‫ﺑﺮﮒ ﺍﺳﺘﻌﻼﻡ ﺑﻬﺎﺀ ﺧﺮﻳﺪ ﺩﺍﺧﻠﯽ ﮐﺎﻻ‬

3757 ‫ﺷﻤﺎﺭﻩ ﺍﺳﺘﻌﻼﻡ ﺑﻬﺎﺀ‬

۲ ‫ ﺍﺯ‬۲ ‫ﺻﻔﺤﻪ‬ ‫ﺗﺎﺭﻳﺦ ﺻﺪﻭﺭ‬
۱ ۳۹۶/۰ ۷/۲۹
‫ﺷﺮﮐﺖ ﭘﺘﺮﻭﺷیﻤﯽ ﻓﺠﺮ‬
mt31_9546507 ‫ﺷﻤﺎﺭﻩ ﺩﺭﺧﻮﺍﺳﺖ‬
((‫ﻗﻴﻤﺖ ﮐﺎﻻ ))ﺭﻳﺎﻝ‬ ((‫ﺑﻬﺎﺀ ﻭﺍﺣﺪ ﺑﻪ ﺣﺮﻭﻑ ))ﺭﻳﺎﻝ‬ ((‫ﺑﻬﺎﺀ ﻭﺍﺣﺪ ﺑﻪ ﻋﺪﺩ ))ﺭﻳﺎﻝ‬ ‫ﻣﻘﺪﺍﺭ‬ ‫ﻭﺍﺣﺪ‬ ‫ﻣﺸﺨﺼﺎﺕ ﮐﺎﻻ‬ ‫ﺷﻤﺎﺭﻩ ﻃﺒﻘﻪ ﺑﻨﺪﯼ ﺷﻤﺎﺭﻩ ﻗﻄﻌﻪ‬ ‫ﺭﺩﻳﻒ ﻗﻠﻢ‬

PART FOR ((CHLORIDE)) DUAL BATTERY CHARGER,

1.9KVA. DUAL EXCEL,400VAC /110VDC, 3PH. 50HZ.
5500KW.
TYPE RB315295, S/NO. L05-0720, DRWG. NO. DT315295

REF. CHLORIDE FRANCE

SIX-PULSE BRIDGE NC SUB-ASSY. 24-400VDC. 60A

1 NO , main part no : 5040501206 6556136553 1
PARTS FOR ((CHLORIDE)) DC/AC UPS, 5 KVA.
TYPE RB316089, INPUT 400 VAC, OUTPUT 24VAC,
50HZ, 20.83 A.
DRWG. NO: DT316089, PROJECT NO: 060717/05, NR.
L06-07
REF. CHLORIDE, FRANCE

PCB NRV20 , main part no :

1 NO 0416012057 6556115083 2
:‫ﻧﺎﻡ ﻭ ﺍﻣﻀﺎﺀ ﻭ ﻣﻬﺮ ﻓﺮﻭﺷﻨﺪﻩ‬
Project: UTILITIES AND OFFSITES FOR FAJR II
Customer: NPC-FAJR PETROCHEMICAL CO.

Dual Charger Apodys2 110Vdc 40-26A

Chloride ref: DT319609

Installation, Operation and Maintenance manual Project ID: 100320 / 05
OF: W018479
 CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF REVISIONS

ISSUE DATE REVISED PAGES

05 04/07/11 FINAL ISSUE

Page 2 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF CONTENTS

Title Page

1. SAFETY 7

1.1. GENERAL 7

1.2. NATURE OF HAZARD 8

1.3. SAFETY PRECAUTIONS 8

1.4. EMERGENCY ACTION AND TREATMENT 9

1.5. BATTERY 9

1.6. COSHH STATEMENT 11

2. DESCRIPTION AND OPERATION 14

2.1. DESCRIPTION 14

2.2. TOPOLOGY 14

2.3. OPERATING MODES 16

3. SYSTEM SPECIFICATION 18

3.1. CHARACTERISTICS 18

4. INSTALLATION 19

4.1. HANDLING ON ARRIVAL 19

4.2. STORAGE 20

4.3. PUTTING INTO INSTALLED POSITION 20

4.4. ELECTROLYTE / CELL OIL 21

4.4.1. Cells delivered filled 21
4.4.2. Cells delivered empty 21

4.5. CABLE ENTRIES 21

4.6. TERMINAL CONNECTIONS 21

4.6.1. Phase rotation 21
4.6.2. Battery 21
4.6.3. Neutral 22
4.6.4. Earth 22

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 CHLORIDE
INDUSTRIAL SYSTEMS

4.7. VENTILATION 22

4.8. BATTERY-VENTED CADMIUM NICKEL 22

4.9. BATTERY INSTALLATION 22

5. OPERATING INSTRUCTIONS 24

5.1. LIGHT EMITTING DIODES (LEDS) 25

5.2. DISPLAY 26

5.3. CONTROL PUSH-BUTTONS 27

5.4. PRESENTATION OF THE MENUS 28

5.5. GENERAL MENU 28

5.6. CHARGER BLOCK MENUS 29

5.7. CONTROL PANEL MENUS 30

5.8. CHANGE CHARGER MODE 34

5.9. MEASURES, FAULTS AND WARNINGS 35

5.10. HEADING 35

5.11. ADJUST PARAMETERS WITH THE DISPLAY 38

5.12. OPERATING INSTRUCTIONS 41

5.12.1. Start-up 41
5.12.2. Emergency shutdown 41

6. ROUTINE MAINTENANCE 42

6.1. GENERAL 42

6.2. ONCE A WEEK 42

6.3. ONCE A MONTH 42

6.4. AT LEAST 4 TIMES PER YEAR 43

6.5. ANNUALLY 43

6.6. FANS 43

7. FAULT DIAGNOSIS 44

7.1. DISPLAY MENU 45

7.2. CHARGER FAULT 46

7.3. CHARGER VOLUNTARY STOPPED 47

7.4. CHARGER WARNING 47

Page 4 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

7.5. BATTERY FAULT 48

7.6. BATTERY WARNING 49

8. SPARE PARTS 50

8.1. GENERAL NOTES 50

9. DRAWINGS 51

9.1. GENERAL NOTES 51

10. SPECIFIC FEATURES 52

10.1. BATTERY EARTH FAULT MONITOR - TYPE CIC 52

10.2. SOFT START 53

11. ATTACHMENTS 54

11.1. BATTERY MANUAL 54

Page 5 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF ILLUSTRATIONS

Title Page

Figure 2.1 : Block Diagram 14

Figure 2.2 : Voltage Current Characteristic of Charger 15

Figure 2.3 : Normal Mode 16

Figure 2.4 : Primary AC Supply Fail Mode 17

Figure 2.5 : DC Alarms During Primary Supply Failure 17

Page 6 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

1. SAFETY

Title Page

1.1. GENERAL 7

1.2. NATURE OF HAZARD 8

1.3. SAFETY PRECAUTIONS 8

1.4. EMERGENCY ACTION AND TREATMENT 9

1.5. BATTERY 9

1.6. COSHH STATEMENT 11

1.1. GENERAL

Read this section and this manual before starting work on any part of the system.
When working on live equipment (batteries are always live), a second person who is aware of
all safety precautions and emergency actions should be present at all times.
It is the responsibility of each individual to be aware of national legislation, local legislation
and site rules governing safety and working practices. If in doubt ask.
Use only good quality insulated tools and accessories, properly maintained and calibrated
instruments, and suitable and adequate supports and lifting equipment.
It is essential that all safety instructions are strictly observed.

Note A note in this style is used to emphasise an important point in the text

CAUTION : USED TO PREVENT DAMAGE TO EQUIPMENT

WARNING : A WARNING IS USED TO ALERT PERSONNEL TO

HAZARDS TO PERSONAL SAFETY.

Installation, maintenance and repair of the equipment and batteries should only be
undertaken by trained, experienced and authorised electrical personnel.
The handling, installation and maintenance of the battery associated with this equipment must
be in accordance with the instructions and safety precautions published by the battery
manufacturer and supplied with the battery.

Page 7 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

1.2. NATURE OF HAZARD

ELECTRICAL ENERGY can be supplied from the battery, the charging equipment, the AC
supply or the external alarm or auxiliary control terminals. The battery terminals are LIVE at
all times. A short circuit, even on a discharged battery, will result in a high current which can
cause personal injury, fire or damage to the battery or battery cables.

BATTERY ELECTROLYTE in ALL batteries is dangerous and can cause severe burns if
allowed to come into contact with the skin or eyes. It will also attack clothing and some paint
finishes and metals. NICKEL CADMIUM batteries contain potassium hydroxide (Caustic
Potash) solution.
HYDROGEN and OXYGEN are given off at the cell plates during charging and can be
present at other times, particularly if cells are moved or shaken. Hydrogen in conjunction with
air or oxygen can be explosive in the presence of sparks or flame.
In sealed cells the amount of gas produced is reduced by the use of restricted charging
techniques. If sealed cells are over charged hydrogen and oxygen will be released to the air
via the pressure vent.
Battery cells or cellblocks can be very heavy and often have to be moved to positions with
difficult access. When working on batteries with many cells or blocks, muscle strain may
occur suddenly or after battery installation is complete. The immediate results and long term
effects can be dangerous and painful.

1.3. SAFETY PRECAUTIONS

Use only insulated tools, particularly when connecting a battery. Stand on a rubber mat.
Personal effects of metal such as rings, watches, bracelets and necklaces which may cause a
short circuit and metal objects (pens, tools etc) which may fall from open pockets while
bending over batteries or chargers should be removed.
Transfer to MAINTENANCE MODE (See Section 5) before working on the equipment.
If it is necessary to make adjustments with the equipment connected to the AC supply and/or
the battery, remove only those protective covers which are absolutely necessary for access.
Always use eye protection and rubber gloves when handling cells. Handle cells with care,
ensuring they are kept upright.
Use properly constructed staging or platforms as a resting-place close to the final position and
enlist assistance with large cells or large numbers of cells. Keep the back straight and upright
when lifting cells. Use only proper lifting techniques.
Do not smoke. Do not use open flames. Avoid creating an arc or sparks when working on this
equipment. Avoid wearing clothing which is susceptible to discharge of static electricity.
After work is complete, refit all protective covers and close and lock all doors.

Page 8 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

1.4. EMERGENCY ACTION AND TREATMENT

ELECTRICAL SHOCK - Immediate action is essential. Severe electric shock may affect
heart action and breathing.
Make sure it is safe to approach. If the casualty is in contact with a live conductor, isolate by
switching off the supply. See section 5 "EMERGENCY SHUTDOWN". If this is not
possible, or it is doubtful whether the system is electrically isolated, stand on dry insulating
material and pull or push the casualty clear using dry insulating material, e.g. wood, plastic,
fabrics etc.
If necessary give artificial respiration. Seek the assistance of others to summon medical
attention.
ELECTRICAL BURNS - Apply a dry sterile dressing.
ELECTROLYTE CONTACT - EYES - Irrigate the eyes with a saline solution. If saline
solution is not available wash with clean running water for at least 10 minutes
SKIN - Wash skin burns with plenty of clean water. Remove any contaminated clothing.
Cover the area with dry gauze.

IN ALL CASES SEEK IMMEDIATE MEDICAL ATTENTION.

ELECTROLYTE SPILLAGE - These should be washed away using large volumes of clean
water or mopped up using absorbent material which should then be sealed in secure
containers and sent to a recognised chemical disposal company.
Operatives handling spillage should wear adequate clothing including eye protectors and
gloves. Electrolyte will attack many fabrics. In the event of spillage on clothing, the garments
should be removed and washed thoroughly in large volumes of clean water or discarded.

1.5. BATTERY

WARNING : IN CASES WHERE THE UNIT IS NOT BEING USED, E.G.

DURING MAINTENANCE, IT IS RECOMMENDED TO
DISCONNECT THE BATTERY TO AVOID IT DISCHARGING
AND BEING DAMAGED.

Nature of hazard.
The hazards are

Risk of electric shock

Risk of electric burns
Risk of chemical burns
Risk of poisoning

Page 9 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

ELECTRIC SHOCK

An electric shock from d.c. is more damaging than a shock from a.c. of the same voltage
because d.c. has the characteristics "NO-LET-GO" due to the muscles being contracted by the
single direction of flow of the current. Risk of d.c. shock between battery terminals and earth
is limited in this equipment by incorporating double wound transformers in both the inverter
and rectifier so that the entire d.c. link is floating. Anyone coming into contact with it
experiences only the equalising charge which is unlikely to cause injury. However, this
protection could be defeated if, for example, a metal tool were to fall between a battery
terminal and earth (wooden battery stands are preferred for this reason).
The system would continue to perform normally but the battery and d.c. link would be in a
dangerous condition for anyone intending to carry out maintenance work on it.
Where an earth fault detector is fitted this will raise an alarm. The principle of operation is to
verify that the d.c. positive and negative rails are respectively at symmetrical voltages with
respect to earth. Any abnormal short, even of high resistance, will disrupt this symmetry.

WARNING IF THE EARTH FAULT ALARM IS ACTIVE DO NOT CARRY

OUT MAINTENANCE ON THE BATTERY.

The other possibility for electric shock would be if a person were to come into contact with
two distant battery terminals in the same string. This possibility is avoided by arranging for
the battery layout to be configured so that the maximum distance separates the highest voltage
difference.

ELECTRIC BURNS

The prospective short circuit current from a battery is very great. So even a modest cell will
deliver over a thousand amps into a short circuit such as a metal watch strap, ring or an
uninsulated tool. The battery assembly may consist of well over a hundred cells in series in
many applications so the potential for serious injury exists.

WARNING REMOVE METAL RINGS AND WATCHSTRAPS WHEN

WORKING WITH BATTERIES. USE PROPERLY
INSULATED TOOLS.

CHEMICAL BURNS FROM ELECTROLYTE

The electrolyte is Potassium Hydroxide (Caustic Potash). It is corrosive to clothing and to

living tissue. Even minute traces can cause irritation and make holes in clothes.
Protect the eyes nose and mouth either with goggles and face mask or wear a full face visor.
Protect the body with all enclosing overalls.
Protect the hands with gauntlets.
Protect the feet with boots that have sealed seams. Stitched seams can allow seepage.
An eyewash must be available and any splashes must be flooded with copious amounts of
water or saline solution to dilute the electrolyte. Seek medical attention.
Neutralising agent must be on hand. Scatter it on any electrolyte spills.

