteries on boost charge Determination of openings The amount of ventilation air flow shall preferably be ensured by natural ventilation otherwise by forced artificial ventilation Battery rooms or enclosures require an air inlet and an air outlet with a minimum free area of opening calculated by the following formula A 28xQ with Q ventilation flow rate of fresh air m h A free area of openin
13. M8 Female 10 12 88 106 SLA M10 Female 20 25 175 220 FLB M6 Female 7 9 62 80 SLA UMTB M Male 7 8 65 70 FIT UMTB M6 Male sy 44 62 This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual 11 Insulate all the connectors by means of the plastic covers being supplied with the battery accessories 12 Affix the cell number stickers to the cell jars making sure that the surfaces are dry and clean It is usual to number the cells beginning with 1 at the positive end of the battery numbering consecutively in the same order as the cells are connected electrically through to the negative end of the battery 13 Check the total battery voltage which should comply with the total number of cell connected in series 14 The cells are usually designed to be installed in vertical position the horizontal position could in some cases stress the cells Here below the correct cell arrangements for large capacity AGM cells Example of installation and cell arrangement position of poles of AGM batteries with capacity equal or higher than 800Ah Batteries installed into cabinet For safety reasons we would not recommend to pre assemble the blocs into
14. be made of wood or metal with a coating of acid resistant paint If metal racks are used they must be fitted with rubber or plastic insulators to prevent the cells coming into contact with the metal e To facilitate proper battery operation maintenance and care post a battery data card instruction table in a conspicuous place near the battery to provide the attendant with service information and data SAFETY It is recommended that full precautions be taken at all times when working on batteries The safety standards of the country of installation must be risk explosives gasses heavy components Protective Equipment Make sure that the following equipment is available to personnel working with batteries e Instructions manual e Tools with insulated handles e Fire extinguisher e PPE Personal Protective Equipment must be worn glasses gloves aprons etc To avoid static electricity when handling batteries material of clothing safety boots and gloves are required to have a surface resistance o lt 10 Q and an insulation resistance gt 10 Q e First aid equipment must be available Safety Precautions Observe the following precautions at all times This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this pu
15. blication Installation amp Operating Instruction Technical Manual e Batteries are no more dangerous than any other equipment when handled correctly e Do not allow metal objects to rest on the battery or fall across the terminals even when disconnected a battery remain charged e Never wear rings or metal wrist bands when working on batteries e Do not smoke or permit open flames near batteries or do anything to cause sparks e Do not try to remove the battery cap to add water or acid into the cell s e Never lift or pull up the battery at the terminals e Air exchange must be provided to prevent the formation of explosive hydrogen concentration e For further information please refer to EN 50272 2 Safety requirements for secondary batteries and battery installations Part 2 Stationary batteries Battery Disposal Lead acid batteries must be disposed according to the country law It is strongly recommended to send batteries for recycling to a lead smelter Please refer to the local Standards for any further information these batteries need to be collected separately for wast disposal As of the 31st of December 1994 all Valve Regulated Lead Acid VRLA battery has to have the following symbols present in conformance to EG guideline 93 86 EWG SELECTION OF STANDARDS APPLICABLE FIAMM Valve Regulated Lead Acid Batteries comply with e IEC 60896 Part 21 Stationary lead acid battery Valve Regulated Type
16. e range of internal pressures and conditions of thermal cycling Intercell connections in the FIAMM multicell AGM battery design are electrically welded through the cell walls to minimise the internal impedance while maintaining complete separation of the individual cells Special plastic terminal caps are provided for transportation assuring a protection against short circuit during transportation Cutaway drawing of FIAMM AGM cell le va TYPICAL TOP TERMINAL BLOCK TYPICAL FRONTAL TERMINAL BLOCK Venting strip Positive plate Battery plastic lid Terminal Battery plastic container Plates strap Negative plate Through cells partition welding AGM Absorbed Glass Mat separator 0 Safety valve Page 3 of 3 Edition 06 2013 EMEA FIAMM Standby Batteries Installation amp Operating Instruction Technical Manual Edition 06 2013 EMEA Connections Suitable solid connectors are made of tin or lead plated copper suitable insulated plastic are made of ABS V0 From 5 to 10 mm Remote Venting System RVS Most of FFAMM AGM batteries are designed with an optional central degassing system on the top lid covering sheet So if batteries need to be installed in a totally sealed cabinet it is advisable to use the remote venting system available from the manufacturer to conduct any gas from the batteries to the outside of the cabinet itself RVS front side used for FIT
