Beruflich Dokumente
Kultur Dokumente
TECHNICAL MANUAL
Contents
1. Introduction 3
2. Benefits of the block battery 4
2.1 Complete reliability 4
2.2 Long cycle life 4
2.3 Exceptionally long lifetime 4
2.4 Low maintenance 4
2.5 Wide operating temperature range 4
2.6 Fast recharge 4
2.7 Resistance to mechanical abuse 4
2.8 High resistance to electrical abuse 4
2.9 Simple installation 4
2.10 Extended storage 4
2.11 Well-proven pocket plate construction 4
2.12 Environmentally safe 4
2.13 Low life-cycle cost 4
3. Electrochemistry of nickel-cadmium batteries 5
4. Construction features of the block battery 6
4.1 Plate assembly 7
4.2 Separation 8
4.3 Electrolyte 8
4.4 Terminal pillars 8
4.5 Venting system 8
4.6 Cell container 8
5. Battery types and applications 10
5.1 Type L 11
5.2 Type M 11
5.3 Type H 11
5.4 Choice of type 11
6. Operating features 12
6.1 Capacity 12
6.2 Cell voltage 12
6.3 Internal resistance 12
6.4 Effect of temperature on performance 13
3
6.5 Short-circuit values 14
6.6 Open circuit loss 14
6.7 Cycling 14
6.8 Effect of temperature on lifetime 14
6.9 Water consumption and gas evolution 16
7. Battery sizing principles and sizing method
in stationary standby applications 17
7.1 The voltage window 17
7.2 Discharge profile 17
7.3 Temperature 17
7.4 State of charge or recharge time 17
7.5 Aging 18
7.6 Floating effect 18
8. Battery charging 19
8.1 Charging generalities 19
8.2 Constant voltage charging methods 19
8.3 Charge acceptance 20
8.4 Charge efficiency 22
8.5 Temperature effects 22
8.6 Commissioning charge 22
9. Special operating factors 23
9.1 Electrical abuse 23
9.2 Mechanical abuse 23
10. Installation and storage 24
10.1 Batteries on arrival 24
10.2 Cell oil 24
10.3 Emplacement 25
10.4 Ventilation 25
10.5 Preparation for service 26
11. Maintenance of block batteries in service 27
11.1 Cleanliness/mechanical 27
11.2 Topping up 27
11.3 Capacity check 28
11.4 Changing electrolyte 28
11.5 Recommended maintenance procedure 28
4
1 Introduction
3
2 Benefits of the block battery
4
3 Electrochemistry of nickel-cadmium batteries
The nickel-cadmium battery uses nickel During discharge the trivalent nickel
hydroxide as the active material for the hydroxide is reduced to divalent nickel
positive plate, and cadmium hydroxide hydroxide, and the cadmium at the
for the negative plate. negative plate forms cadmium
hydroxide.
The electrolyte is an aqueous solution of
potassium hydroxide containing small On charge, the reverse reaction takes
quantities of lithium hydroxide to place until the cell potential rises to a
improve cycle life and high temperature level where hydrogen is evolved at the
operation. negative plate and oxygen at the positive
plate which results in water loss.
The electrolyte is only used for ion
transfer; it is not chemically changed or Unlike the lead acid battery, there is little
degraded during the charge/ discharge change in the electrolyte density during
cycle. In the case of the lead acid charge and discharge. This allows large
battery, the positive and negative active reserves of electrolyte to be used without
materials chemically react with the inconvenience to the electrochemistry of
sulphuric acid electrolyte resulting in an the couple.
aging process.
Thus, through its electrochemistry, the
The support structure of both plates is nickel-cadmium battery has a more
steel. This is unaffected by the stable behavior than the lead acid
electrochemistry, and retains its battery, giving it a longer life, superior
characteristics throughout the life of the characteristics and a greater resistance
cell. In the case of the lead acid battery, against abusive conditions.
the basic structure of both plates are
lead and lead oxide which play a part in Nickel-cadmium cells have a nominal
the electrochemistry of the process and voltage of 1.2 volts.
are naturally corroded during the life of
the battery.
discharge
2 NiOOH + 2H2O + Cd 2 Ni(OH)2 + Cd(OH)2
charge
5
4 Construction features of the block battery
Connector covers
Material: hard PVC plastic.