Page 10 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

NOTE: Lead acid electrolyte is acidic, Nickel Cadmium electrolyte is alkaline so

different neutralising agents are needed.

POISONING

If electrolyte is swallowed it will be corrosive to internal organs.

Medical opinion is divided on whether to attempt to dilute it with milk or water or to do
nothing until medical help arrives.
Therefore at the outset consult the local medical authority who would have to deal with an
emergency and post suitable notices in the battery room.
EXPLOSION

During the recharge cycle the voltage of the battery will be raised above the gassing voltage
Hydrogen and oxygen will be given off .
Risk of explosion exists when the concentration of hydrogen in air is more than 3.8%.
Therefore the battery room must be adequately ventilated. Volume flow for the required
air change can be calculated as follows;

Q = 55 x N x I ( for vented cells )

Where
Q = The required volume flow in litres / hour
N = The number of cells
I = The maximum charge current

This calculation applies to normal land based installations. Shipboard installations need twice
this calculated flow rate in order to comply with maritime regulations.
If this damages the battery casing there can be a flood of battery electrolyte with risk of acid
burns to the feet of anyone caught in the way. Therefore approach any battery explosion with
caution. The battery room must be adequately ventilated to disperse gases, particularly during
Charge mode or Boost charge. Preclude all sources of ignition. Do not smoke. Ensure all
electrical connections between cells are securing and tight to prevent sparking.

1.6. COSHH STATEMENT

When this equipment finally reaches the end of its useful life it must be disposed of with due
care. It contains material which could present a variety of hazards to the environment and to
living organisms if not dealt with properly. Contact a reputable disposal service. The
following information is a guide to the disposal problems as known at the time of
manufacture.

BATTERY ELECTROLYTE

Nickel Cadmium batteries contain a corrosive electrolyte of Potassium Hydroxide (Caustic

Potash). It must never be washed into public or general-purpose drains.

Page 11 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

BATTERY PLATES

The plates will be of Nickel, Oxides of Nickel, Cadmium and Oxides of Cadmium or a
combination of these dependant upon the condition of the battery. The plates may be porous
and impregnated with Potassium Hydroxide.

SEMICONDUCTORS

There are large semiconductors mounted on extruded aluminium, finned heat sinks. These are
thyristors and diodes. They are all doped silicon semi conductors incorporating P type and N
type silicon. These materials will be hermetically sealed inside discrete devices. Some contain
silicon, copper and other metals and metallic compounds including beryllium. They are sealed
and must not be opened. If the seal is broken, use protective gloves when handling the semi-
conductors and seal them into tough plastic bags before disposal.

PRINTED CIRCUIT BOARDS

The circuit boards are constructed of fibreglass and resin board with copper track. The
components include metal film resistors, silicon transistors, capacitors (both bipolar and
electrolytic). Silicon diodes, micro chips type CMOS, high speed CMOS and TTL.

INDICATOR PANEL

The indicator panel includes light emitting diodes and liquid crystal displays.

WIRES AND CABLES

The internal wiring is of copper bar and copper wire covered with flame retardant PVC.

HEATSINKS

These are of aluminium.

METAL PARTS

These are of mild steel painted with an epoxy resin paint finish.

CAPACITORS

These contain no PCBs or similarly toxic materials. Capacitors are sealed and must not be
opened. If the seal is broken use protective gloves when handling the capacitors and seal them
into tough PVC bags before disposal.

Page 12 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

Restricted Sales Distribution

WARNING:
This is a product for restricted sales distribution to informed
partners. This product must be operated by only personnel
authorised to enter restricted access location. Installation
restrictions or additional measures may be needed to prevent
disturbances.

Page 13 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

2. DESCRIPTION AND OPERATION

Title Page

2.1. DESCRIPTION 14

2.2. TOPOLOGY 14

2.3. OPERATING MODES 16

2.1. DESCRIPTION

This DC Power System is designed to supply DC electric power that is protected from
abnormal occurrences on the public electricity supply. The public supply is used to power a
rectifier in order to store energy in a battery to be used during a power cut. This supply is a
pure quality DC which is immune to defects on the incoming AC supply.

2.2. TOPOLOGY

The equipment consists of two independent systems with a common distribution board. Each
half system consists of two major parts, see Figure 2.1. Block Diagram, the Rectifiers/
Chargers and the Batteries

CHARGER A

RECTIFIER
SUPPLY

OUTPUT
CHARGER B
BATTERY A
RECTIFIER
SUPPLY

BATTERY B

Figure 2.1 : Block Diagram

Page 14 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

VOLTAGE
Boost

Charge
Float

CURRENT

Figure 2.2 : Voltage Current Characteristic of Charger

RECTIFIER/CHARGER

Converts the Primary AC supply to a regulated DC voltage which charges the battery, powers
the load. It operates in four possible modes.

Mode 1. FLOAT MODE. This is the normal mode. It is a constant-voltage charge mode so
battery charge current will tend to taper off to near zero as the battery becomes
fully charged. The voltage chosen is that value at which the internal losses are
compensated by the charge current into a charged battery. The battery is
maintained fully charged yet remains below gassing voltage so that the rate of
loss of electrolyte is negligible.

Mode 2. AC SUPPLY FAIL MODE. When the power to the charger is interrupted the
charger stops and without any switching taking place or operator intervention the
battery supplies the load.

Mode 3. CHARGE MODE Automatically selected when the AC supply is restored.

Slightly higher constant voltage charge to shorten the time to recharge the
battery. It is controlled by two timers. Timer No.1 selects CHARGE MODE after
an AC supply fail has lasted more than a minimum specified time. Timer No. 2
terminates CHARGE MODE after a specified duration (See Test Certificate for
specified times). It can be engaged or terminated manually by an operator by
means of push buttons inside the cubicle.

Mode 4. BOOST MODE. Very high constant voltage charge. Intended for use at
commissioning to complete the forming process of the battery plates. It can only
be engaged manually, by an operator. It may be terminated either manually or
automatically by an inbuilt clock.

Page 15 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

BATTERY

This stores energy from the charger to be used during a power cut when it will discharge to
power the load.
The autonomy of the system during a main fail depends on the amp-hour capacity of the
installed battery.

2.3. OPERATING MODES

Since the 2 chargers/batteries are independent of each other, the mode of one is linked via the
distribution board to the other.

NORMAL MODE

CHARGER A

RECTIFIER
SUPPLY

OUTPUT
CHARGER B
BATTERY A
RECTIFIER
SUPPLY

BATTERY B

Figure 2.3 : Normal Mode

Page 16 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

PRIMARY AC SUPPLY FAIL MODE

If only one charger supply fails, the other charger will continue to feed the load. If both
charger supplies fail, both chargers are stopped and the batteries feed the load.

CHARGER A

RECTIFIER
SUPPLY

OUTPUT
CHARGER B
BATTERY A
RECTIFIER
SUPPLY

BATTERY B

Figure 2.4 : Primary AC Supply Fail Mode

The charger stops and the battery powers the load. The DC voltage falls and the following
alarms occur.

M A IN S
FA IL

FLO A T
V O LTA GE

LO W DC TRIP

Figure 2.5 : DC Alarms During Primary Supply Failure

When the primary AC supply returns the charger will start in Float Mode after a short AC
supply failure or Charge Mode after a long AC supply Failure.

Page 17 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

3. SYSTEM SPECIFICATION

Title Page

3.1. CHARACTERISTICS 18

3.1. CHARACTERISTICS

CHARGER

Nominal AC supply voltage: 400 V

Frequency: 50 Hz

Maximum current per phase: 11.05 A

Floating voltage: 124.6 V

Charge voltage : 129.1 V

Boost voltage : 151.3 V

Boost current : A

Charger nominal current: 60 A

Battery MC 70P

Capacity: 70 Ah

Number of cells 89

Autonomy 240 min.

Page 18 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

4. INSTALLATION
Title Page

4.1. HANDLING ON ARRIVAL 19

4.2. STORAGE 20

4.3. PUTTING INTO INSTALLED POSITION 20

4.4. ELECTROLYTE / CELL OIL 21

4.4.1. Cells delivered filled 21

4.4.2. Cells delivered empty 21

4.5. CABLE ENTRIES 21

4.6. TERMINAL CONNECTIONS 21

4.6.1. Phase rotation 21

4.6.2. Battery 21

4.6.3. Neutral 22

4.6.4. Earth 22

4.7. VENTILATION 22

4.8. BATTERY-VENTED CADMIUM NICKEL 22

4.9. BATTERY INSTALLATION 22

4.1. HANDLING ON ARRIVAL

Unpack the equipment. Take care not to short circuit battery terminals together. Do not
discard keys, battery connectors or accessories when disposing of packing materials.
The cubicle keys will be in a bag taped to the cubicle door
Check the contents against the consignment note. The equipment has a rating plate normally
affixed inside the door panel at the front which will identify the cubicle. Report immediately
to the carrier and supplier if anything is missing or damaged. Delay in reporting may invalid
claims for free repair or replacement.

NOTE: The battery and equipment cubicle often arrive separately.

Page 19 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

The cubicle and battery must be handled with care, keep them upright. Do not drop or subject
them to impact. Cubicles are often top heavy with offset centres of gravity.
The transit case is designed to be handled by a fork lift truck. Note the centre of gravity is
often offset and cubicles may be top heavy, so take care to position the lift forks safely.
The equipment may be lifted by crane. It will be necessary to pass slings underneath the
cubicle. The slings should be positioned under the extremities of the cubicle with safety straps
to prevent them slipping towards the centre when under vertical tension. Also protect
protrusions such as meters and switches from accidental damage from the lifting slings.

4.2. STORAGE

The cubicle should be stored in a clean dry environment. Although it is designed to operate in
an ambient of 0°C to 40°C it can be stored in temperatures as low as -20°C.
If it is to be stored for a long period of time some packing will be needed to prevent dirt
getting inside through grilles and openings. When storing or shipping batteries at sub-zero
temperatures the electrolyte must not be allowed to freeze otherwise mechanical damage can
occur to the plates. Freezing occurs at about -20°C. Batteries should be maintained fully
charged as this keeps the freezing point low. Follow the manufacturer's instructions.

4.3. PUTTING INTO INSTALLED POSITION

The equipment will have to be lifted from its pallet and manoeuvred into position. Note that
battery cubicles are extremely heavy and adequately strong lifting gear is needed.
Once in position adjacent cubicles should be fastened to each other by means of through bolts
(these are provided inside plastic bags inside the cubicles), and to the floor using anchor
bolts. Before fitting each anchor bolt, level the cubicles for both horizontal and vertical planes
as required using incompressible shims.

The procedure for fixing the panels together is as follows:

Take the kit comprising of 4 screws and nuts (HM6 x 70mm)
Remove the 2 transfer screws on the separating panel
But the cubicles together holding the separating panel in place.
The separating panel is sandwiched between the cubicles
Take the 4 screws and open the panel doors
Put the screws through the holes in the uprights which go through the separating panel.
There are 2 at the top and 2 at the bottom. Put the nut on the screw and tighten.

Page 20 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

4.4. ELECTROLYTE / CELL OIL

4.4.1. Cells delivered filled

Check the level of electrolyte. The cells must have a level of electrolyte above the plates. If it
is not the case, adjust the level of electrolyte with distilled or deionised water to 5 mm above
the plate tops. Cells delivered filled have already the cell oil in place.

4.4.2. Cells delivered empty

Fill empty cells with electrolyte to 5 mm above the plate tops. Then add the oil with the
syringe, according to the quantity indicated in the table on the reverse of this card.
NOTE: Please, always refer to manufacturer’s manual.

4.5. CABLE ENTRIES

Refer to the general arrangement drawing for cable entry positions.

Cable sizes are not specified in this manual. The installer must assess the requirements of
each site with regard to the regulations and the relevant codes of practice.
Before making the connections set all power switches, isolators and circuit breakers to OFF.
Remove the battery fuse (if any).
The incoming cables must be secured by means of a strain relief glands to the gland plate
where they enter the cubicle. The gland plate is not pierced so a suitable hole will have to the
cut for each cable entry. The gland plate must be removed from the equipment and taken
elsewhere to be drilled to prevent swarf entering the unit. The wires are then to be routed
to their respective terminals ensuring that there is enough slack to prevent strain on the
terminal. Cable runs should be cleated at intervals of 1/2 metre to rigid structure inside the
cubicle.

4.6. TERMINAL CONNECTIONS

4.6.1. Phase rotation

The equipment requires the phase rotation to be correct for correct operation. Terminals are
labelled for that purpose.

4.6.2. Battery

The battery cable should be connected with the battery fuse removed and the battery isolator
OFF. Check and double check that the polarity of the battery connection is correct. An error
here can cause major damage to the system.

WARNING : DO NOT CLOSE BATTERY ISOLATOR OR FIT FUSES

UNTIL THE FILTER CAPACITORS HAVE BEEN PRE-
CHARGED BY THE CHARGER.

Page 21 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

4.6.3. Neutral

Within the rectifier if no neutral-to-earth link is provided the rectifier neutral adopts the same
potential as the incoming Reserve Neutral if present. Therefore if the Reserve input has no
fixed neutral the rectifier output Phase and Neutral will float.
Note: Do not set up a neutral line that has two separate connections to earth
because this will set up an EARTH LOOP which can have the effect of
introducing noise into the rectifier output.

4.6.4. Earth

The cubicle earth bar must be grounded to a suitable earth point.

Apart from the mandatory safety protection it provides, it also acts as a drain for spurious
noise. Consequently there is a continuous leakage to earth of several tens of mA in normal
operation. Therefore Earth Leakage Trips (ELT) or RCCD on the input should take into
account this small leakage.

4.7. VENTILATION

All ventilation apertures must be kept free and clean. These systems can work in a continuous
environment within 0 to 40°C temperature range, although, ideally the ambient temperature
should be below 25°C.
The heat can be removed from the equipment room by a forced cooling ventilation system or,
alternatively, an air conditioning system.
The required air changes per hour will depend on the system rating, the heat loss and the
cooling air temperature.

