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Technical manual
May 2011
Contents
2.1 Complete reliability +122F), and accept extreme 2.10 Extended storage
The block battery does not suffer temperatures, ranging from as When stored in the empty and
from the sudden death failure low as 50C (58F) to up to discharged state under the
associated with the lead acid +70C (+158F) (see section recommended conditions, the
battery (see section 4.1 Plate 4.3 Electrolyte). block battery can be stored for
assembly). many years (see section 10.2
2.6 Fast recharge Installation and operating
2.2 Long cycle life The block battery can be instructions).
The block battery has a long recharged at currents which
cycle life even when the allow very fast recharge times to 2.11 Well-proven pocket
charge/discharge cycle involves be achieved (see section 8.3 plate construction
100% depth of discharge (see Charge acceptance). Saft has nearly 100 years of
section 6.7 Cycling). manufacturing and application
2.7 Resistance to experience with respect to the
2.3 Exceptionally long mechanical abuse nickel-cadmium pocket plate
lifetime The block battery is designed to product, and this expertise has
A lifetime in excess of twenty have the mechanical strength been built into the twenty-plus
years is achieved by the Saft Nife required to withstand all the years design life of the block
block battery in many harsh treatment associated with battery product (see section 4
applications, and at elevated transportation over difficult Construction features of the
temperatures it has a lifetime terrain (see section 9.2 block battery).
unthinkable for other widely Mechanical abuse).
available battery technologies 2.12 Environmentally safe
(see section 6.8 Effect of 2.8 High resistance to Saft operates a dedicated
temperature on lifetime). electrical abuse recycling center to recover the
The block battery will survive nickel, cadmium, steel and
2.4 Low maintenance abuse which would destroy a plastic used in the battery
With its generous electrolyte lead acid battery, for example (see section 12 Disposal and
reserve, the block battery overcharging, deep discharging, recycling).
reduces the need for topping-up and high ripple currents (see
with water, and can be left in section 9.1 Electrical abuse). 2.13 Low life-cycle cost
remote sites for long periods When all the factors of lifetime,
without any maintenance (see 2.9 Simple installation low maintenance requirements,
section 6.9 Water consumption The block battery can be used simple installation and storage
and gas evolution). with a wide range of stationary and resistance to abuse are
and mobile applications as it taken into account, the Saft Nife
2.5 Wide operating produces no corrosive vapors, block battery becomes the most
temperature range uses corrosion-free polypropylene cost effective solution for many
The block battery has an containers and has a simple professional applications.
electrolyte which allows it to have bolted connector assembly system
a normal operating temperature (see section 10 Installation and
of from 20C to +50C (4F to operating instructions).
4
3. Electrochemistry of
nickel-cadmium batteries
Protective cover
to prevent external
short-circuits Flame-arresting vents
in line with Material: polypropylene.
EN 50272-2 (safety)
with IP2 level
Cell container
Material: translucent
Plate group bus
polypropylene.
Connects the plate
tabs with the terminal
Plate tab post. Plate tabs and
Spot-welded both to the plate terminal post are
side-frames and to the upper projection-welded to
edge of the pocket plate. the plate group bus.
Plate
Horizontal pockets
of double-perforated
steel strips.
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 Nife
L M H
battery types
mini 3h 30 min 1s
Autonomy
maxi 100 h 3h 30 min
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 - Signaling
Railways
intercity & l l l
urban transport
Stationary
Utilities
electricity, gas,
l l l
water production
& distribution
Oil and gas
offshore & onshore,
l l l
petrochemical
refineries
Industry
chemical, mining, l l l
steel metal works
Buildings
l l l
public, private
Medical
hospitals, l l l
X-ray equipment
Telecom
radio,
satellite, cable, l l
repeater stations,
cellular base stations
Railroad
substations l l l
& signaling
Airports l l l
Military
l l l
all applications
10
5.1 Type L 5.3 Type H 5.4 Choice of type
The L type is designed for The H type is designed for In performance terms the
applications where the battery is applications where there is a ranges cover the full time
required to provide a reliable demand for a relatively high spectrum from rapid high
source of energy over relatively current over short periods, current discharges of a second
long discharge periods. Normally, usually less than 30 minutes in to very long low current
the current is relatively low in duration. The applications can discharges of many hours.
comparison with the total stored have frequent or infrequent Table 2 shows in general terms
energy, and the discharges are discharges. The range is typically the split between the ranges for
generally infrequent. Typical uses used in starting and power the different discharge types.
are power backup and bulk backup applications. The choice is related to the
energy storage. discharge time and the end of
discharge voltage. There are, of
course, many applications
5.2 Type M where there are multiple
The M type is designed for discharges, and so the optimum
applications where the batteries range type should be calculated.
are usually required to sustain This is explained in the section 7
electrical loads for between Battery sizing.