Separating grids
Separate the plates and
insulate the plate frames
Plate tab from each other. The grids
Spot-welded both to the allow free circulation of
plate side-frames and to the electrolyte between the
upper edge of the pocket plates.
plate.
Plate frame
The cells are welded Seals the place pockets
together to form rugged and serves as a current
blocks of 1-10 cells collector.
depending on the cell size.
Plate
Horizontal pockets
of double-perforated
steel strips.
6
4.1 Plate assembly containment which promotes conductivity
and minimizes electrode swelling.
The nickel-cadmium cell consists of two These plates are then welded to a current
groups of plates, the positive containing carrying bus bar assembly which further
nickel hydroxide and the negative ensures the mechanical and electrical
containing cadmium hydroxide. stability of the product.
7
4.2 Separation 4.4 Terminal pillars
Separation between plates is provided by Short terminal pillars are welded to the
injection molded plastic separator grids, plate bus bars using a well established
integrating both plate edge insulation and proven method. These posts are
and plate separation. By providing a manufactured from steel bar, internally
large spacing between the positive and threaded for bolting on connectors and
negative plates and a generous quantity nickel plated.
of electrolyte between plates, good
electrolyte circulation and gas dissipation The sealing between the cover and the
are provided, and there is no terminal is provided by a compressed
stratification of the electrolyte as found visco-elastic sealing surface held in place
with lead acid batteries. by compression lock washers. This
assembly is designed to provide
4.3 Electrolyte satisfactory sealing throughout the life of
the product.
The electrolyte used in the block battery,
which is a solution of potassium hydroxide 4.5 Venting system
and lithium hydroxide, is optimized to give
the best combination of performance, life, The block battery is fitted with a special
energy efficiency and a wide temperature flame arresting flip top vent to give an
range. effective and safe venting system.
8
The block battery uses 4 plate sizes
or plate modules. These are
designated module type 1, 2, 3
and 4. They can be recognized from
the block dimensions as follows:
9
5 Battery types and applications
In order to provide an optimum solution for the wide range of battery applications
which exist, the block battery is constructed in three performance ranges.
Saft Battery
SBL SBM SBH
types
mini 1h 15 min 1s
Autonomy
maxi 100 h 2h 30 min
Capacity mini 7.5 11 8.3
range maxi 1540 1390 920
Power Power Starting,
Use of battery backup backup Power
Bulk energy backup
storage
Applications Engine starting - Switchgear - UPS - Process control -
Data and information systems - Emergency lighting -
Security and fire alarm systems -
Switching and transmission systems - Signalling
Railways
intercity and ▼ ▼ ▼
urban transport
Stationary
Utilities
electricity, gas,
▼ ▼ ▼
water production
and distribution
Oil and gas
offshore & onshore,
▼ ▼ ▼
petrochemical
refineries
Industry
chemical, mining, ▼ ▼ ▼
steel metal works
Buildings
▼ ▼ ▼
public, private
Medical
hospitals, ▼ ▼ ▼
X-ray equipment
Telecom
radio,
satellite, cable, ▼ ▼
repeater stations,
cellular base stations
Railroad
substations ▼ ▼ ▼
& signalling
Airports ▼ ▼ ▼
Military
▼ ▼ ▼
all applications
10
5.1 Type L discharges. The range is typically
used in starting and power backup
The SBL is designed for applications applications.
where the battery is required to
provide a reliable source of energy 5.4 Choice of type
over relatively long discharge periods.
Normally, the current is relatively low In performance terms the ranges
in comparison with the total stored cover the full time spectrum from
energy, and the discharges are rapid high current discharges of a
generally infrequent. Typical uses are second to very long low current
power backup and bulk energy discharges of many hours. Table 2
storage. shows in general terms the split
between the ranges for the different
5.2 Type M discharge types. The choice is related
to the discharge time and the end of
The SBM is designed for applications discharge voltage. There are, of
where the batteries are usually course, many applications where
required to sustain electrical loads for there are multiple discharges, and so
between 30 minutes to 3 hours or for the optimum range type should be
“mixed” loads which involve a calculated. This is explained in the
mixture of high and low discharge chapter “Battery Sizing”.
rates. The applications can have
frequent or infrequent discharges.
The range is typically used in power
backup applications.