4.8. BATTERY-VENTED CADMIUM NICKEL

The battery is a vented cadmium nickel type. It gives off significant amounts of gas (hydrogen
and oxygen).
A specially ventilated battery room is required.
The battery needs its electrolyte topped up routinely

However the battery is suitable for boost charging.

4.9. BATTERY INSTALLATION

WARNING: REMOVE RINGS AND METAL WATCHSTRAPS WHEN

WORKING ON BATTERIES. ALSO USE INSULATED TOOLS.

It is the responsibility of the installer to arrange suitable protection.

The installer will have to connect the inter-cell cables as shown in the battery diagram in
section 10 of this manual.
Before starting, remove the battery fuses and ensure the battery breaker or isolator is OFF.

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BATTERY INSTALLATION CHECK LIST

Battery isolator OFF

Battery fuse removed
Batteries on each group interconnected.
Voltage check of each battery group
Check no short from battery to earth
Check metal battery cubicles (or metal stands) are earthed.
Interconnect the battery in accordance with Battery Diagram.
Use voltmeter to check the voltage of each half of the battery.
Terminate the cables linking the battery and the UPS.
Make absolutely sure these are the correct polarity, as an error will cause substantial
damage when the equipment is started up.

CAUTION: DO NOT CONNECT BATTERY POWER TO THE UPS UNTIL

THE RECTIFIER SOFT START HAS BEEN ALLOWED TO
PRECHARGE THE SMOOTHING CAPACITORS SEE
SECTION 5 FIRST START UP.

Check the ambient temperature and once the system is running measure the temperature
in the battery cubicle.

Once the system is running check the charge voltage in:

− FLOAT MODE
− CHARGE MODE
− BOOST MODE

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5. OPERATING INSTRUCTIONS

Title Page

5.1. LIGHT EMITTING DIODES (LEDS) 25

5.2. DISPLAY 26

5.3. CONTROL PUSH-BUTTONS 27

5.4. PRESENTATION OF THE MENUS 28

5.5. GENERAL MENU 28

5.6. CHARGER BLOCK MENUS 29

5.7. CONTROL PANEL MENUS 30

5.8. CHANGE CHARGER MODE 34

5.9. MEASURES, FAULTS AND WARNINGS 35

5.10. HEADING 35

5.11. ADJUST PARAMETERS WITH THE DISPLAY 38

5.12. OPERATING INSTRUCTIONS 41

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The Charger incorporates the necessary controls, instruments and indicators to allow the operator to
monitor the system status and performance and take any appropriate action. Furthermore, interfaces
are available, which allow extended monitoring and control, as well as service functions.

5.1. LIGHT EMITTING DIODES (LEDS)

The Charger has three Light Emitting Diodes (LEDs) to indicate the overall system operation status as
well as the condition of the sub-assemblies. These LEDs interact with the active mimic diagram
displayed on the graphical display.

Led view Led colour Description Comments

Green Charger normal The charger is running

operation

Green flashing The load is well supplied The battery is in operation and/or a
but there is a problem on warning or a fault is presents
the charger/battery.

Orange Charger warning One or more subassemblies are

affected but the Charger not
stopped

Red Charger fault One or more subassemblies are

faulty and stopped or manually
stopped.
STO

Red flashing CAN communication The charger communication CAN

fault BUS is not correctly plugged or in
failure.

The three LEDs are functioning in a permanent way. It is not compulsory to be on the mimic diagram
part of the display to activate the operation of the LEDs.

The LEDs are functioning independently the ones from the others and they can be lit simultaneously in
some circumstances.

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5.2. DISPLAY

A graphical (64 x 128 pixels) illuminated Liquid Crystal Display (LCD) is provided to enable the
operating parameters, all the measurements and the active mimic diagram of the Charger to be
monitored. The LCD messages are accessed by push-buttons (see figure below).

The text is available in English, French, Spanish or German or Italian.

This local human-machine interface is composed of:

1 A graphical (64 x 128 pixels) illuminated Liquid Crystal Display (LCD).

2 Three LEDs indicating global system functioning and subassemblies functioning.
3 Four push-buttons to access different menus and showed measures.
4 Two push-buttons to power ON and OFF the equipment.
5 One push-button to cut the audible alarm.

1 3 2

5 4

The display has two operating modes:

1. Visualization of an active mimic diagram which gives a graphic representation of the Charger
status.

2. Navigation through various menus for visualization of status or measurements information or

possible actions on the Charger.

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User push-buttons used to control the Graphical Liquid Crystal Display:

Select previous
Up in menus.

Select next
Down in menus.

Validate parameters
OK Enter in menus.

Cancel parameters
C Back in menus.

User push-button used to control the alarm buzzer:

Cancel audible alarm

It cancels internal audible alarm until a new alarm occurs.

5.3. CONTROL PUSH-BUTTONS

In the right part of the display there are two further push-buttons to control the charger:

Starts rectifier/charger operation:

The control incorporates a safety feature to prevent inadvertent operation yet still
allow rapid shutdown in the event of an emergency. This shall be achieved by
pressing the button for 1 second before the charger starts. “SWITCH ON
0 1
CHARGER” message is temporarily displayed on the LCD and an ON pictogram
Rectifier
appears on the charger block.

Stops inverter operation :

The control incorporates a safety feature to prevent inadvertent operation yet still
allow rapid shutdown in the event of an emergency. This shall be achieved by
pressing the button for 2 seconds before the charger starts. “SWITCH OFF
0 1 CHARGER” message is temporarily displayed on the LCD and an OFF pictogram
Inverter appears on the charger block

REMARK: The START and the STOP push-buttons are permanently active. The action is valid
when an ON or OFF message appears on the display. Then graphical display shows
the mimic diagram to confirm the new Charger status.

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5.4. PRESENTATION OF THE MENUS

The information available on the display is of two types: mimic diagram or menu.
The Charger is structured in "blocks". The organization of the information in the menus is the
reflection of this structure.
You will find in the General Menu all the Charger blocks as well as some controls.

Examples of menus:

MENU
Charger
Battery
Reset CHARGER
Event log
Display Setting Status
Changing Mode CHARGER MEASURES
Measurements UDC = 220.1 V
Faults IDC = 60.0 Amp
Warnings U12 = 241.2 V
General menu U23 = 242.0 V
U31 = 241.0 V
I1 = 70.0 Amp
Charger menu

Charger measures
(three-phase Charger)
5.5. GENERAL MENU

The general menu allows access to the following sub-menus:

Sub-menus for the two charger blocks:

Charger

Battery
Sub-menus for the controls:

Reset

Event log

Display Setting

Date/Time

Contact

About

Adjust Param

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To navigate in the menus, use the push-buttons:

to come back to the previous item

to move to the next item

OK to validate the chosen item and access to the sub-menu corresponding to this item.

NOTES:

The menus and sub-menus are circular roll down menus.

The selected item is indicated by an arrow (4) at the beginning of the line.

5.6. CHARGER BLOCK MENUS

1. CHARGER

MENU

Charger
Battery
Reset
Event log
Display Setting

This module allows entry to the following menus:

CHARGER

Charger status menu (to display the charger operational
Status status).
Changing Mode
Measurements
Change charger mode menu (used to change the battery
Faults charge mode).
Warnings
See Change charger mode chapter for more details.

Charger measurements menu (for a list of measurements
on the charger).
See Measures and Faults chapter for more details.

Charger faults menu (for a list of active faults on the
charger).

Charger warnings menu (for a list of active warnings on
the charger).

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2. BATTERY

MENU

Charger
Battery
Reset
Event log
Display Setting

This module allows entry to the following menus:

BATTERY

Battery status menu (to display the battery operational
Status status).
Measurements
Faults
Battery measurements menu (for a list of measurements
Warnings on the battery).

Battery faults menu (for a list of active faults on the
battery).

Battery warnings menu (for a list of active warnings on
the battery).

5.7. CONTROL PANEL MENUS

1. RESET

MENU

Charger
Battery
Reset
Event log
Display Setting

This module allows entry to the following menus:

RESET

RESET charger menu (to erase the memorized charger
Charger Reset defaults)
Event Log Reset
Autonom Calcul Rst
RESET Log event menu

RESET Autonom Calcul Rst menu (to get the initial
value of Battery Capacity used for the calculation of the
battery autonomy
To validate charger log RESET, click on
OK of the RESET to erase. The display will automatically
go back to the general menu.

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2. EVENT LOG

MENU

Charger
Battery
Reset
Event log
Display Setting

This module allows to display one by one all the events memorised into the historical record, in a
chronological order.

Example of event:
EVENT N° 1
Charger Fault
◆High DC voltage
Memorised

Initiated:
17 fev 05 06:18:37

To access the Event Log, select the item Event Log in the general menu of the equipment. The first
event of the list is then displayed. If no event has occurred yet, the message « No event » is displayed.

Every event is detailed as follows:

The concerned block,

The text of the detected fault or alarm,

The nature of the event (indicates if the event appeared or disappeared)

The date and time when the event occurred.

The scheduling and the memorizing of the events depend on the choice of the event mode memorizing
in the Event Log:
Saturable Mode:
The first memorised event corresponds to the first fault or alarms that occurred on the
equipment, after a UPS power on, or after a Even Log reset.
The Event Log is limited up to 100 events and any more events past this limit are memorized.
The classification of the events never changes.
N°1 : the first event which has occurred (oldest).
N°100: the 100th event.

FIFO Mode:
The first event corresponds to the fault or warning memorized occurred most recently.
Once the limit of 100 events memorized in the Event log, if a new event occurs, the oldest
event of the Event log will be removed and event which has just occurred will be memorized.
The classification of the events always corresponds to the order of which has occurred of the
events.
N°1 : the most recent
N°100: oldest. (if 100 recorded events).

See chapter 4 Display Setting for the selection of the Event Log Mode.

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3. DISPLAY SETTING
MENU

Charger
Battery
Reset
Event log
Display Setting

This module allows entry to the following menus:

DISPLAY SETTING

Serial link menu (to direct the serial link of the display
Serial link board)
Language
Event Log Mode
Language menu (to read information in different
language.

Event Log Mode menu (to chose between the two modes
of Event Log memorizing.
Select with Up and Down push-buttons the option requested: to
validate, click on OK . You will then enter the item chosen.

SERIAL LINK: This module allows entry to the following menus indicating the two possibilities.

SERIAL LINK

Internal menu (to direct the serial link to SUB D9 (SK8)
Internal of the display board)
External
Selected Link:
External menu (to direct the serial link to RJ 45 (SK6) of
Internal the display board)
Select with Up and Down push-buttons the serial link

requested: to validate, click on OK . You will then

enter the new serial link chosen.

LANGUAGE: This module allows entry to the following menus:

LANGUAGE

English menu (to read information in English).
English
French
French menu (to read information in French).
Spanish
German
Spanish menu (to read information in Spansh).
Italian

German menu (to read information in German).

Italian menu (to read information in Italian).

To validate the language, click on O K corresponding to

your choice using arrows to go up and down. The display will
then return to the general menu.

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EVENT LOG MODE: This module allows entry to the following menus indicating the two
possibilities.

EVENT LOG MODE

Saturable Mode (allow to memorize the first 100 events)
Saturable Mode
FIFO Mode
FIFO Mode (allow to memorize permanently until the last
Actual Setting: 100 events )
FIFO Mode
Select with Up and Down push-buttons the mode requested: to
validate, click on OK . You will then enter the new mode
chosen.

It is advised to make a Reset of Event Log after having

changed mode

4. DATE / TIME
This module allows access to the actual date and time of the equipment.

5. CONTACT
This module allows access to CHLORIDE contact information.

6. ABOUT
This module allows access to the equipment information (serial number, issue…).

NOTE: The Contact and About sub-menus are not circular roll menus but only roll down menus.

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5.8. CHANGE CHARGER MODE

CHARGER
Status
Changing Mode
Measurements
Faults
Warnings

CHANGING MODE In the Charger menu, click O K on Changing Mode to enter

the sub-menu:
Request Action
No Request
Request action
Charger Status
Floating
Charger status

CHANGING MODE Click O K on Request Action to enter sub-menu:

Request Action▼ Request Action
No Request
Floating

No request
Equalisation
Floating
Boost
Equalisation
Battery Test
Boost

Battery test
Select the needed mode and click O K . The display will go
back to the previous menu to display the required action and
also if the charger has really changed the mode.

Click C to come back to previous menus.

Nota: access to certain modes is not always possible depending
on battery types.

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5.9. MEASURES, FAULTS AND WARNINGS

Each sub-menu Measures, Faults and Warnings are circular roll down menus which can be scanned
with arrows :

To select previous item

To select next item

For Faults and Warnings menus, if no fault or warning is present, you can read a label saying “No
fault” or “No warning”.

For detailed information, please refer to General Arrangement Drawings and to Chapter Fault &
Diagnosis.

5.10. HEADING

The heading displays the active mimic diagram of the Charger system (see figures below). By pressing
the
or or buttons, the user can enter the general menu. While
navigating in the menus, the user can return to the active mimic diagram by pressing the
button as many times as necessary.

NOTE: If the user does not request any action (such as pressing a button) for 5 minutes while
displaying the menus, the system will automatically return to the display of the heading active mimic
diagram.

Active mimic panel

(Single phase output UPS)

The active mimic diagram displays the following information:

 Graphical view of the connected load,
 Graphical view and percentage of the battery charge level,
 Graphical view of the power flow,
 Graphical view of the status of each subassembly.

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Below is one example of active mimic situations:

Mains input failure

Charger stopped
Battery discharging

Active mimic panel (Single phase)

The display shows the following information:

1 Charger status
2 Battery status
3 Battery current status
4 Output current status
5 Battery charger level status

3
4

5 2

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Pictograms list:

Charger block
Charger ON and OK
Charger ON but with warnings ON
Charger stopped following faults detection
Charger voluntary OFF
Communication problem with the charger

Battery block
Battery OK
Battery warnings detection
Battery faults detection
Communication problem with the battery
Add to battery pictograms – battery status:
Battery in charge
Battery in discharge

.... cut off flow

__ continuous flow

NOTE 1:

Pictogram voluntary OFF has priority on and .

Pictogram has priority on .