17. ed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual Pilot Cell For regular monitoring of the battery condition select one or more cells of the battery as a pilot cell s for batteries comprising more than 60 cells select one pilot cell for every 60 cells Periodic Inspections Written records must be kept of battery maintenance so that long term changes in battery condition may be monitored The following inspection procedures are recommended EVERY SIX MONTHS e Visual inspection on cells racks appearance cracks or corrosion signs electrolyte leakage e check and record the overall float voltage at the battery terminals not at the charger measure and record the pilot cell s voltage e measure and record the pilot cell s temperature e room ventilation YEARLY all the controls indicated at six months check and record the voltage of all cells measure and record the pilot cell s temperature make sure all connection are torque according to connection torque table in case of frequent high discharge current please consider to check e clean the cells Page 10 of 10 Edition 06 2013 EMEA FIAMM Standby Batteries BATTERY TEST Test must be conducted in accordance with EN 60896 2122 Bef
18. erent temperatures Boost charge Recharge following a discharge Boost charge has to be used to recharge a battery after a discharge it will restore the battery to a fully charged state within a relatively short period of time Use a constant voltage 2 4 V cell at 20 C with a maximum current of 0 25 C10 However this recharge should be Page 7 of 7 This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication FIAMM Standby Batteries BATTERY INSTALLATION All necessary precaution must be taken when working with lead acid batteries as per electrical risk explosives gasses heavy components corrosive liquids Use insulated tools and wear protective equipment Installation FIAMM front terminal valve regulated recombination batteries can be fitted on stands or into cabinets FIAMM offers a wide selection of stands from one tier one row to six tiers three rows to suit most applications Cabinets are available with or without circuit breaker and its relevant compartment l Avoid any impact or shock which could cause breaking or micro fractures to container Do not lift cells by its terminals 2 Make sure that all cell jars and covers are thoroughly clean and dry 3 Synthetic cleaning cloths must not be used Clean l
19. fied e It is recommended to realize the same storage conditions within a batch pallet or room Storage time Temperature e VRLA battery ranges have a shelf life of 6 months at a storage temperature of 20 C e The temperature has an impact on the self discharge rate of battery cells e Higher temperatures increase the rate of self discharge and therefore storage life is reduced e FIAMM AGM batteries have a self discharge rate of lt 2 per month at 20 C and therefore are stored for prolonged periods of time e MAXIMUM storage period before refresh at the given average storage ambient temperature 1s as follows 6 months at 20 C 4 months at 30 C 2 months at 40 C Storage Recharge e As during storage batteries will lose part of their capacity due to self discharge lt 2 per month at 20 C a refreshing charge must be given 1 when MAXIMUM STORAGE TIME 1s reached OR 2 when the OCV open circuit voltage approaches 2 11 Volts cell whichever occurs first Recharge the cells as directed in FIAMM S instruction table for AGM battery type Usually at 2 4 volt per cell for a period of 24 hours at 20 C Recharge is not necessary Refreshing charge must be applied as soon as possible It is important to avoid this area months Fig 6 Storage time versus temperatures Page 12 of 12 Edition 06 2013 EMEA FIAMM Standby Batteries VENTILATION in accordance with EN 502