5.3 Type H
1.14 V
1.10 V H
1.05 V M
1.00 V L
11
6 Operating features
12
6.4 Effect of temperature on
performance
14
In general terms, for every 9ºC increase
in temperature over the normal
operating temperature of 25ºC, the
reduction in service life for a nickel-
cadmium battery will be 20%, and for a
lead acid battery will be 50 %. In high
temperature situations, therefore, special
consideration must be given to
dimensioning the nickel-cadmium
battery. Under the same conditions, the
lead-acid battery is not a practical
proposition, due to its very short lifetime.
The VRLA battery, for example, which
has a lifetime of about 7 years under
good conditions, has this reduced to less
than 1 year, if used at 50ºC.
Figure 2 - Capacity loss on open circuit stand
15
6.9 Water consumption
and gas evolution
16
7 Battery sizing principles in stationary standby applications
17
7.5 Aging 7.6 Floating effect
18
8 Battery charging
Table 5 - Charge and float voltages for the block battery ranges
19
8.3 Charge acceptance
Figure 6(a) - Typical recharge times from a fully discharged state for the H block
Figure 6(b) - Typical recharge times from a fully discharged state for the M block
20
These graphs give the recharge time for The charge time for an M type plate at
a current limit of 0.2 C5 amperes. different charge regimes for a fixed
Clearly, if a lower value for the current is voltage is given in Figure 6(d).
used, e.g. 0.1 C5 amperes, then the
battery will take longer to charge. If a If the application has a particular
higher current is used then it will charge recharge time requirement then this must
more rapidly but, does so less efficiently, be taken into account when calculating
and so this is not a pro-rata relationship. the battery.
Figure 6(c) - Typical recharge times from a fully discharged state for the L block
Figure 6(d) - Typical recharge times for different charge rates for the M block
21
8.4 Charge efficiency A constant current first charge is
preferable and this should be such as to
The charge efficiency of the battery is supply 300 % of the rated capacity of the
dependent on the state of charge of the cell. Thus, a 250 Ah cell will require
battery and the temperature. For much of 750 ampere hours input, e.g. 50 amperes
its charge profile, it is recharged at a for 15 hours.
high level of efficiency.
Cells which have been stored for less
In general, at states of charge less than than one year should be charged for
80% the charge efficiency remains high, 15 hours at the recommended charge
but as the battery approaches a fully current* before being placed in service.
charged condition, the charging Cells that have been stored for more
efficiency falls off. This is illustrated than one year, or have been supplied
graphically in Figure 7. empty and have been filled, should be
charged for 15 hours at the
8.5 Temperature effects recommended charge current*,
discharged to 1.0 volts per cell and then
As the temperature increases, the charged for 10 hours at the
electrochemical behavior becomes more recommended charge current*.
active, and so, for the same floating In cases where it is not possible to
voltage, the current increases. As the provide constant current charging, it is
temperature is reduced then the reverse possible to achieve this with a constant
occurs. Increasing the current increases voltage by using a high voltage level,
the water loss, and reducing the current e.g. 1.65 voltage limit may be used for
creates the risk that the cell will not be 20 to 30 hours, if the current limit is
sufficiently charged. Thus, as it is clearly approximately equivalent to the 5 hour
advantageous to maintain the same charge current*. If the current rating is
current through the cell, it is necessary lower, then the charge time should be
to modify the floating voltage as the increased accordingly.
temperature changes. The recommended
change in voltage required, or When the charger maximum voltage
“temperature compensation”, is -3 mV/ ºC, setting is too low to supply constant
starting from an ambient temperature of current charging, divide the battery into
+20ºC to +25ºC. two parts to be charged individually at a
high voltage. The battery can now be put
8.6 Commissioning charge into service.
23
10 Installation and storage
10.1 Batteries on arrival year, then they must be given a Cells after storage
maintenance cycle as follows:
On receiving the battery, open the All cells after storage must be
cases and check for any indication of a) Remove transport seals from the prepared for service and fully
damage in transit. cells. commissioned as described in
section 8.6.