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5.11. ADJUST PARAMETERS WITH THE DISPLAY

During commissioning, some parameters of the equipment could be adjusted in order to

customize some setting, to take into account substantial modifications of the project (for example:
changing battery cells number).
It is also possible to adjust date and time of the equipment to inform correctly the "Event Log"

This document explains the procedure to adjust parameters of the equipment with CANDIS board
(without using a PC or PPVis software of supervision).

Modifiable parameters

Find below the parameters modifiable directly by the Display:

0 Cell Number choice battery cell number *

1 Boost Ref Setting regulation voltage for boost mode
2 Equal Ref Setting regulation voltage for equalization mode
3 Float Ref Setting regulation voltage for floating mode
4 Bat Test Ref Setting charger safety voltage for battery test
5 Battery Check Ref Setting voltage monitoring during battery test
6 Tempo Equal Timer for Equalization mode
7 Tempo Boost Timer for Boost mode
8 Tempo Bat Test Timer for battery test
9 High Voltage Thresh Threshold for high DC voltage alarm
10 High Voltage Reset Reset for high DC voltage alarm
11 Charger low voltage Thresh Threshold for charger low DC voltage alarm
12 Charger low voltage Reset Reset for charger low DC voltage alarm
13 Begin of Discharge Thresh Threshold for battery beginning of discharge alarm
14 Begin of Discharge Reset Reset for battery beginning of discharge alarm
15 Imminent Shutdown Thresh Threshold for battery imminent end of discharge alarm
16 Imminent Shutdown Reset Reset for battery imminent end of discharge alarm
17 End of Discharge Thresh Threshold for battery end of discharge
18 End of Discharge Reset Reset for battery end of discharge
19 Charger I ref Setting charger limitation current
20 Bat I Ref Setting battery limitation current in floating and equalization mode
21 Bat I Boost Ref Setting battery limitation current in Boost mode
22 Bat I high Thresh Threshold for battery high current
23 Adjust Year Setting Year
24 Adjust Month Setting Month
25 Adjust Day Setting Day
26 Adjust Hour Setting Hour
27 Adjust Minute Setting Minute

* be careful, battery cell number modification doesn’t auto correct regulation voltage and
threshold alarm. It is necessary to adjust the whole of the parameters individually.

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Adjustment procedure

1. Unplug RJ45 cables on the CANDIS board (SK1 and SK2).

This operation could be done with equipment under voltage and running: the
charger still run correctly.
On these connectors only signals forward low tension so this operation is not
dangerous.

2. Switch jumper SW1 and SW2 in position ON.

3. Plug RJ45 cable on CANDIS board (SK1 and SK2)

4. Consequently new menu appears at the end of the drop-down list: "Adjust param".
Use the keys and to choose the right menu.
Choose the "Adjust param" menu and validate with O K key.

MENU
Display Setting
Date/Time
Contact
About
Adjust Param

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5. Choose the parameter to set in the drop-down list with and keys
Validate with O K key.

MENU
Cell Number
Boost Ref
Equal Ref
Float Ref
Bat Test Ref

6. Setting the parameter:

Use and to set parameter value.
Press OK key to validate.

Param
Cell Number

New value
102
Actual System Value
105

7. If needed, adjust other parameter:

Take again items 5 and 6 for the other parameters.

8. Confirm the new adjustments

In the menu "Adjust param" press the C key.
If at least a parameter was modified, then the following menu appears:

SAVE
No
Yes

Choose "YES" to safeguard the modifications or "No" pour escape.

Press OK to validate your choice.

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9. Unplug RJ45 cables on the CANDIS board (SK1 and SK2)

10. Switch jumper SW1 and SW2 in position OFF.

5.12. OPERATING INSTRUCTIONS

5.12.1. START-UP

1. Starting situation. All switches, breakers and isolators “OFF”.

2. Switch Primary Supply ON. Close AC input circuit breaker Q3.
3. The LCD display board shall lit and begin an initialisation sequence for 10 seconds.
4. Push on “1” control push button for one second to start the charger on front door
display if the charger block shows an initial “OFF state”.
5. Charger output voltage will increase to normal.
6. Use a hand held test meter to check :
a) Charger voltage
b) Battery voltage
7. If both previous voltages are correct in amplitude and polarity, charger isolators
(Q2_1/ Q2_2) ON.
8. Switch battery protection fuse switches (Q5_1/ Q5_2) ON.
9. Close Q01/Q02.
10. Repeat steps 1-7 for start up second charger.
System is now powered up.

5.12.2. EMERGENCY SHUTDOWN

To be used in the event of an emergency such as fire or casualty.

CAUTION : This procedure interrupts the load.
For a single charger :
1. Switch battery isolators (Q5_1 and Q5_2) OFF.
2. Push on “0” control push button for 2 seconds to stop the charger on the front door
display.
3. Switch Primary Isolators OFF. Open Q3.

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6. ROUTINE MAINTENANCE

Title Page

6.1. GENERAL 42

6.2. ONCE A WEEK 42

6.3. ONCE A MONTH 42

6.4. AT LEAST 4 TIMES PER YEAR 43

6.5. ANNUALLY 43

6.6. FANS 43

6.1. GENERAL

Under normal operating conditions only preventative maintenance is required. The intervals
between maintenance actions will vary according to the level of remote monitoring and the
standard of cleanliness of the equipment room.

6.2. ONCE A WEEK

Check all alarm and status indicators.

Check meter readings are normal. Compare them with the test certificate. Check the cause of
any significant changes. For example, change in load, recent discharge
Record all abnormal occurrences in the service log

6.3. ONCE A MONTH

Check ventilation apertures are clean and clear of obstructions

On cells check the battery electrolyte levels and top up if necessary in accordance with the
manufacturers instructions.

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6.4. AT LEAST 4 TIMES PER YEAR

Check ventilation grilles

Visually check electrical connections and component for signs of overheating or corrosion.
Rectify as necessary.
Check painted and plated components for signs of damage or corrosion. Rectify as necessary

6.5. ANNUALLY

Carry out a test discharge of the battery for the specified autonomy.

Note: The test should be carried out at a time of low risk and followed immediately by
a full recharge. Consult the battery manufacturer's instructions for guidance on
frequency of testing, depth of discharge etc.

6.6. FANS

Fans are rated for a 5-year life. It is recommended that fan failures be pre-empted by renewing
them after four years.

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7. FAULT DIAGNOSIS

Title Page

7. FAULT DIAGNOSIS 44

7.1. DISPLAY MENU 45

7.2. CHARGER FAULT 46

7.3. CHARGER VOLUNTARY STOPPED 47

7.4. CHARGER WARNING 47

7.5. BATTERY FAULT 48

7.6. BATTERY WARNING 49

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7.1. DISPLAY MENU

Charger fault is designed by on the charger

pictogram.

Select Charger in the general menu and click on

OK to valid.

In order to have access to the Faults menu, select

Faults in the Charger menu and click on OK to
valid.

In this menu all faults appear (instantaneous and

memorized faults)

If no faults are shown on the display then No

faults appears in this menu.

Click twice on Cancel to come back to the

general menu.

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7.2. CHARGER FAULT
CHARGER FAULTS POSSIBLE CAUSES
AC Supply fault Loss of AC supply, lack of one
phase, too high or too low
amplitude, wrong phase
sequence for three phase charger
Wrong phase sequence On three phase charger, the
phase sequence is not correct
High DC Voltage Loss of charger voltage
regulation in case of charger
alone configuration (The fault is
not memorized and the charger
runs intermittently in order to
continue to supply the DC load).
High DC Voltage Loss of charger voltage
Memorised regulation in case of parallel
configuration charger (The fault
is memorized and the charger is
cut) . The DC load is supplied
by the redundant charger(s)
Too high I battery Loss of battery current
Memorised regulation.
Charger fuse blown Charger bridge high speed fuse
blown due to sudden short
circuit on the DC side or
problem on charger control
loop.
Input protection opened Input protection tripped or
opened.
3 other charger fault specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement drawing (PA)
CHLORIDE
INDUSTRIAL SYSTEMS
SOLUTIONS
Check fault nature on the LCD
display (amplitude or phase
problem).
Check input supplies.
If AC supply is OK on power
input terminals, check auxiliary
fuses on internal electronic door
(F10)
Interchange two phases, to
reverse direction of phase
rotation
Check all the wires connected
to the INCA circuit board. If the
wiring is correct, the problem
can be linked with card
problem:
Call engineer.
Check all the wires connected
to the INCA circuit board. If the
wiring is correct, the problem
can be linked with card
problem: Call engineer.
Reset this memorized fault with
the LCD display charger reset.
Check all the wires connected
to the INCA board and the
battery current Hall effect
sensor. If the wiring is correct,
the problem can be linked with
card or sensor problem: Call
engineer.
Reset this memorized fault with
the LCD display charger reset.
Check loading, thyristors,
renew fuse, rearm the
microswitch detector. In case of
a new occurrence, check the
control wiring on the INCA
board. The problem can be
linked with a board: Call
engineer.
Check loading and possible
short circuit or overload on the
DC side. Rearm the protection.
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7.3. CHARGER VOLUNTARY STOPPED

Charger switch Off The charger is cut from the Give an ON charger order with
CANDIS board. CANDIS push button.

7.4. CHARGER WARNING

CHARGER WARNING POSSIBLE CAUSES SOLUTIONS

DC voltage low The charger DC voltage is not
yet in voltage level regulation:
Overload on the DC side, or
battery is charging in current
limitation after a discharge, or
possible problem of voltage
regulation due to a too low AC
mains level.
Test mode The charger is in special
production or commissioning
mode.
Check if the DC load is not too
high or if the charger is in
battery current limitation, by
looking at IDC or Ibatt current
level on the display board. If
both preceeding points are not
satisfied, check if the AC mains
amplitude is not too low before
to call engineer.
Call engineer

3 other charger warning specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement drawing (PA)

Battery fault is designed by on the battery

pictogram.

Select Battery in the general menu and click on

OK to valid.

In order to have access to the Faults menu, select

Faults in the Battery menu and click on OK to
valid.

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In this menu only faults appear (instantaneous

and memorized faults)

If no faults are shown on the display then No

faults appears in this menu.

Click twice on Cancel to come back to the

general menu.

7.5. BATTERY FAULT

BATTERY FAULTS POSSIBLE CAUSES SOLUTIONS

Battery Test Fault Following an automatic or a Check battery connections.

Memorized manual battery test, a battery Check battery not damaged.
fault has been detected due a too Call engineer.
rapid discharge rate. Reset this memorized fault with
the LCD display charger reset.
End of discharge Low DC trip level has been If AC supply fail, no action.
passed. Check no charger fault.
Call engineer.
Battery protection Battery fuse or circuit breaker Check DC loading then re-
opened open. connect.
3 other battery fault specific messages can be detected in this part due to equipment
customisation. Check these optional messages in the General Arrangement drawing (PA)

Page 48 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

7.6. BATTERY WARNING

BATTERY WARNINGS POSSIBLE CAUSES SOLUTIONS

DC Earth fault Current leakage between battery Danger, DO NOT CARRY OUT
and earth or DC polarities and BATTERY
earth. MAINTENANCE.Check battery
cable insulation. Check battery
cell insulation. Try to isolate the
failed part by switching DC load
or battery off.
Call engineer.
Battery begin of discharge AC supply fail. If AC supply fail, no action.
Check no charger fault.
Call engineer.
Imminent shutdown AC supply fail. If AC supply fail, no action.
Battery voltage is low. Indicates Check no charger fault.
battery discharged close to trip Call engineer
level.

3 other battery warning specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement drawing (PA)

Page 49 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

8. SPARE PARTS

Titre Page

8.1. GENERAL NOTES 50

8.1. GENERAL NOTES

To maintain the high level of performance and reliability of these secure power systems the
following rules are applied:

− Careful choice of components

− Manufacturing according to recognised standards and codes of practice
− Strict quality control
− Careful adjustment and regulation.

However, in use, problems can occur which require parts to be replaced or repaired.
Replacement of defective parts can sometimes be made by the user to restore correct
operation of the system which may then be returned to service. For this spare parts will be
required.
For continued reliability only approved, identical replacement parts may be used. Where
necessary these must be adjusted to the original set values. Chloride Industrial Systems After
Sales Service Department has records of recommended spares for all equipment.
When ordering spare parts it is essential to identify the equipment by quoting the serial
number and the design number (RB) stamped on the rating plate.

Page 50 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

9. DRAWINGS

Title Page

9.1. GENERAL NOTES 51

9.1. GENERAL NOTES

The drawings included in this manual are current at time of issue but are not necessarily
changed at each revision. Check the site master drawing system for the latest issue status.
Wire numbering. Internal wiring is identified on a point to point basis. Each wire has an
individual number and is identified at both ends unless too short for two markers. All wire
numbers and termination points are detailed on the schematic diagrams.

Terminal identification. Terminals are identified on the schematic.

Drawing identification. The Chloride drawing prefixes identify the type of drawing

PA - General arrangement drawing PA-319609

SU - Single line diagram SU-319609
DT - Technical file DT-319609

Circuit card drawings. Detailed circuit drawings are not provided. These represent the
proprietary knowledge and experience of Chloride Industrial Systems and are commercially
confidential. In addition they do not assist with the understanding, operation and maintenance
of the UPS systems. Except in the hands of adequately trained, experienced and qualified
personnel we have found that these diagrams are often used to adjust or modify the systems in
ways detrimental to the performance and reliability of the systems.
These diagrams will only be supplied to personnel who have successfully completed a
Chloride Industrial Systems training course or who have adequately proved to the quality
manager of Chloride Industrial Systems that their level of training, experience and
qualification is sufficient to enable them to use the information safely. Such issue is on a
personal basis and does not authorise 3rd party use.