20. g in air inlet and outlet cnr Note For the purpose of this calculation the air velocity is assumed to be 0 1 m s The air inlet and outlet shall be located at the best possible location to create best conditions for exchange of air 1 e e openings on opposite walls e minimum separation distance of 2 m when openings on the same wall The following picture gives an indication of the correct opening to assure a complete battery room air exchange This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual Forced ventilation Where an adequate air flow Q cannot be obtained by natural ventilation and forced ventilation 1s applied the charger shall be interlocked with the ventilation system or an alarm shall be actuated to secure the required air flow for the mode of charging selected The air extracted from the battery room shall be exhausted to the atmosphere outside the building Close vicinity to the battery In the close vicinity of the battery the dilution of explosive gases is not always secured Therefore a safety distance extending through air must be observed within which sparking or glowing devices max surface temperature 300 C are prohibited The
21. ids and containers only with antistatic cotton cloths soaked in a solution of mild soap and completely wrung out 4 Should the terminal posts have a white film on them lightly abrade their contact surfaces using a Scotchbrite pad or fine grit abrasive paper to remove any surface oxidation 5 Do not lift cells by terminals do not use terminals as point of lifting during handling installation process 6 Place the single units at their correct position according to the electrical layout 7 In order to allow heat dissipation a minimum distance of 5 10mm between cells blocs is recommended this is normal using FIAMM standard connectors for special requirements please contact FIAMM 8 Care must be taken to avoid short circuiting the cells with any of the battery hardware 9 Start with the lowest shelf to ensure stability Carefully preserve the sequence positive negative positive negative throughout the whole battery Flexible cable connectors for connecting from one shelf to the one below will be applied once that all the blocs have been connected we would suggest to connect such inter shelf or inter row cable connectors at the final User s premises only 10 To ensure a good electrical contact between the bottom of each terminal and the connecting strap and at the same time to ensure that the threaded terminals are not damaged by excessive torque use a torque spanner set on the value of a ee Ce SLA UMTB FIT FLB
22. o the lids to facilitate handling Separators e The separators are made of glass microfibre mats by a special process which results in a high porosity with very small pore diameters to ensure maximum oxygen diffusion while maintaining high plate utilisation and low internal resistance The plates are completely wrapped by the separator and the electrolyte is completely absorbed in the separator and plates By this method the shedding of active material which during the battery life causes shorting with flooded battery construction is avoided Electrolyte The electrolyte is sulphuric acid of 1 3 sp gr at 20 C with same purity characteristics as other types of high quality lead acid batteries Valves D Each cell has a one way valve to permit the release of gases from the cell whenever the internal pressure exceeds the fixed safety value The valve is rated at 0 15 0 30 atmospheres 15 30 Kpa Terminal posts E This document and the confidential information it contains shall be distributed routed or made available solely with written permission of FIAMM FIAMM S p A reserves the right to change or revise without notice any information or detail given in this publication Installation amp Operating Instruction Technical Manual Suitable threaded post design male or female pole with solid connectors are provided to ensure low ohmic losses Post to lid seals are designed to prevent leakage over a wid
23. oltage checks Specific gravity reading Cell Appearance Pilot Cell Periodic Inspections BATTERY TEST APPLICABLE STANDARDS Page2 of 2 FIAMM Standby Batteries INTRODUCTION In a high technological environment it is extremely important to have a backup power source whenever possible In fact mains power failure could cause severe losses and damages anytime FIAMM has been developing throughout years of research and experience several ranges of Absorbed Glass Batteries AGM to ensure the best reliability and quality CONSTRUCTION FEATURES The main construction features of FIAMM AGM batteries are shortly described in the below section Plates A Both positive and negative plates are of the flat pasted type The active material is made of a paste of lead oxide water sulphuric acid and other materials needed to obtain the performances and stability required throughout the battery life The grids are made of a high quality lead alloy with calcium and tin which assures good resistance against corrosion Containers B Battery cases and lids are made of a type of ABS which complies with American Standards UL 94 class V 0 and with IEC 707 method FVO This material is shock resistant and flame retardant They are also designed to fully withstand the internal pressure variations during battery operation This is further ensured by reinforced container walls and lids Handles have been designed for some batteries int