Remove the cells and any accessories b) Discharge at the charging current*
from the packaging, and check that to 1.0 volts per cell. 10.2 Cell oil
the contents are in order and inspect
for any damage in transit. c) Charge for 10 hours at the On top of the electrolyte of filled cells
charging current* or equivalent. floats a layer of cell oil to reduce self
Damage must be reported discharge and water loss due to
immediately to the carrier, and the d) Wait 24 hours for all gassing to evaporation. This layer is
company or its agent. stop. approximately 5 mm thick and, when
the cells are delivered empty, must be
If batteries are not put into service e) Replace plastic transport seals and added to the cells after they have
immediately they should be stored in return to store. been filled with electrolyte.
a clean, dry, cool and well ventilated
storage space on open shelves. For batteries stored more than 12 *Please refer to the installation and
Plastic cells should not be exposed to months, at least one discharge/charge operation instruction sheet.
direct sunlight. cycle as above should be carried out
before the commissioning charge is
Before storage, ensure that: begun.
a) Cells are kept clean with adequate Discharged and empty cells
protective finish, such as neutral
grease on posts and connectors. Cells discharged and empty can be
stored for many years if kept under
b) Electrolyte in cells is filled to the the correct conditions. They should
correct level. be stored in a clean, dry, cool (+
10ºC to +30ºC) and well ventilated
c) Vents are correctly seated and vent storage space on open shelves. It is
plugs firmly in position.Keep the important that they are sealed with
transit sealing tape in position. the transport seals firmly in place.
These should be checked at least
Note that if excessive loss of yearly, and if necessary replaced or
electrolyte in transit is found in cells refitted. Failure of the seal will result
supplied filled, ensure that the cells in an ingress of carbon dioxide from
are correctly filled before storage. the atmosphere, which will result in
carbonation of the plates. This can
Filled cells affect the capacity of the battery.
24
10.3 Emplacement If the battery is enclosed in a cabinet or
other such enclosed space, it is important
The battery should be installed in a dry to provide sufficient space to disperse the
and clean location away from direct gasses given off during charging, and also
sunlight, strong daylight and heat. to minimize condensation.
25
The volume of hydrogen found by this Carefully remove the plastic transport seal,
calculation can be expressed as a and visually check that the electrolyte levels
percentage of the total volume of the in the opened cells are at the MAX level.
battery room, and from this, the number of
air changes required to keep the If necessary, adjust by careful addition of
concentration of hydrogen below a certain approved distilled or demineralised water.
level can be calculated.
Thus, to maintain a maximum Wipe away any small spillage on cells
concentration of 2 % (for example), the air using a clean cloth and close the flip-top
in the room will need changing vents to complete preparation for service.
3/2 = 1.5 times per hour.
The cells can now be commissioned as
Example: described in section 8.6.
A battery of 98 cells, type SBH 77 on a
Discharged and empty cells
two step, two tier stand, is placed in a
room of dimensions 2m x 2m x 3m.
Check that cells are externally clean with
The charging system is capable of adequate protective finish on posts and
charging at 0.1C5 and so the charging connectors.
current is 7.7 amperes.
The volume of hydrogen evolved per Identify and calculate the electrolyte type
hour in this, the worst, case is: and quantity required to fill the cells*. Do
= 98 x 7.7 x 0.00045 m3= 0.34m3 not remove the plastic transport seals at
this stage.
The total volume of the room is
2 x 2 x 3 = 12 m3
Prepare new electrolyte to requirement from
Approximate volume of battery and solid electrolyte or liquid electrolyte, as
stand does not exceed 1 m3, and so, supplied. When filling the cells, refer to the
the volume of free air in the room is ”Electrolyte Instructions” data sheet supplied
11 m. with the electrolyte. Ensure that only
Therefore, the concentration of demineralised or pure distilled water is used.
hydrogen gas after charging for 1 hour
at full gassing potential at 0.1C5 will be: Carefully remove the plastic transport seal
= 0.34 = 3% and leave the flip-top vents open.
11
Carefully fill the cells using a plastic jug
and funnel to a level 5-10 mm below the
In practice, a typical figure for natural MAX level. Allow the cells to stand for
room ventilation is about 2.5 air changes 24 hours. For large installations, a pump
per hour, and so, in this case, it would system is recommended.
not be necessary to introduce any
forced ventilation. Add cell oil as described in the electrolyte
In a floating situation, the current flowing is leaflet.
very much lower than when the cell is being
charged, and the gas evolution is minimal; After 24 hours stand, carefully complete
it may be calculated in the same way using filling the cell to the maximum level.
typical floating currents.
Wipe away any small spillage on cells
10.5 Preparation for service using a clean cloth and close the flip-top
vents to complete preparation for service.