Page 51 of 54
Page Titre/Title 00 01 02 03 04 05 06 07 08 09 10 11 12 13

0 TITLE PAGE xx xx xx
1 GENERAL ARRANGEMENT xx xx
2 CUBICLE FOOTPRINT DETAIL xx CUSTOMER : NPC-FAJR PETROCHEMICAL CO.
3 BOTTOM GLAND PLATE AND AIR INLET ARRANGEMENT xx
4 DISPLAY DETAIL xx PROJECT : UTILITIES AND OFFSITES FOR FAJR II
PROJECT

EQUIPMENT : DUAL CHARGER APODYS 2 110Vdc / 40A-18A

ITEM / TAG : 95-CH-21

GENERAL ARRANGEMENT

16/02/2011 LLO AS BUILT 02

24/06/2010 LLO Charger Rating Updated 01 Indice/ Page

Issue
27/04/2010 NFE FOR APPROVAL 00
PA319609 02 0
Date Creat. Verif. App. Description modif. Indice/Issue
 Height : 1982 mm
Width : 1600 mm TAG: =CNV1+A2
Depth : 608 mm =CH1+A1 =CH2+A3
Protection : IP41
Paint : RAL7032
Lock : Retractable Handle P43
V

Key : 9233
Cable entry : BOTTOM
Panel thickness : 1.2 mm
Door thickness : 2 mm
Paint thickness : 50 µm

Terminals
Cable support
200mm 400mm

225 kg 120 kg 225 kg

=CH1+A1 : CHARGER 1 CUBICLE
=CH2+A3 : CHARGER 2 CUBICLE
=CNV1+A2 : DC REGULATOR 1 CUBICLE
200 mini 200 mini
-P43 : DC REGULATOR OUTPUT VOLTAGE
WALL WALL
TAG: 95-CH-21
600 400 600

SHIPPING BREAK

382x120 182x120 382x120

GENERAL ARRANGEMENT Ind/Rev Page

16/02/2011 LLO AS BUILT PA319609 02 1
Date Creat. Verif. App. Description modif.
 430 230

85 85

600 400

Ø13

72.5

100

ANGLE FOOT DETAIL

CUBICLE FOOTPRINT DETAIL Ind/Rev Page

27/04/2010 NFE FOR APPROVAL PA319609 00 2
Date Creat. Verif. App. Description modif.
 600 400

382x120 182x120

109.0 109.0

WxH GLAND PLATE

WxH AIR INLET

BOTTOM GLAND PLATE AND AIR INLET ARRANGEMENT Ind/Rev Page

27/04/2010 NFE FOR APPROVAL PA319609 00 3
Date Creat. Verif. App. Description modif.
 Rectifier information
STOP

Status indications Measurements indications

Charger OFF Charger output DC voltage
C CHARGER
Initialisation Charger output DC current
100%
Charger Stop Charger input voltage (between each phase)
Idc Equalisation mode Charger input current (on each phase)
Equalisation imposed Charger input frequency
100% 0
Number of mains failures
Floating mode
Battery test mode
OK 0 1 Battery test imposed
Boost mode

Faults indications Warnings indications

No fault Test mode
High DC voltage DC voltage low
High DC voltage memorised Overload inhibit
Too high Ibattery memorised Charger in current limit
LED view LED colour Description Comments Charger fuse blown Transformer overload detected
Input protection open
DC UPS or rectifier Charger off
Green / Wrong phase sequence
normal operation AC supply fault
Transformer overload detected
Green flashing Load on battery Loads powered by battery.

DC UPS or rectifier One or more subassembly are

Orange
WARNING affected but not stopped.
Battery information
DC UPS or rectifier Subassembly are faulty and
Red
FAULT stopped or manually stopped. Status indications Measurements indications
Normal Battery voltage
STOP CAN communication The UPS communication CAN Discharging Battery current
Red flashing BUS is not correctly plugged or Charging Battery temperature
FAULT Fault or warning Battery autonomy (%)
in failure.
Faults indications Warnings indications
No fault DC earth fault
Cancel audible alarm Battery test fault memorised Battery begin discharge
End of discharge Imminent shutdown
(It cancels internal audible alarm until a new alarm occurs) Battery protection open
Battery fuse blown
User switches used to control the Graphical Liquid Crystal Display:

Select previous Cancel parameters

Up in menus
C Back in menus Remote Alarms
Charger general alarm
DC earth fault
High DC voltage
Select next Valid parameters End of discharge
Down in menus OK Enter in menus Charger mains fault
Battery disconnecting or fuse blown

DISPLAY DETAIL Ind/Rev Page

27/04/2010 NFE FOR APPROVAL PA319609 00 4
Date Creat. Verif. App. Description modif.
Page Titre/Title 00 01 02 03 04 05 06 07 08 09 10 11 12 13

0 TITLE PAGE xx xx xx
CUSTOMER : NPC-FAJR PETROCHEMICAL CO.
1 SINGLE LINE DIAGRAM xx xx

PROJECT : UTILITIES AND OFFSITES FOR FAJR II

PROJECT

EQUIPMENT : DUAL CHARGER APODYS 2

110Vdc / 40A-18A

ITEM / TAG : 95-CH-21

SINGLE LINE DIAGRAM

16/02/2011 LLO AS BUILT 02

24/06/2010 LLO UPDATED 01 Indice/ Page

Issue
27/04/2010 NFE FOR APPROVAL 00
SU319609 02 0
Date Creat. Verif. App. Description modif. Indice/Issue
 =CH1+A1 APODYS =CNV1+A2
DISPLAY
U, I, F U, I U
-P43
V
CHARGER 1 =
A51_1 -K6
110VDC/40-18A
-T3
AC SUPPLY 1 -Q3 -V2 -Q2 -Q01
(11.5kVA)
(25A / 50kA) (40A) (40A) -A46 (32A/10kA) -Q001
3 Ph+N / 400 VAC +/-10%
SPARE
50Hz +/-5%
Terminals P10 10 DIODES / 1 step
32A

K100 T-V
-Q002
-P01 0.3 KW LV SWITCHBOARD
BATTERY 1 110VDC
Type : NiCd I
DC LOAD 1
Reference : MC70P
-Q5_1 110VDC +10/-15%
Number of Cells : 89 Terminals P10
Capacity : 70Ah (40A)
Autonomy : 240min * (P16)
-Q003
1.20KW 6kV SWITCHBOARD

BATTERY 2 110VDC
Type : NiCd
Reference : MC70P
Number of Cells : 89
Capacity : 70Ah -Q5_2 -Q004
Autonomy : 240min (40A) SPARE

* (P16)
Float : 1.4V/cell I
Charge : 1.45V/cell
Manu. Boost : 1.7V/cell
End of Disch.: 1.051V/cell
=CH2+A3 APODYS
DISPLAY
U, I, F U, I U

CHARGER 2
A51_2 -K6
110VDC/40-18A
-T3 -Q02
AC SUPPLY 2 -Q3 (11.5kVA) -V2 -Q2
-A46 (32A/10kA)
3 Ph+N / 400 VAC +/-10% (25A / 50kA) (40A) (40A)
50Hz +/-5%
Terminals P10 10 DIODES / 1 step
32A

=CH1+A1 : CHARGER 1 CUBICLE

=CH2+A3 : CHARGER 2 CUBICLE
=CNV1+A2 : DC REGULATOR 1 CUBICLE

-Q2 : CHARGER OUTPUT ISOLATOR DC DISTRIBUTION

-Q3 : CHARGER INPUT CIRCUIT BREAKER LABEL RATING TERMINAL
-P43 : DC REGULATOR OUTPUT VOLTAGE -Q5_1&2 : BATTERY FUSE SWITCH
-Q001 16A P10
-Q01 : DC LOAD 1 MAIN CIRCUIT BREAKER
-Q002 16A P10
-Q02 : DC LOAD 2 MAIN CIRCUIT BREAKER
SIZE OF TERMINALS -Q003 16A P10
-Q001 TO Q004 : DISTRIBUTION FUSE SWITCH
P6 : 0.14 to 4 mm² -Q004 16A P10
-A46 : DROPPING DIODES
P8 : 0.2 to 6 mm²
P10 : 0.5 to 10 mm²
-K6 : DROPPING DIODE SHUNT CONTACTOR
P12 :1.5 to 16 mm² -V2 : CHARGER OUTPUT BLOCKING DIODE
P16 : 1.5 to 35 mm²
P32 (M10) : 25 to 50 mm² -K100 : EARTH FAULT MONITOR
P40 (M12) : 35 to 95 mm² -P01 : OUTPUT VOLTAGE TRANSDUCER 4-20 mA
P46 (M12) : 50 to 150 mm² * INTERCONNECTION CABLES
P53 (M16) : 70 to 240 mm² NOT SUPPLIED BY CHLORIDE
Co Busbars: Copper busbars

SINGLE LINE DIAGRAM Ind/Rev Page

24/06/2010 LLO UPDATED SU319609 01 1
Date Creat. Verif. App. DESCRIPTION
 CHLORIDE
INDUSTRIAL SYSTEMS

10. SPECIFIC FEATURES

Title Page

10.1. BATTERY EARTH FAULT MONITOR - TYPE CIC 52

10.2. SOFT START 53

10.1. BATTERY EARTH FAULT MONITOR - TYPE CIC

APPLICATION

The earth fault monitor type CIC can be used with any floating dc supply but has been
specifically designed for use with the Chloride range of ac and dc UPS equipment. The CIC
continuously monitors isolation of the dc circuit with reference to earth.

OPERATION

The earth fault monitor type CIC is entirely electronic and consists of a normally balanced
resistor bridge, amplifiers and comparators.
When an earth fault occurs, the voltages across the resistor bridge become unbalanced. This
voltage deviation is amplified and compared to enable the fault to be detected.
Indication of the polarity (i.e. positive to earth or negative to earth) of the fault is provided by
two light emitting diodes. In addition, detection of a fault energises a relay with a volt free
changeover contact. This contact can then be used to allow remote fault indication.
The monitor is fitted with two pushbuttons, which allow the simulation of either a positive or
negative earth fault for testing purposes.

CHARACTERISTICS

Power supply derived from source being monitored

(i.e. external power supply not required)

Hysterisis varies according to sensitivity adjustment.

Fault indication time delayed to protect against transient conditions.

Volt free changeover contact rating 100W dc, 2000VA-8A ac.

Page 52 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

Nominal Nominal Nominal

Voltage Current Power Sensitivity Adjustment Range Time Delay
(dc) Consumption Consumption
24V 72mA 1.73W 25kΩ (9.5mA) to 9kΩ (7mA) 1.5 seconds
48V 48mA 2.3W 4kΩ (12mA) to 21kΩ (2.4mA) 1.5 seconds
120V 54mA 6.48W 13kΩ (9mA) to 56kΩ (2mA) 1.5 seconds
220V 47mA 10.3W 30kΩ (7.3mA) to 124kΩ (1.8mA) 1.5 seconds

SCHEMATIC DIAGRAM

TEST

TEST

10.2. SOFT START

The inrush current to the rectifier is limited on this equipment. It consists of a time delayed
contactor which puts resistors in series with the rectifier input while the input transformer is
being magnetised.

Page 53 of 54
 CHLORIDE
INDUSTRIAL SYSTEMS

11. ATTACHMENTS
Title Page

11.1. BATTERY MANUAL 54

11.1. BATTERY MANUAL

Page 54 of 54
 S3.4
April 2007

Single Cell Range

Technical manual
 Single Cell Range
Contents

1. Introduction 3 7. Battery sizing principles

2. Benefits of the Alcad pocket plate in stationary standby applications 15
Ni-Cd battery 4 7.1 The voltage window 15
2.1 Complete reliability 4 7.2 Discharge profile 15
2.2 Long cycle life 4 7.3 Temperature 15
2.3 Exceptionally long lifetime 4 7.4 State of charge or recharge time 15
2.4 Low maintenance 4 7.5 Ageing 16
2.5 Wide operating temperature range 4 7.6 Floating effect 16
2.6 Fast recharge 4 8. Battery charging 17
2.7 Resistance to mechanical abuse 4 8.1 Charging generalities 17
2.8 High resistance to electrical abuse 4 8.2 Constant voltage charging methods 17
2.9 Simple installation 4 8.3 Charge acceptance 18
2.10 Extended storage 4 8.4 Charge efficiency 20
2.11 Well-proven pocket plate construction 4 8.5 Temperature effects 20
2.12 Environmentally safe 4 8.6 Commissioning 20
2.13 Low life-cycle cost 4 9. Special operating factors 21
3. Electrochemistry of Ni-Cd batteries 5 9.1 Electrical abuse 21
4. Construction features of the 9.2 Mechanical abuse 21
pocket plate battery 6 10. Installation and operating
4.1 Plate assembly 7 instructions 22
4.2 Separation 8 10.1 Receiving the shipment 22
4.3 Electrolyte 8 10.2 Storage 22
4.4 Terminal pillars 8 10.3 Installation 22
4.5 Venting system 8 10.4 Commissioning 24
4.6 Cell container 8 10.5 Charging in service 24
5. Battery types and applications 9 10.6 Periodic maintenance 25
5.1 Type L 9 10.7 Changing electrolyte 25
5.2 Type M 9 11. Maintenance of batteries in
5.3 Type H 9 service 26
5.4 Choice of type 9 11.1 Cleanliness/mechanical 26
5.5 Applications 9 11.2 Topping-up 26
6. Operating features 10 11.3 Capacity check 27
6.1 Capacity 10 11.4 Recommended maintenance
6.2 Cell voltage 10 procedure 27
6.3 Internal resistance 10 12. Disposal and recycling 28
6.4 Effect of temperature on performance 11
6.5 Short-circuit values 12
6.6 Open circuit loss 12
6.7 Cycling 12
6.8 Effect of temperature on lifetime 13
6.9 Water consumption and gas evolution 14
1 Introduction

The nickel-cadmium battery is the most reliable
battery system available in the market today. Its
unique features enable it to be used in applications
and environments untenable for other widely
available battery systems.
It is not surprising, therefore, that the nickel-
cadmium battery has become an obvious first
choice for users looking for a reliable, long life,
low maintenance system.
This manual details the design and operating
characteristics of the Alcad pocket plate battery to
enable a successful battery system to be achieved.
A battery which, while retaining all the advantages
arising from nearly 100 years of development of the
pocket plate technology, can be so worry free that its
only major maintenance requirement is topping-up
with water.