24. ore any discharging test batteries have to be properly repared with a boost charge 2 4 volt per cell for 24 hours at 20 C to ensure they are in a fully charge condition In order to take temperature readings of a battery one pilot cell or block shall be chosen The surface temperature of the container wall centre of each pilot cell or block shall be measured immediately prior to the discharge test The individual readings shall be between 15 C and 30 C The temperature of the selected block shall be considered as representative of the average temperature of the battery It is desirable that the average cell surface temperature and the ambient temperature fall as nearer to the reference temperature of 20 C or 25 C as possible In case of batteries having a capacity lower than 80 of the nominal rating it is advisable to replace them within 12 months Here below some precaution to be taken e Discharge must be stopped at the final discharge voltage e Deeper discharges must not be carried out unless specifically agreed with FIAMM e Recharge immediately the battery after each full or partial discharge test Service Functional test This is a test of the battery s ability to satisfy the design requirements of the system It means to discharge the battery directly to the load in this case take precautions to ensure that a battery failure does not jeopardise other equipment or dummy load to simulate a main failure
25. rge rate 0 7 Temperature correction factor 0 6 0 5 Temperature Fig 3 Capacity Correction factor versus temperature for a 10 hours discharge rate for FFAMM Lead Acid AGM batteries Internal impedance and short circuit current The internal impedance of a lead acid battery is a direct result of the type of internal construction plate thickness number of plates separator material electrolyte sp gr temperature and state of charge The internal resistance and the short circuit current of FIAMM VRLA batteries at 100 state of charge and 20 C is indicated in the relative Product Sheet These values are calculated in accordance with IEC 60896 part 21 22 Different instruments are available to detect the internal resistance or impedance of lead acid batteries These instruments use a different way to determinate these values The values obtained from these instruments will be different to the values stated in FIAMM Product Sheet Edition 06 2013 EMEA FIAMM Standby Batteries Installation amp Operating Instruction Technical Manual Edition 06 2013 EMEA Service life e ineach string only cells or monoblocs of the same type model and quantity should be used According to the main international standards a battery is e a symmetrical layout of the batteries should be considered at the end of its service life whenever designed i e length and type of connector to delivering less than 80 of its nominal capaci
26. ter a discharge Recharge as soon as possible to ensure maximum protection against subsequent power outages Early recharge also ensures the maximum battery life 80 Et sl IER ES E a p Fe FR i RIDE A pe a a a say Da IRN O O Y A A a 1 0 05 C10 RS Bb U b Recharged Capacity Ah 40 Floating charge 20 INI ILS ENE AINT TTT TT NUE TTT TT TNT GG a a tO P OCR Floating battery systems are those where the charger the ox cr tee et estan nn ee en ec eal battery and the load are connected 1n parallel 0 5 10 15 20 The float setting will maintain the battery in a fully meus charged state with minimal water consumption The voltage recommended for float charge 1s 2 27 V at 20 C The recommended float voltages to maximise the battery life over the range of temperatures between 20 and 60 C are shown in the figure 6 The normal float current observed in fully charged FIAMM front terminal batteries at 2 27 VPC and a temperature of 20 C is approximately 0 3 mA Ah Because of the nature of recombination phenomena the float current observed in the case of the FIAMM front terminal batteries is normally higher than that of vented batteries and is not an indication of the state of charge of batteries NN NON D E g Fig 7 Recharge curves at 2 4 volt per cell with different limit of current Temperature C Tempearture F Float Voltage V cell Fig 6 Recommended Float Voltage at diff
27. the cabinets before shipment to the final Customer However if this is normal practice for some system makers we would strongly recommend to pay special attention to protect the battery system from mechanical stress and vibrations occurring during transport For this purpose we would require to properly fasten all the blocs to the relevant cabinet shelves by means of plastic band and or other adequate methods Furthermore the cabinet should be protected in the outside with shock absorbing packaging material in order to prevent any transmission of vibrations to the internal components such as the battery blocs Special precautions must be taken to avoid accidental short circuits do not connect all the batteries divide the battery circuit low voltage parts For any further information please refer to EN50272 Standard or contact FIAMM at info standby fiamm com Ripple Residual Ac ripple is usually present in the output voltage of chargers amplitude and frequency depends on charger design and it can affect negatively the battery life Ripple could increase water loss battery temperature and accelerate corrosion with a result to reduce the battery life It is recommended therefore that voltage regulation across the system including the load but without the battery connected under steady state conditions shall be better than 1 through 5 to 100 load Transient and other ripple type excursions can be accommodated provided that