30 minutes to 3 hours or for
mixed loads which involve a
mixture of high and low discharge
rates. The applications can have
frequent or infrequent discharges.
The range is typically used in
power backup applications.
There are a number of methods 7.1 The voltage window 7.3 Temperature
which are used to size nickel- This is the maximum voltage and The maximum and minimum
cadmium batteries for standby the minimum voltage at the temperatures and the normal
floating applications. The method battery terminals acceptable for ambient temperature will have
employed by Saft is the the system. In battery terms, the an influence on the sizing of the
IEEE 1115 recommendation maximum voltage gives the battery. The performance of a
which is accepted internationally. voltage which is available to charge battery decreases with
This method takes into account the battery, and the minimum decreasing temperature and
multiple discharges, temperature voltage gives the lowest voltage sizing at a low temperature
de-rating, performance after acceptable to the system to increases the battery size.
floating and the voltage window which the battery can be Temperature de-rating curves
available for the battery. discharged. In discharging the are produced for all cell types to
nickel-cadmium battery, the cell allow the performance to be
A significant advantage of the voltage should be taken as low recalculated.
nickel-cadmium battery as possible in order to find the
compared to a lead acid battery, most economic and efficient
is that it can be fully discharged battery.
without any inconvenience in
terms of life or recharge. Thus,
to obtain the smallest and least 7.2 Discharge profile
costly battery, it is an advantage This is the electrical
to discharge the battery to the performance required from the
lowest practical value in order to battery for the application. It may
obtain the maximum energy from be expressed in terms of
the battery. amperes for a certain duration,
or it may be expressed in terms
The principle sizing parameters of power, in watts or kW, for a
which are of interest are: certain duration. The requirement
may be simply one discharge or
many discharges of a complex
nature.
17
7.4 State of charge 7.6 Floating effect
or recharge time When a nickel-cadmium cell is
Some applications may require maintained at a fixed floating
that the battery shall give a full voltage over a period of time,
duty cycle after a certain time there is a decrease in the
after the previous discharge. The voltage level of the discharge
factors used for this will depend curve. This effect begins after
on the depth of discharge, the one week and reaches its
rate of discharge, and the maximum in about 3 months. It
charge voltage and current. can only be eliminated by a full
A requirement for a high state of discharge/charge cycle, and it
charge does not justify a high cannot be eliminated by a boost
charge voltage if the result is a charge. It is therefore necessary
high end of discharge voltage. to take this into account in any
calculations concerning batteries
in float applications.
7.5 Ageing
Some customers require a value As the effect of reducing the
to be added to allow for the voltage level is to reduce the
ageing of the battery over its autonomy of the battery, the
lifetime. This may be a value effect can be considered as
required by the customer, for reducing the performance of the
example 10%, or it may be a battery and so performance
requirement from the customer down-rating factors are used.
that a value is used which will
ensure the service of the battery
during its lifetime. The value to
be used will depend on the
discharge rate of the battery and
the conditions under which the
discharge is carried out.
18
8. Battery charging
8.1 Charging generalities system and accepts a To minimize the water usage, it is
The block battery can be smaller voltage window than the important to use a low charge
charged by all normal methods. two-rate charger. voltage per cell, and so the
Generally, batteries in parallel minimum voltage for the single
operation with charger and load The two-rate charger has an level and the two level charge
are charged with constant initial high voltage stage to voltage is the normally
voltage. In operations where charge the battery followed by a recommended value. This also
the battery is charged lower voltage maintenance helps within a voltage window to
separately from the load, charge. This allows the battery obtain the lowest, and most
charging with constant current to be charged quickly, and yet, effective, end of discharge
or declining current is possible. have a low water consumption voltage per cell (see section 7
High-rate charging or due to the low maintenance Battery sizing).
overcharging will not damage charge or float voltage level.
the battery, but excessive The values given as maximum
charging will increase water The values used for the block are those which are acceptable
consumption to some degree. battery ranges for single and to the battery, but would not
two-rate charge systems are as normally be used in practice,
shown in Table 4 below. particularly for the single level,
8.2 Constant voltage because of high water usage.
charging methods
Batteries in stationary
applications are normally
charged by a constant voltage Cell Single level (V/cell) Two level (V/cell)
float system and this can be of type
min max min max floating
two types: the two-rate type,
L 1.43 1.50 1.47 1.70 1.42 0.01
where there is an initial constant
voltage charge followed by a M 1.43 1.50 1.45 1.70 1.40 0.01
lower voltage floating voltage; or H 1.43 1.50 1.45 1.70 1.40 0.01
a single-rate floating voltage.