Filled cells
The cells can now be commissioned as
Check that cells are externally clean with described in section 8.6.
adequate protective finish on posts and
connectors. *Please refer to the installation and
operation instruction sheet.
26
11 Maintenance of block batteries in service
27
11.3 Capacity check 11.5 Recommended maintenance
procedure
Electrical battery testing is not part of
normal routine maintenance, as the In order to obtain the best from your
battery is required to give the back-up battery, the following maintenance
function and cannot be easily taken out procedure is recommended.
of service.
Yearly
However, if a capacity test of the battery
check charge voltage settings
is needed, the following procedure
should be followed: check cell voltages
(30mV deviation from average
a) Discharge the battery at the rate of
is acceptable)
0.1C5 to 0.2C5 amperes (10 to 20
amperes for a 100 Ah battery) to a check float current of the battery
final average voltage of 1.0 volts per check electrolyte level
cell (i.e. 92 volts for a 92 cell battery) equalizing charge if agreed
b) Charge 200% (i.e. 200 Ah for a 100 Ah for application
battery at the same rate used in a) clean cell lids and battery area
check torque values grease terminals
c) Discharge at the same rate used in a),
and connectors
measuring and recording current,
voltage and time every hour, and more every 5 years or as required
frequently towards the end of the capacity check
discharge. This should be continued as required
until a final average voltage of 1.0 volts
per cell is reached. The overall state of top-up with water according to
the battery can then be seen, and if defined period (depend on float
individual cell measurements are voltage, cycles and temperature)
taken, the state of each cell can be
observed.
It is also recommended that a
11.4 Changing electrolyte maintenance record be kept which
should include a record of the
In most stationary battery operations, the temperature of the battery room.
electrolyte will retain its effectiveness for
the life of the battery. Thus, normally it is
not necessary to change the electrolyte.
28
12 Disposal and recycling
CADMIUM DISTILLATION
PLATES
STEEL
WORKS
NEW
SPENT
BATTERIES
BATTERIES
BATTERY
USE
29
Argentina Mexico Doc. No. RM06.01 - 210812
Saft Argentina SA, Buenos Aires Saft Mexico SA de CV, Mexico D.F. Data in this document are subject to change
Tel: +54 11 4 686 1994 Tel: +52 280 0619 without notice and becomes contractual only
Fax: +54 11 4 686 1925 Fax: +52 281 3559 after written confirmation.
Canada Norway
Please contact USA office Saft AS, Osteråas
Tel: +47 67 16 6160
France Fax: +47 67 16 6170
Division France, Bagnolet
Tel: +33 (0) 1 49 93 19 18 Singapore
Fax: +33 (0) 1 49 93 19 50 Saft Pte Ltd
Singapore
Germany Tel: +65 84 65 700
Saft GmbH, Nuremberg Fax: +65 74 16 396
Tel: +49 911 94 1740
Fax: +49 911 426 144 Spain
Saft Iberica, Madrid
Hong-Kong Tel: +34 91 302 15 47
Saft Ltd, Kowloon Fax: +34 91 766 24 74
Tel: +852 2795 27 19
Fax: +852 2798 05 77 Sweden
Saft AB, Solna
Italy Tel: +46 8 5984 9750
Saft SpA, Genova Fax: +46 8 5984 9755
Tel: +39 0 10 37 47 911
Fax: +39 0 10 38 62 73 United Kingdom
Saft Ltd, Hainault
Japan Tel: +44 20 8498 1177
Sumitomo Corp., Tokyo Fax: +44 20 8498 1115
Tel: +81 3 3230 7010 Industrial Battery Group
Fax: +81 3 3237 5370 USA 12 rue Sadi Carnot - 93170 -
Saft America Inc, Stationary batteries Bagnolet - France
Korea North Haven, Connecticut Tel: +33 (0) 1 49 93 19 18
Saft Korea Co Ltd Tel: +1 203 239 4718 Fax: +33 (0) 1 49 93 19 50
Kyunggi-Do Fax: +1 203 234 7598
Tel: +82 343 41 1134 www.saftbatteries.com
Fax: +82 343 41 1139 Railway batteries
Cockeysville, MD
Malaysia Tel: +1 410 771 3200
Saft Bhd, Kuala Lumpur Fax: +1 410 771 1144
Tel: +60 3 985 29 96
Fax: +60 3 984 49 95