3 SINGLE CELL TECHNICAL MANUAL

2 Benefits of the Alcad pocket plate Ni-Cd battery
2.1 Complete reliability
The Alcad battery does not suffer from the sudden
death failure associated with the lead acid battery
(see section 4.1 Plate assembly).
2.2 Long cycle life
The Alcad battery has a long cycle life even when the
charge/discharge cycle involves 100% depth of
discharge (see section 6.7 Cycling).
2.3 Exceptionally long lifetime
A lifetime in excess of twenty years is achieved by the
Alcad battery in many applications, and at elevated
temperatures it has a lifetime unthinkable for other
widely available battery technologies (see section 6.8
Effect of temperature on lifetime).
2.4 Low maintenance
With its generous electrolyte reserve, the Alcad
battery reduces the need for topping-up with water,
and can be left in remote sites for long periods
without any maintenance (see section 6.9 Water
consumption and gas evolution).
2.5 Wide operating temperature range
The Alcad battery has an electrolyte which allows it
to have a normal operating temperature of from
– 20°C to + 50°C (– 4°F to + 122°F), and to accept
extreme temperatures, ranging from as low as – 50°C
to up to + 70°C (– 58°F to up to + 158°F) (see section
4.3 Electrolyte).
2.6 Fast recharge
The Alcad battery can be recharged at currents which
allow very fast recharge times to be achieved
(see section 8.3 Charge acceptance).
2.7 Resistance to mechanical abuse
The Alcad battery is designed to have the mechanical
strength required to withstand all the harsh treatment
associated with transportation over difficult terrain
(see section 9.2 Mechanical abuse).
4 SINGLE CELL TECHNICAL MANUAL
2.8 High resistance to electrical abuse
The Alcad battery will survive abuse which would
destroy a lead acid battery, for example overcharging,
deep discharging, and high ripple currents
(see section 9.1 Electrical abuse).
2.9 Simple installation
The Alcad battery can be used with a wide range of
stationary and mobile applications as it produces no
corrosive vapours, uses corrosion-free polypropylene
containers and has a simple bolted connector
assembly system (see section 10 Installation and
operating instructions).
2.10 Extended storage
When stored in the empty and discharged state under
the recommended conditions, the Alcad battery can
be stored for many years (see section 10.2 Storage).
2.11 Well-proven pocket plate
construction
Alcad has nearly 100 years of manufacturing and
application experience with respect to the nickel-
cadmium pocket plate product, and this expertise has
been built into the twenty-plus years’ design life of
the battery (see section 4 Construction features of the
pocket plate battery).
2.12 Environmentally safe
Alcad operates a dedicated recycling centre to recover
the nickel, cadmium, steel and plastic used
(see section 12 Disposal and recycling).
2.13 Low life-cycle cost
When all the factors of lifetime, low maintenance
requirements, simple installation and storage and
resistance to abuse are taken into account, the Alcad
battery becomes the most cost effective solution for
many professional applications.
3 Electrochemistry of Ni-Cd batteries
The nickel-cadmium battery uses nickel hydroxide as
the active material for the positive plate, and
cadmium hydroxide for the negative plate.
The electrolyte is an aqueous solution of potassium
hydroxide containing small quantities of lithium
hydroxide to improve cycle life and high
temperature operation.
The electrolyte is only used for ion transfer; it is not
chemically changed or degraded during the
charge / discharge cycle. In the case of the lead acid
battery, the positive and negative active materials
chemically react with the sulphuric acid electrolyte
resulting in an ageing process.
The support structure of both negative and
positive plates is steel. This is unaffected by the
electrolyte, and retains its strength throughout the life
of the cell. In the case of the lead acid battery, the
basic structure of both plates are lead and lead oxide
which play a part in the electrochemistry of the
process and are naturally corroded during the life of
the battery.
The charge / discharge reaction of a nickel-cadmium
battery is as follows:
discharge
2 NiOOH + 2H2O + Cd
charge
5 SINGLE CELL TECHNICAL MANUAL
During discharge the trivalent nickel hydroxide is
reduced to divalent nickel hydroxide, and the
cadmium at the negative plate forms
cadmium hydroxide.
On charge, the reverse reaction takes place until the
cell potential rises to a level where hydrogen is
evolved at the negative plate and oxygen at the
positive plate which results in water loss.
Unlike the lead acid battery, there is little change in
the electrolyte density during charge and discharge.
This allows large reserves of electrolyte to be used
without inconvenience to the electrochemistry
of the couple.
Thus, through its electrochemistry, the nickel-
cadmium battery has a more stable behaviour than
the lead acid battery, giving it a longer life, superior
characteristics and a greater resistance against abusive
conditions.
Nickel-cadmium cells have a nominal voltage
of 1.2 volts (V).
2 Ni(OH)2 + Cd(OH)2
4 Construction features of the pocket plate battery

Connector cover Flame-arresting vent

In line with
EN 50272-2 (safety)
with IP2 level. Terminal seal
This is mechanically clipped
and provides an excellent seal.
This minimises carbonation
deposits.

Plate tab
Spot welded to the plate
side frames, to the upper
Plate group bus
edge of the pocket plate
Connects the plate tabs
and to the plate group bus.
with the terminal post.
Plate tabs and terminal
posts are projection
welded to the plate Separating grids
group bus. These separate the plates
and insulate the plate
frames from each other.
The grids allow free
circulation of electrolyte
Plate
between the plates.
Horizontal pockets of
double-perforated
steel strips.

Plate frame
Seals the plate pockets
and serves as a current
collector.

Alcad cells fulfil all requirements

specified by IEC 60623

6 SINGLE CELL TECHNICAL MANUAL

4.1 Plate assembly
The nickel-cadmium cell consists of two groups of
plates, the positive containing nickel hydroxide and
the negative containing cadmium hydroxide.
The active materials of the Alcad pocket plate battery
are retained in pockets formed from steel strips
double-perforated by a patented process.
These pockets are mechanically linked together, cut to
the size corresponding to the plate width and
compressed to the final plate dimension. This process
leads to a plate which is not only mechanically very
strong but also retains its active material within a steel
containment which promotes conductivity and Nickel-cadmium batteries have an exceptionally good
minimises electrode swelling. lifetime and cycle life because their plates are not
gradually weakened by corrosion, as the structural
These plates are then welded to a current carrying bus component of the plate is steel. The active material of
bar assembly which further ensures the mechanical the plate is not structural, only electrical. The alkaline
and electrical stability of the product. electrolyte does not react with steel, which means
that the supporting structure of the battery stays
intact and unchanged for the life of the battery.
There is no corrosion and no risk of “sudden death”.
In contrast, the lead plate of a lead acid battery is
both the structure and the active material and this
leads to shedding of the positive plate material and
eventual structural collapse.

7 SINGLE CELL TECHNICAL MANUAL

4.2 Separation
Separation between plates is provided by injection
molded plastic separator grids, integrating both plate
edge insulation and plate separation.
By providing a large spacing between the positive and
negative plates and a generous quantity of electrolyte
between plates, good electrolyte circulation and gas
dissipation are provided, and there is no stratification
of the electrolyte as found with lead acid batteries.
4.3 Electrolyte
The electrolyte used in the Alcad battery, a solution of
potassium hydroxide and lithium hydroxide, is
optimised to give the best combination of
performance, life, energy efficiency and a wide
temperature range.
The concentration of the standard electrolyte is such
as to allow the cell to be operated to temperature
extremes as low as – 20°C (– 4°F) and as high as
+ 50°C (+ 122°F). This allows the very high
temperature fluctuation found in certain regions to be
accommodated.
For very low temperatures a special high density
electrolyte can be used.
The electrode material is less reactive with the
alkaline electrolyte (nickel-cadmium secondary
batteries) than with acid electrolytes (lead acid
secondary batteries). Furthermore, during charging
and discharging in alkaline batteries the electrolyte
works mainly as a carrier of oxygen or hydroxyl ions
from one electrode to the other; hence the
composition or the concentration of the electrolyte
does not change noticeably. In the charge/discharge
reaction of the nickel-cadmium battery, the
potassium hydroxide is not mentioned in the reaction
formula. A small amount of water is produced during
the charging procedure (and consumed during the
discharge). The amount is not enough to make it
possible to detect if the battery is charged or
discharged by measuring the density of the
electrolyte.
8 SINGLE CELL TECHNICAL MANUAL
Once the battery has been filled with the correct
electrolyte either at the battery factory or during the
battery commissioning there is no need to check the
electrolyte density periodically. The density of the
electrolyte in the battery either increases or decreases
as the electrolyte level drops because of water
electrolysis or evaporation or rises at topping-up.
Interpretation of density measurements is difficult
and could be misleading.
In most applications the electrolyte will retain its
effectiveness for the life of the battery and will never
need replacing. However, under certain conditions,
such as extended use in high temperature situations,
the electrolyte can become carbonated.
If this occurs the battery performance can be
improved by replacing the electrolyte.
The standard electrolyte used for the first fill in cells
is E22 and for replacement in service is E13.
4.4 Terminal pillars
Short terminal pillars are welded to the plate bus bars
using a well established and proven method. These
posts are manufactured from steel bar, internally
threaded for bolting on connectors, and nickel-plated.
The sealing between the cover and the terminal is
provided by a compressed visco-elastic sealing surface
held in place by compression lock washers. This
assembly is designed to provide satisfactory sealing
throughout the life of the product.
4.5 Venting system
The Alcad battery is fitted with a special flame-
arresting flip-top vent to give an effective and safe
venting system.
4.6 Cell container
The material in the cell containers is translucent
polypropylene, a tough and well-proven plastic for
battery use. The lid and container are welded
together by heat sealing, creating a
homogeneous joint.
5 Battery types and applications
In order to provide an optimum solution for the wide
range of battery applications which exist, the Alcad
battery is constructed in three performance ranges.
5.1 Type L
The L type is designed for applications where the
battery is required to provide a reliable source of
energy over relatively long discharge periods.
Normally, the current is relatively low in comparison
with the total stored energy, and the discharges are
generally infrequent. Typical uses are power back-up
and bulk energy storage.
5.2 Type M
The M type is designed for applications where the
batteries are usually required to sustain electrical loads
for between 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 back-up applications.
5.3 Type H
The H type is designed for applications where there
is a demand for a relatively high current over short
periods, usually less than 30 minutes in duration.
The applications can have frequent or infrequent
discharges.
The range is typically used in starting and power
back-up applications.
Table 1– General selection of cell range
9 SINGLE CELL TECHNICAL MANUAL
5.4 Choice of type
In performance terms the ranges cover the full time
spectrum from rapid high current discharges of a
second to very long low current discharges of many
hours. Table 1 shows in general terms the split
between the ranges for the different discharge types.
The choice is related to the discharge time and the
end of discharge voltage. There are, of course, many
applications where there are multiple discharges, and
so the optimum range type should be calculated. This
is explained in section 7 Battery sizing.
5.5 Applications
Alcad batteries are providing standby back-up and
emergency power for industry and commerce,
government and defence departments, electricity
supply and distribution installations, railway
authorities, hospitals, airports, public buildings, bus
and commercial vehicle companies, communications
networks, oil and petrochemical industries, etc. The
applications are all industrial applications such as
emergency lighting, switchgear, UPS, process control,
data and information systems, security and fire alarm
systems, signalling, turbine and engine starting and
electric train duties.
6 Operating features
6.1 Capacity
The nickel-cadmium battery capacity is rated in
ampere-hours (Ah) and is the quantity of electricity at
+ 20°C (+ 68°F) which it can supply for a 5 hour
discharge to 1.0 V after being fully charged for
7.5 hours at 0.2 C5 A. This figure conforms to the
IEC 60623 standard.
According to the IEC 60623 (Edition 4), 0.2 C5 A is also
expressed as 0.2 It A. The reference test current ( It ) is
expressed as:
It A = Cn Ah
1h
where:
Cn is the rated capacity declared by the
manufacturer in ampere-hours (Ah),
and
n is the time base in hours (h) for
which the rated capacity is declared.
6.2 Cell voltage
The cell voltage of nickel-cadmium cells results from
the electrochemical potentials of the nickel and the
cadmium active materials in the presence of the
potassium hydroxide electrolyte. The nominal voltage
for this electrochemical couple is 1.2 V.
10 SINGLE CELL TECHNICAL MANUAL
6.3 Internal resistance
The internal resistance of a cell varies with the
temperature and the state of charge and is, therefore,
difficult to define and measure accurately.
The most practical value for normal applications is the
discharge voltage response to a change in discharge
current.
The internal resistance of an Alcad pocket plate cell
depends on the performance type and size. The
normal values are given in the performance data
brochures.
The normal values are for fully charged cells. For
lower states of charge the values increase. For cells
50% discharged the internal resistance is about
20% higher, and when 90% discharged, it is about
80% higher. The internal resistance of a fully
discharged cell has very little meaning.
Reducing the temperature also increases the internal
resistance, and at 0°C (+ 32°F), the internal resistance
is about 40% higher.
6.4 Effect of temperature on
performance
Variations in ambient temperature affect the
performance of the cell and this needs to be taken
into account when sizing the battery.
Low temperature operation has the effect of reducing
the performance, but the higher temperature
characteristics are similar to those at normal
temperatures. The effect of low temperature is more
marked at higher rates of discharge.
The factors which are required in sizing a battery to
compensate for temperature variations are given in a
graphical form in Figure 1(a), H type, Figure 1(b),
M type and Figure 1(c) L type for operating
temperatures from – 20°C to + 50°C (-4°F to +122°F).

Figure 1 (a) –
Temperature
de-rating factors
for L type cell

Figure 1 (b) –
Temperature
de-rating factors
for M type cell

Figure 1 (c) –
Temperature
de-rating factors
for H type cell

11 SINGLE CELL TECHNICAL MANUAL

6.5 Short-circuit values 6.7 Cycling
The typical short-circuit value in amperes for an Alcad The Alcad battery is designed to withstand the wide
pocket plate battery cell is approximately 9 times the range of cycling behaviour encountered in stationary
ampere-hour capacity for L type, 16 times the applications. This can vary from low depth of
ampere-hour capacity for M type and 28 times the discharges to discharges of up to 100% and the
ampere-hour capacity for H type. number of cycles that the product will be able to
provide will depend on the depth of discharge.
A battery with conventional bolted assembly
connections will withstand a short-circuit current of The less deeply a battery is cycled, the greater the
this magnitude for many minutes without damage. number of cycles it is capable of performing before it
is unable to achieve the minimum design limit.
6.6 Open circuit loss A shallow cycle will give many thousands of
The state of charge of a cell on open circuit slowly operations, whereas a deep cycle will give only
decreases with time due to self-discharge. hundreds of operations.
In practice this decrease is relatively rapid during the
first two weeks, but then stabilises to about 2% per
month at + 20°C (+ 68°F).
The self-discharge characteristics of a nickel-cadmium
cell are affected by the temperature. At low
temperatures, the charge retention is better than at
normal temperature, and so the open circuit loss is
reduced. However, the self-discharge is significantly
increased at higher temperatures.
The typical open circuit loss for a pocket plate
battery for a range of temperatures which may be
experienced in a stationary application is shown
in Figure 2.