Table 4 - Charge and float voltages for the block battery ranges
Important n If the cells are shipped filled as 5% per 10C (18F) above
recommendations and charged, the cells are +30C (+86F) per year.
nN ever allow an exposed flame ready for assembly. Remove
or spark near the batteries, the plastic transport seals only n Cells empty and discharged
particularly while charging. before use.
n Never smoke while Saft recommends to store cells
performing any operation on n If the cells are shipped empty empty and discharged. This
the battery. and discharged, do not ensures compliance with
n For protection, wear rubber remove the plastic transport IEC 60623 section 4.9
gloves, long sleeves, and seals until ready to fill the (storage).
appropriate splash goggles cells. Cells can be stored like this for
or face shield. many years.
n The electrolyte is harmful to The cells must never be
skin and eyes. In the event charged with the transport n When deliveries are made
of contact with skin or eyes, seals in place as this can cause in cardboard boxes, store
wash immediately with plenty permanent damage. without opening the boxes.
of water. If eyes are affected, n When deliveries are made
flush with water, and obtain in plywood boxes, open the
10.2 Storage
immediate medical attention. boxes before the storage.
Store the battery indoors in a
n Remove all rings, watches The lid and the packing
dry, clean, cool location (0C to
and other items with metal material on top of the cells
+30C / +32F to +86F) and
parts before working on the must be removed.
well ventilated space on open
battery. shelves.
n Use insulated tools.
n Avoid static electricity and Do not store in direct sunlight or
take measures for protection expose to excessive heat.
against electric shocks.
n Discharge any possible static n Cells filled and charged
electricity from clothing
and/or tools by touching If cells are stored filled, they
an earth-connected part must be fully charged prior to
ground before working on storage.
the battery. Cells may be stored filled
and charged for a period not
10.1 Receiving the exceeding 12 months from
shipment date of dispatch from factory.
Unpack the cells immediately
upon arrival. Do not overturn the Storage of a filled battery at
package. Transport seals are temperatures above +30C
located under the cover of the (+86F) can result in loss of
vent plug. capacity. This can be as much
24
10.3 Electrolyte / cell oil according to the quantity The connectors and terminals
n Cells delivered filled and indicated in the Installation and should be corrosion-protected by
charged: Operating Instructions sheet. coating with a thin layer of anti-
Check the level of electrolyte. It corrosion oil.
should not be more than 20 mm 10.4 Installation
below the maximum level mark 10.4.1 Location Remove the transport seals
(upper). If this is not the case, Install the battery in a dry and and close the vent plugs.
adjust the level with distilled or clean room. Avoid direct sunlight
deionized water. Cells delivered and heat. The battery will give 10.5 Commissioning
filled have already cell oil in the best performance and Verify that the transport seals
place. maximum service life when the are removed, the vents are
ambient temperature is between closed and the ventilation is
In case of spillage of electrolyte +10C to +30C (+50F to +86F). adequate during this operation.
during the transport, the
cells have to be topped-up 10.4.2 Ventilation A good commissioning is
with E22 electrolyte. Fill the During the last part of charging, important. Charge at constant
cells about 20 mm above the the battery is emitting gases current is preferable.
minimum level mark (lower) (oxygen and hydrogen mixture).
with electrolyte. Wait 4 hours At normal float-charge the gas If the current limit is lower than
and adjust if necessary before evolution is very small but some indicated in the Installation and
commissioning. ventilation is necessary. Operating Instructions sheet,
charge for a proportionally
n Cells delivered empty and Note that special regulations longer time.
discharged: for ventilation may be valid in
If the electrolyte is supplied dry, your area depending on the n For cells filled and charged
prepare it according to its separate application. by the factory and stored
instructions sheet. The electrolyte less than 6 months:
to be used is E22. Remove the 10.4.3 Mounting Constant current charge:
transport seals just before filling. Verify that cells are correctly Charge for 10 h at 0.2 C5 A
interconnected with the recommended (see the
Fill the cells about 20 mm above appropriate polarity. The battery Installation and Operating
the minimum level mark (lower) connection to load should be Instructions sheet).
with electrolyte. with nickel plated cable lugs. Note: At the end of the charge,
Recommended torques for the cell voltage may reach the
Wait 4 to 24 hours and terminal bolts are: level of 1.85 V per cell, thus the
adjust if necessary before M 6 = 11 1.1 N.m charger shall be able to supply
commissioning. (97.4 9.8 lbf.in) such voltage.