28. tial pilot cell temperature C A 0 006 for tests gt 1 hour A 0 01 for tests 1 hour Trending battery capacity during years will provide information in predicting when the battery will no longer meet design requirements Page 11 of 11 FIAMM Standby Batteries UNPACKING Inspection Upon receiving a shipment of battery cells it is advisable to open the shipping containers and carefully check the cells and hardware against the packing list The contents of each consignment are carefully inspected by FIAMM before shipment Any damage must be reported immediately to the carrier and the damaged items retained for inspection by the carrier s representative Handling Monolite units are shipped fully charged and must be treated with care at all times The product is capable of supplying high short circuit currents even if the case or lid are damaged Always lift the individual unit from underneath or by the build in lifting handles Never apply force to or drop anything on the terminal posts doing so may damage the threads or the post seals STORAGE Storage prior to installation VRLA batteries range are delivered activated filled and charged ready for installation If they cannot be installed immediately the following instructions need to be respected Storage Conditions A good storage practice requires as follows e Battery storage area has to be clean cool and dry e Surroundings have to be
29. ty The minimize possible resistance variations recommended operating temperature range is between e the quantity of strings in parallel should be 10 C to 30 C FIAMM VRLA batteries can operate over reasonable in terms of layout and application a temperature range of 20 to 50 C and higher Usually 4 strings could be connected in parallel operation at temperature higher than 20 C reduces life However depending on strings voltage and cables expectancy according to the graph in figure 4 length a higher number of strings could be safely connected to reach required total capacity 120 E ERNE die ca d 100 L P The measurement of the open circuit voltage battery has to be disconnect from charger system for at least 24 hours provides an approximate indication of the state of charge of the cells 80 Battery Life 96 Open Circuit Voltage V cell TEMPERATURE C Fig 4 Expected service life vs working temperature State of Charge Gassing All Lead Acid Batteries emits gases during the charge process FIAMM VRLA batteries have a high recombination efficiency gt 98 and for cells operated at 20 C under normal operating conditions venting is virtually negligible Laboratory test measurements show the following gassing rates e 2ml Ah cell month at a float voltage of 2 27 V cell e 10 ml Ah cell month at a recharge voltage of 2 40 V cell The quantity of gas given off in the
30. with the battery disconnected but the load connected the system peak to peak voltage including the regulation limits falls within 2 5 of the recommended float voltage of the battery Under no circumstances should the current flowing through the Page 8 of 8 Edition 06 2013 EMEA FIAMM Standby Batteries battery when it is operating under float conditions reverse into the discharge mode Battery room requirements e The battery room should be dry well ventilated and have its temperature as moderate as the climate will allow preferably between 10 C and 30 C e DO NOT permit smoking or the use of open flames in the battery room e Adequate ventilation to change the air in the battery room is essential to prevent an accumulation of the gases given off during charge for further information please refer to VENTILATION paragraph e The battery will give the best results and life when working in a room temperature of 20 C but will function satisfactorily when operating in temperatures between 20 C and 60 C High temperatures increase the performance but decrease the life of the cells low temperatures reduce the performance e Do not allow direct sunlight to fall on any part of the battery e Ifa rack is not supplied by FIAMM suitable racks should be provided to support the cells These should be arranged to provide easy access to each cell for inspection topping up and general maintenance Suitable racks may
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