Figure 2 –
Capacity loss on
open circuit
stand

12 SINGLE CELL TECHNICAL MANUAL

Figure 3 gives typical values for the effect of depth of
discharge on the available cycle life, and it is clear that
when sizing the battery for a cycling application, the
number and depth of cycles have an important
consequence on the predicted life of the system.
6.8 Effect of temperature on lifetime
The Alcad battery is designed as a twenty year life
product, but as with every battery system, increasing
temperature reduces the expected life. However, the
reduction in lifetime with increasing temperature is
very much lower for the nickel-cadmium battery than
for the lead acid battery.
The reduction in lifetime for the nickel-cadmium
battery, and for comparison, a high quality lead acid
battery is shown graphically in Figure 4. The values
13 SINGLE CELL TECHNICAL MANUAL
for the lead acid battery are as supplied by the
industry and found in Eurobat and IEEE
documentation.
In general terms, for every 9°C (16.2°F) increase in
temperature over the normal operating temperature
of + 25°C (+ 77°F), 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 valve-regulated lead acid (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 + 50°C (+ 122°F).
Figure 3 –
Typical cycle
life versus
depth of
discharge
Figure 4 –
Effect of
temperature
on lifetime
6.9 Water consumption and gas
evolution
During charging, more ampere-hours are supplied to
the battery than the capacity available for discharge.
These additional ampere-hours must be provided to
return the battery to the fully charged state and, since
they are not all retained by the cell and do not all
contribute directly to the chemical changes to the
active materials in the plates, they must be dissipated
in some way. This surplus charge, or overcharge,
breaks down the water content of the electrolyte
into oxygen and hydrogen, and pure distilled or
deionized water has to be added to replace this loss.
Water loss is associated with the current used for
overcharging. A battery which is constantly cycled,
i.e. is charged and discharged on a regular basis,
will consume more water than a battery on
standby operation.
In theory, the quantity of water used can be found by
the Faradic equation that each ampere-hour of
overcharge breaks down 0.366 cm3 of water. However,
in practice, the water usage will be less than this, as
the overcharge current is also needed to counteract
self-discharge of the electrodes.
14 SINGLE CELL TECHNICAL MANUAL
The overcharge current is a function of both voltage
and temperature, so both have an influence on the
consumption of water. Figure 5 gives typical water
consumption values over a range of voltages for
different cell types.
Example : An MB 415 P is floating at 1.43 V/cell. The
electrolyte reserve for this cell is 1400 cm3. From
Figure 5, an M type cell at 1.43 V/cell will use
0.27 cm3/month for one Ah of capacity. Thus an
MB 415 P will use 0.27 x 415 = 112 cm3 per month
and the electrolyte reserve will be used in
1400 = 12.5 months.
112
The gas evolution is a function of the amount of
water electrolysed into hydrogen and oxygen and are
predominantly given off at the end of the charging
period. The battery gives off no gas during a normal
discharge.
The electrolysis of 1 cm3 of water produces 1865 cm3
of gas mixture and this gas mixture is in the
proportion of 2/3 hydrogen and 1/3 oxygen. Thus the
electrolysis of 1 cm3 of water produces 1243 cm3 of
hydrogen.
Figure 5 –
Water
consumption
values for
different
voltages and
cell types
7 Battery sizing principles in stationary standby applications
There are a number of methods which are used to
size nickel-cadmium batteries for standby floating
applications. The method employed by Alcad is the
IEEE 1115 recommendation which is accepted
internationally. The method takes into account
multiple discharges, temperature de-rating,
performance after floating and the voltage window
available for the battery.
A significant advantage of the nickel-cadmium battery
compared to a lead acid battery, is that it can be fully
discharged without any inconvenience in terms of life
or recharge. Thus, to obtain the smallest and least
costly battery, it is an advantage to discharge the
battery to the lowest practical value in order to obtain
the maximum energy from the battery.
The principle sizing parameters which are of
interest are:
7.1 The voltage window
This is the maximum voltage and the minimum
voltage at the battery terminals acceptable for the
system. In battery terms, the maximum voltage gives
the voltage which is available to charge the battery,
and the minimum voltage gives the lowest voltage
acceptable to the system to which the battery can be
discharged. In discharging the nickel-cadmium
battery, the cell voltage should be taken as low as
possible in order to find the most economic and
efficient battery.
15 SINGLE CELL TECHNICAL MANUAL
7.2 Discharge profile
This is the electrical performance required from the
battery for the application. It may be expressed in
terms of amperes for a certain duration, or it may be
expressed in terms of power, in watts or kW, for a
certain duration. The requirement may be simply one
discharge or many discharges of a complex nature.
7.3 Temperature
The maximum and minimum temperatures and the
normal ambient temperature will have an influence
on the sizing of the battery. The performance of a
battery decreases with decreasing temperature and
sizing at a low temperature increases the battery size.
Temperature de-rating curves are produced for all cell
types to allow the performance to be recalculated.
7.4 State of charge or recharge time
Some applications may require that the battery shall
give a full duty cycle after a certain time after the
previous discharge. The factors used for this will
depend on the depth of discharge, the rate of
discharge, and the charge voltage and current.
A requirement for a high state of charge does not
justify a high charge voltage if the result is a high end
of discharge voltage.
7.5 Ageing It is therefore necessary to take this into account in
any calculations concerning batteries in float
Some customers require a value to be added to allow applications.
for the ageing of the battery over its lifetime. This
may be a value required by the customer, for example As the effect of reducing the voltage level is to reduce
10%, or it may be a requirement from the customer the autonomy of the battery, the effect can be
that a value is used which will ensure the service of considered as reducing the performance of the
the battery during its lifetime. The value to be used battery and so performance down-rating factors are
will depend on the discharge rate of the battery and used.
the conditions under which the discharge is carried out.
7.6 Floating effect
When a nickel-cadmium cell is maintained at a fixed
floating voltage over a period of time, there is a
decrease in the voltage level of the discharge curve.
This effect begins after one week and reaches its
maximum in about 3 months. It can only be
eliminated by a full discharge/charge cycle and cannot
be eliminated by a boost charge.

16 SINGLE CELL TECHNICAL MANUAL

8 Battery charging

8.1 Charging generalities
The Alcad battery can be charged by all normal
methods. Generally, batteries in parallel operation
with charger and load are charged with constant
voltage. In operations where the battery is charged
separately from the load, charging with constant
current or declining current is possible. High-rate
charging or overcharging will not damage the battery,
but excessive charging will increase water
consumption to some degree.
8.2 Constant voltage charging methods
Batteries in stationary applications are normally
charged by a constant voltage float system and this
can be of two types: the two-rate type, where there is
an initial constant voltage charge followed by a lower
floating voltage; or a single rate floating voltage.
The single voltage charger is necessarily a compromise
between a voltage high enough to give an acceptable
charge time and low enough to give a low water
usage. However, it does give a simpler charging
system and accepts a smaller voltage window than
the two-rate charger.
The two-rate charger has an initial high voltage stage
to charge the battery followed by a lower voltage
maintenance charge. This allows the battery to be
charged quickly, and yet, have a low water
consumption due to the low maintenance charge or
float voltage level.
The values used for the Alcad pocket plate battery
ranges for single and two-rate charge systems are as
shown in Table 2 below.
To minimise the water usage, it is important to use a
low charge voltage per cell, and so the minimum
voltage for the single level and the two level charge
voltage is the normally recommended value. This also
helps within a voltage window to obtain the lowest,
and most effective, end of discharge voltage per cell
(see section 7 Battery sizing).
The values given as maximum are acceptable to the
battery, but would not normally be used in practice,
particularly for the single level, because of high
water usage.

Cell type Single level: (V/cell) Two level: (V/cell)

min max min max floating
L 1.43 1.50 1.47 1.70 1.42 ± 0.01
M 1.43 1.50 1.45 1.70 1.40 ± 0.01
H 1.43 1.50 1.45 1.70 1.40 ± 0.01
Table 2 – Charge and float voltages for the Alcad pocket plate battery ranges

17 SINGLE CELL TECHNICAL MANUAL

8.3 Charge acceptance
A discharged cell will take a certain time to achieve a
full state of charge. Figures 6(a), (b) and (c) give the
capacity available for typical charging voltages
recommended for the pocket plate battery range
during the first 30 hours of charge from a fully
discharged state.

Figure 6(a) –
Typical recharge
times from a
fully discharged
state for the
L type cell

Figure 6(b) –
Typical recharge
times from a
fully discharged
state for the
M type cell

18 SINGLE CELL TECHNICAL MANUAL

 Figure 6(c) –
Typical recharge
times from a
fully discharged
state for the
H type cell

These graphs give the recharge time for a current limit The charge time for an M type cell at different charge
of 0.2 C5 amperes. Clearly, if a lower value for the regimes for a fixed voltage is given in Figure 6(d).
current is used, e.g. 0.1 C5 amperes, then the battery
If the application has a particular recharge time
will take longer to charge.
requirement then this must be taken into account
If a higher current is used then it will charge more when calculating the battery.
rapidly. This is not in general a pro rata relationship
due to the limited charging voltage.

Figure 6(d) –
Typical recharge
times for
different charge
rates for the
M type cell

19 SINGLE CELL TECHNICAL MANUAL

8.4 Charge efficiency 8.6 Commissioning*
The charge efficiency of the battery is dependent on It is recommended that a good first charge should be
the state of charge of the battery and the given to the battery. This is a once only operation, and
temperature. For much of its charge profile, it is is essential to prepare the battery for its long service
recharged at a high level of efficiency. life. It is also important for discharged and empty cells
which have been filled, as they will be in a totally
In general, at states of charge less than 80% the
discharged state.
charge efficiency remains high, but as the battery
approaches a fully charged condition, the charging A constant current first charge is preferable and this
efficiency falls off. should be such as to supply 200% of the rated capacity
of the cell. Thus, a 250 Ah cell will require
8.5 Temperature effects 500 ampere-hours input, e.g. 50 amperes for 10 hours.
As the temperature increases, the electrochemical *Please refer to the operating instructions in section 10.
behaviour becomes more active, and so, for the same
floating voltage, the current increases. As the
temperature is reduced then the reverse occurs.
Increasing the current increases the water loss, and
reducing the current creates the risk that the cell will
not be sufficiently charged.
For standby application, it is normally not required to
compensate the charging voltage with the temperature.
However if water consumption is of main concern,
temperature compensation should be used if the battery
is operating at high temperature such as + 35°C (+ 95°F).
At low temperature (< 0°C/+ 32°F), there is a risk of
poor charging and it is recommended either to adjust
the charging voltage or to compensate the
charging voltage with the temperature (value:
– 3 mV/°C / – 1.7mV/°F), starting from an ambient
temperature of +20°C to +25°C (+ 68°F to + 77°F).