M 8 = 20 2 N.m When the charger maximum
It is recommended to add the (177.0 17.7 lbf.in) voltage setting is too low
cell oil after the commissioning M10 = 30 3 N.m to supply constant current
charge, with the syringe, (265.0 26.6 lbf.in) charging, divide the battery
25
into two parts to be charged Constant voltage charge: For capacity test purposes,
individually. a) Charge for 30 h at the battery has to be charged
Constant voltage charge: 1.65 V/cell with current in accordance with IEC 60623
Charge for 24 h at limited to 0.2 C5 A (see the section 4.
1.65 V/cell, current limited to Installation and Operating
0.2 C5 A or charge for 48 h at Instructions sheet). 10.6 Charging in service
1.55 V/cell, current limited to b) Discharge at 0.2 C5 A to n Continuous parallel
0.2 C5 A (see the Installation 1.0 V/cell operation, with occasional
and Operating Instructions c) Charge for 30 h at battery discharge.
sheet). 1.65 V/cell with current Recommended charging
limited to 0.2 C5 A or charge voltage (+20C to +25C /
n For cells filled on location for 48 h at 1.55 V/cell +68F to +77F):
or for filled cells which have current limited to 0.2 C5 A For two level charge:
been stored more than 6 (see the Installation and float level
months: Operating Instructions sheet). = 1.42 0.01 V/cell
Constant current charge: for L cells
a) Charge for 10 h at 0.2 C5 A nC
ell oil & electrolyte after = 1.40 0.01 V/cell
recommended (see the commissioning: wait for 4 for M and H cells
Installation and Operating hours after commissioning.
Instructions sheet). high level
b) Discharge at 0.2 C5 A to F
or cells delivered filled by the = 1.47 - 1.70 V/cell
1.0 V/cell factory: for L cells
c) Charge for 10 h at 0.2 C5 A - Cell oil is already in place. = 1.45 - 1.70 V/cell
recommended (see the - Check the electrolyte level for M and H cells.
Installation and Operating and adjust it to the maximum
Instructions sheet). level mark (upper) by adding A high voltage will increase
Note: At the end of the charge, distilled or deionized water. the speed and efficiency of the
the cell voltage may reach the recharging.
level of 1.85 V per cell, thus the F
or cells filled on location:
For single level charge:
charger shall be able to supply - Add the cell oil with the
float level: 1.43 - 1.50 V/cell.
such voltage. syringe, according to the
quantity indicated in the
nB
uffer operation, where the
When the charger maximum Installation and Operating
load exceeds the charger
voltage setting is too low Instructions sheet.
rating.
to supply constant current - Check the electrolyte level
charging, divide the battery and adjust it to the maximum
Recommended charging voltage
into two parts to be charged level mark (upper) by adding:
(+20C to +25C / +68F to
individually. electrolyte.
+77F): 1.50 - 1.60 V/cell.
www.saftbatteries.com
30
Saft is committed to the highest standards of environmental stewardship.
As part of its environmental commitment, Saft gives priority to recycled raw materials over virgin raw materials, reduces
its plants releases to air and water year after year, minimizes water usage, reduces fossil energy consumption and
associated CO2 emissions, and ensures that its customers have recycling solutions available for their spent batteries.
Regarding industrial Ni-Cd batteries, Saft has had partnerships for many years with collection companies in most EU countries, in
North America and in other countries. This collection network receives and dispatches our customers batteries at the end of their
lives to fully approved recycling facilities, in compliance with the laws governing trans-boundary waste shipments.
This collection network is undergoing minor adaptations to meet the requirements of the EU batteries directive. A list of our collection
points is available on our web site.
In other countries, Saft assists users of its batteries in finding environmentally sound recycling solutions. Please contact your sales
representative for further information.
Doc N 21081-2-0511
Saft Edition: May 2011
Industrial Battery Group Data in this document is subject to change without
12, rue Sadi Carnot notice and becomes contractual only after written
confirmation.
93170 Bagnolet France
Tel: +33 (0) 1 49 93 19 18 Photo credit: Royalty-Free/Corbis, PhotoDisc, Saft.