20 SINGLE CELL TECHNICAL MANUAL

9 Special operating factors
9.1 Electrical abuse
Ripple effects
The nickel-cadmium battery is tolerant to high ripple
and will accept ripple currents of up to 0.2 C5 A Ieff.
In fact, the only effect of a high ripple current is that
of increased water usage. Thus, in general, any
commercially available charger or generator can be
used for commissioning or maintenance charging of
the Alcad battery. This contrasts with the valve-
regulated lead acid battery (VRLA) where relatively
small ripple currents can cause battery overheating,
and will reduce life and performance.
Over-discharge
If more than the designed capacity is taken out of a
battery then it becomes deep discharged and
reversed. This is considered to be an abuse situation
for a battery and should be avoided.
In the case of lead acid batteries this will lead to
failure of the battery and is unacceptable.
The Alcad battery will not be damaged by over-
discharge but must be recharged to compensate for
the over-discharge.
21 SINGLE CELL TECHNICAL MANUAL
Overcharge
In the case of the Alcad battery, with its generous
electrolyte reserve, a small degree of overcharge
over a short period will not significantly alter the
maintenance period. In the case of excessive
overcharge, water replenishment is required, but
there will be no significant effect on the life of
the battery.
9.2 Mechanical abuse
Shock loads
The Alcad battery concept has been tested to
IEC 68-2-29 (bump tests at 5 g, 10 g and 25 g) and
IEC 77 (shock test 3 g), where g = acceleration.
Vibration resistance
The Alcad battery concept has been tested to
IEC 77 for 2 hours at 1 g, where g = acceleration.
External corrosion
The Alcad battery is manufactured in durable
polypropylene. All external metal components are
nickel-plated or stainless steel, protected by an anti-
corrosion oil, and then protected by a rigid plastic cover.
10 Installation and operating instructions
Important recommendations
■ Never allow an exposed flame or spark near
the batteries, particularly while charging.
■ Never smoke while performing any operation
on the battery.
■ For protection, wear rubber gloves, long
sleeves, and appropriate splash goggles or
face shield.
■ The electrolyte is harmful to skin and eyes. In
the event of contact with skin or eyes, wash
immediately with plenty of water. If eyes are
affected, flush with water, and obtain
immediate medical attention.
■ Remove all rings, watches and other items
with metal parts before working on the
battery.
■ Use insulated tools.
■ Avoid static electricity and take measures for
protection against electric shocks.
■ Discharge any possible static electricity from
clothing and/or tools by touching an earth-
connected part “ground” before working on
the battery.
10.1 Receiving the shipment
Unpack the battery immediately upon arrival. Do not
overturn the package. Transport seals are located
under the cover of the vent plug.
■ The battery is normally shipped discharged
and empty. Do not remove the plastic transport
seals until ready to fill the battery.
■ If the battery is shipped filled and charged, the
battery is ready for installation. Remove the plastic
transport seals only before use.
The battery must never be charged with the
plastic transport seals in place as this can cause
permanent damage.
10.2 Storage
Store the battery indoors in a dry, clean, cool location
(0°C to + 30°C/+ 32°F to + 86°F) and well ventilated
space on open shelves.
Do not store in direct sunlight or expose to excessive heat.
22 SINGLE CELL TECHNICAL MANUAL
■ Cells empty and discharged
• Alcad recommends to store cells empty and
discharged. This ensures compliance with
IEC 60623 section 4.9 (storage).
• Cells can be stored like this for many years.
■ Cells filled and charged
• If cells are stored filled, they must be fully charged
prior to storage.
• Cells may be stored filled and charged for a period
not exceeding 12 months from date of dispatch.
Storage of a filled battery at temperatures above
+30°C (+ 86°F) can result in loss of capacity. This can
be as much as 5% per 10°C (18°F) above +30°C (+ 86°F)
per year.
• When deliveries are made in cardboard boxes, store
without opening the boxes.
• When deliveries are made in plywood boxes,
open the boxes before storage. The lid and the
packing material on top of the cells must be
removed.
10.3 Installation
10.3.1 Location
Install the battery in a dry and clean room. Avoid direct
sunlight and heat.
The battery will give the best performance and
maximum service life when the ambient temperature is
between +10°C to + 30°C (+ 50°F to + 86°F).
Alcad batteries can be fitted on to stands, floor-
mounted or fitted into cabinets.
Local standards or codes normally define the
mounting arrangements of batteries, and these must
be followed if applicable. However, if this is not the
case, the following comments should be used as a guide.
When mounting the battery, it is desirable to maintain
an easy access to all cells, they should be situated in a
readily available position. Distances between stands,
and between stands and walls, should be sufficient to
give good access to the battery.
The overall weight of the battery must be considered
and the load bearing on the floor taken into account
in the selection of the battery accommodation.
If the battery is enclosed in a cabinet or other such
enclosed space, it is important to provide sufficient
space to disperse the gases given off during charging,
and also to minimise condensation.
It is recommended that at least 200 mm be allowed
above cell tops, to ensure easy access during
inspection and topping-up, and that enough space is
allowed between cabinet walls and the battery to
avoid any risk of short-circuits. Flip-top vents may be
turned through 180° to achieve the most convenient
position for topping-up.
10.3.2 Ventilation
Special regulations for ventilation may be valid
in your area depending on the applications.
When the battery is housed in a cubicle or enclosed
compartment, it is necessary to provide adequate
ventilation.
During the last part of high-rate charging, the battery
is emitting gases (oxygen and hydrogen mixture).
If it is required to establish that the ventilation of the
battery room is adequate, then it is necessary to
calculate the rate of evolution of hydrogen to ensure
that the concentration of hydrogen gas in the room is
kept within safe limits.
The theoretical limit for hydrogen concentration is 4%.
However, some standards call for more severe levels
than this, and levels as low as 1% are sometimes
required.
To calculate the ventilation requirements of a battery
room, the following method can be used:
1 Ah of overcharge breaks down 0.366 cm of water,
3 much lower than when the cell is being charged, and
and 1 cm3 of water produces 1.865 litres of gas in the
proportion 2/3 hydrogen and 1/3 oxygen. Thus
1 Ah of overcharge produces 0.42 litres of hydrogen.
Therefore, the volume of hydrogen evolved from a
battery per hour
= number of cells x charge current x 0.42 litres
or
= number of cells x charge current x 0.00042 m3.
The volume of hydrogen found by this calculation can
be expressed as a percentage of the total volume of
23 SINGLE CELL TECHNICAL MANUAL
the battery room, and from this, the number of air
changes required to keep the concentration of
hydrogen below a certain level can be calculated.
Example:
A battery of 96 cells, type HB 28O P on a three
step, two tier stand, is placed in a room of
dimensions 3m x 5m x 3m.
The charging system is capable of charging at 0.1 C5
and so the charging current is 28 amperes.
The volume of hydrogen evolved per hour in this, the
worst, case is: = 96 x 28 x 0.00042 m3 = 1.13 m3.
The total volume of the room is 3 x 5 x 3 = 45m3
Approximate volume of battery and stand does
not exceed 2 m3, and so, the volume of free air in
the room is 43 m3.
Therefore, the concentration of hydrogen gas after
charging for 1 hour at full gassing potential at
0.1 C5 will be: = 1.13 = 2.7%
43
Thus, to maintain a maximum concentration of
2% (for example), the air in the room will need
changing
2.7 = 1.4 times per hour.
2
In practice, a typical figure for natural room
ventilation is about 2.5 air changes per hour, and so,
in this case, it would not be necessary to introduce
any forced ventilation.
In a floating situation, the current flowing is very
the gas evolution is minimal; it may be calculated in
the same way using typical floating currents.
10.3.3 Mounting
Verify that cells are correctly interconnected with
the appropriate polarity. The battery connection to
load should be with nickel-plated cable lugs.
Recommended torques for terminal bolts are:
•M 6 = 11 ± 1.1 N.m
•M 8 = 20 ± 2 N.m
• M 10 = 30 ± 3 N.m
The connectors and terminal should be corrosion-
protected by coating with a thin layer of anti-
corrosion oil.
Remove the transport seals and close the vent plug.
10.3.4 Electrolyte/cell oil
■ Cells delivered filled and charged:
Check the level of electrolyte. It should not be
more than 20 mm below the upper level mark.
If this is not the case, adjust the level with
distilled or deionized water. Cells delivered filled
have already the cell oil in place.
■ Cells delivered empty and discharged:
If the electrolyte is supplied dry, prepare it
according to its separate instructions sheet. The
electrolyte to be used is E22. Remove the
transport seals just before filling.
Fill the cells about 20 mm above the lower level
mark with electrolyte.
Wait 4 to 24 hours and adjust if necessary
before commissioning.
It is recommended to add the cell oil after the
commissioning charge, with the syringe,
according to the quantity indicated in the
Installation and Operating Instructions sheet.
10.4 Commissioning
Verify that the ventilation is adequate during
this operation.
A good commissioning is important. Charge at
constant current is preferable.
When the charger maximum voltage setting is too low
to supply constant current charging, divide the battery
into two parts to be charged individually. If the
current limit is lower than indicated in the table of the
Installation and Operating Instructions sheet, charge
proportionally for a longer time.
■ For cells filled on location or for filled cells
which have been stored more than 6 months:
• charge 10 h at 0.2 C5 A (recommended)
• or charge for 30 h at 1.65 V/cell, current limited
to 0.2 C5 A
• discharge at 0.2 C5 A to 1.0 V/cell
• charge according to section below.
24 SINGLE CELL TECHNICAL MANUAL
■ For cells filled and charged by the factory and
stored less than 6 months:
• charge 10 h at 0.2 C5 A (recommended)
• or charge 24 h at 1.65 V/cell, current limited
to 0.2 C5 A
• or charge 48 h at 1.55 V/cell, current limited
to 0.2 C5 A.
■ Cell oil and electrolyte after commissioning:
Wait for 4 hours after commissioning. Cells
delivered filled by the factory have already the cell
oil in place.
For cells filled on location, add the cell oil with the
syringe.
Check the electrolyte level and adjust it to the
upper level mark by adding:
• distilled or deionized water for cells filled by the
factory
• electrolyte for cells filled on location.
The battery is ready for use.
10.5 Charging in service
■ Continuous parallel operation, with occasional
battery discharge.
Recommended charging voltage
(+ 20ºC to + 25ºC/+ 68ºF to + 77ºF):
 for two level charge:
• float level
= 1.42 ± 0.01 V/cell for L cells
= 1.40 ± 0.01 V/cell for M and H cells
• high level
= 1.47 - 1.70 V/cell for L cells
= 1.45 - 1.70 V/cell for M and H cells
A high voltage will increase the speed and efficiency
of the recharging.
 for single level charge: 1.43 - 1.50 V/cell.
■ Buffer operation, where the load exceeds the
charger rating.
Recommended charging voltage
(+ 20ºC to + 25ºC/+ 68ºF to + 77ºF): 1.50 - 1.60 V/cell.
10.6 Periodic maintenance 10.7 Changing electrolyte
■ Keep the battery clean using only water. Do not In most stationary battery applications, the electrolyte
use a wire brush or solvents of any kind. Vent plugs will retain its effectiveness for the life of the battery.
can be rinsed in clean water if necessary. However, under special battery operating conditions,
■ Check the electrolyte level. Never let the level fall if the electrolyte is found to be carbonated, the
below the lower mark. Use only distilled or battery performance can be restored by replacing the
deionized water to top-up. Experience will tell the electrolyte.
time interval between topping-up. The electrolyte type to be used for replacement in
Note: these cells is: E13.
Once the battery has been filled with the Refer to "Electrolyte Instructions".
correct electrolyte either at the battery factory
or during the battery commissioning, there is
no need to check the electrolyte density
periodically.
Interpretation of density measurements is
difficult and could be misleading.
■ Check every two years that all connectors are tight.
The connectors and terminal bolts should be
corrosion-protected by coating with a thin layer of
anti-corrosion oil.
■ Check the charging voltage. It is important that
the recommended charging voltage remains
unchanged. The charging voltage should be
checked at least once yearly. High water
consumption of the battery is usually caused by
improper voltage setting of the charger.

25 SINGLE CELL TECHNICAL MANUAL

11 Maintenance of batteries in service

In a correctly designed standby application, the Alcad 11.2 Topping-up

battery requires the minimum of attention. However,
Check the electrolyte level. Never let the level fall
it is good practice with any system to carry out an
below the lower MIN mark. Use only approved
inspection of the system at least once per year, or at
distilled or deionized water to top-up. Do not overfill
the recommended topping-up interval period to
the cells.
ensure that the charger, the battery and the auxiliary
electronics are all functioning correctly. Excessive consumption of water indicates operation at
too high a voltage or too high a temperature.
When this inspection is carried out, it is recommended
Negligible consumption of water, with batteries on
that certain procedures should be carried out to
continuous low current or float charge, could indicate
ensure that the battery is maintained in a good state.
under-charging. A reasonable consumption of water
11.1 Cleanliness/mechanical is the best indication that a battery is being operated
under the correct conditions. Any marked change in
Cells must be kept clean and dry at all times, as dust the rate of water consumption should be investigated
and damp cause current leakage. Terminals and immediately.
connectors should be kept clean, and any spillage
during maintenance should be wiped off with a clean The topping-up interval can be calculated as
cloth. The battery can be cleaned, using water. Do not described in section 6.9. However, it is recommended
use a wire brush or a solvent of any kind. Vent caps that, initially, electrolyte levels should be monitored
can be rinsed in clean water, if necessary. monthly to determine the frequency of topping-up
required for a particular installation.
Check that the flame-arresting vents are tightly fitted
and that there are no deposits on the vent caps. Alcad has a full range of topping-up equipment
available to aid this operation.
Terminals should be checked for tightness, and the
terminals and connectors should be corrosion-
protected by coating with a thin layer of neutral
grease or anti-corrosion oil.

26 SINGLE CELL TECHNICAL MANUAL

11.3 Capacity check
Yearly
Electrical battery testing is not part of normal routine
maintenance, as the battery is required to give the • check charge voltage settings
back-up function and cannot be easily taken out
of service. • check cell voltages
(30 mV deviation from average is
However, if a capacity test of the battery is needed,
acceptable)
the following procedure should be followed:
a) Discharge the battery at the rate of 0.1 C5 to 0.2 C5 • check float current of the battery
amperes (10 to 20 amperes for a 100 Ah battery) to a
final average voltage of 1.0 V/cell (i.e. 92 volts for a
• check electrolyte level
92 cell battery).
b) Charge 200% (i.e. 200 Ah for a 100 Ah battery at • high voltage charge if agreed
the rate given in a) for application
c) Discharge at the same rate used in a), measuring
Every 2 years
and recording current, voltage and time every hour,
and more frequently towards the end of the
• clean cell lids and battery areas
discharge. This should be continued until a final
• check torque values, grease terminals and
average voltage of 1.0 V/cell is reached. The overall
connectors
state of the battery can then be seen, and if individual
cell measurements are taken, the state of each cell Every 5 years or as required
can be observed.
11.4 Recommended maintenance • capacity check
procedure
As required
In order to obtain the best from your battery, the
following maintenance procedure is recommended. • top-up with water according
to defined period (depend on float
It is also recommended that a maintenance record be voltage, cycles and temperature).
kept which should include a record of the
temperature of the battery room.

27 SINGLE CELL TECHNICAL MANUAL

12 Disposal and recycling
In a world where autonomous sources of electric
power are ever more in demand, Alcad batteries
provide an environmentally responsible answer to
these needs. Environmental management lies at the
core of Alcad’s business and we take care to control
every stage of a battery's life-cycle in terms of
potential impact. Environmental protection is our top
priority, from design and production through end-of-
life collection, disposal and recycling.
Our respect for the environment is complemented by
an equal respect for our customers. We aim to
generate confidence in our products, not only from a
functional standpoint, but also in terms of the
environmental safeguards that are built into their life-
cycle. The simple and unique nature of the battery
components make them readily recyclable and this
process safeguards valuable natural resources for
future generations.
28 SINGLE CELL TECHNICAL MANUAL
In partnership with collection agencies worldwide,
Alcad organises retrieval from pre-collection points
and the recycling of spent Alcad batteries.
Information about Alcad’s collection network can be
found on our web site:
www.alcad.com
Ni-Cd batteries must not be discarded as harmless
waste and should be treated carefully in accordance
with local and national regulations. Your Alcad
representative can assist with further information on
these regulations and with the overall recycling
procedure.
 and become contractual only after written confirmation by Alcad.
Photo credits: Alcad, Alstom/Philippe GUIGNARD, Thierry Balazuc,

Data in this document are subject to change without notice

Bob Fleumer, Getty Images, Natalie Loundon.
S3.4 Edition: April 2007
Produced by Arthur Associates.

Alcad Limited

Sweden
Telephone: +46 491 68 100
Facsimile: +46 491 68 110

Alcad Sales Offices

United Kingdom
Telephone: +44 1279 772 555
Facsimile: +44 1279 420 696

Middle East
Telephone: +357 25 871 816
Facsimile: +357 25 343 542

Asia
Telephone: +65 6 7484 486
Facsimile: +65 6 7484 639

USA
Telephone: +1 203 234 8333
Facsimile: +1 203 234 8255

www.alcad.com