November 2013 SRA/SRA LT/SRA HT Ni-Cd Batteries Installation and operating instructions Important recommendations z 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. 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 filled and ready for installation. ■Make sure all items have been received by comparing with the packing list. ■Check for damage or electrolyte spillage. Report any irregularities to the carrier and to Saft. ■Remove the plastic transport seals. The battery must never be used electrically with the plastic transport seal in place as this can cause permanent damage. ■The battery is ready for installation. 2. Storage Store the battery indoors in a dry, clean, cool location (0°C to +30°C / +32°F to +86°F). ■Make sure that the transport seals remain in place during storage. ■Do not store in direct sunlight or exposed to excessive heat. ■A battery delivered charged (80 %) must not be stored more than 3 months (including transport). If a charged battery has to be stored for more than 3 months, discharge the cells at 0.2 C5A down to 1V per cell or less. ■A battery delivered discharged and filled may be stored for many years before it is installed. ■If storage is required prior to commercial service, clean and coat the metallic parts with a thin layer of neutral Vaseline or neutral petroleum jelly grease approved by Saft. Leave the battery in its transport case to protect from dust, moisture and short circuits. 3. Installation Remove the transport seals and close the vent plugs. 3.1. Verify that cells are correctly interconnected and that battery connection to the load is also correct. 3.2. Check tightness of terminal connecting nuts. Torque applied must be: •10 ± 2 N.m for cells SRA 75 to 140 SRA LT 75 to 140 SRA HT 70 to 130 •30 ± 3 N.m for cells SRA 160 to 375 SRA LT 160 to 375 SRA HT 150 to 350 The connectors and terminal nuts should be corrosion-protected by coating with a thin layer of neutral Vaseline or anticorrosion oil agreed by Saft. 3.3. Electrolyte The electrolyte used is specific for each product line: - SRA : E 10 - SRA LT : E 34 - SRA HT : Na 15 L 4. Commissioning Caution: during constant charging operations, the battery box must be open. 4.1. The cells are delivered 80 % charged. Charging and discharging should be done at constant current. ■For a battery stored less than 3 months at T< +30°C No charge/discharge operation is required before use. ■For a battery stored for more than 3 months or at T>+30°C •Discharge the battery at 0.2 C5A down to an average 1V per cell. •Maintain the battery in open circuit during 8 hours or until the battery temperature is between 10°C and 30°C. •Charge the battery at 0.2 C5A for 8 hours. 4.2. The cells are delivered discharged Caution: even if the battery is discharged, there remains a residual charge that may cause an electric shock. Charging and discharging should be done at constant current. ■For a battery placed into service immediately after delivery or after less than one year of storage: •Preferred solution: Constant current charge: charge the battery at 0.2 C5A for 8 hours Caution: during constant current charging the battery box must be open •Constant voltage charge: 1.55V/cell for 20 h with the current limited at 0.2 C5A ■ For a battery stored more than 1 year: •Charge the battery at 0.2 C5A for 8 hours. •Discharge the battery at 0.2 C5A down to an average 1V per cell. •Maintain the battery in open circuit during 8 hours or until the battery temperature is between 10°C and 30°C. •Charge the battery at 0.2 C5A for 8 hours. The battery is ready for use 5. Charging in service ■1.47 V/cell at +20°C (+68°F) with voltage compensation: - 3 mV/°C/cell (-1.7 mV/°F/cell) For higher charging voltages, consult your local Saft representative. 6. Topping-up Frequency of topping-up must be determined for each battery. Topping-up shall be performed every 6 months during the first year in order to determine the ideal topping-up interval which depends on the charging voltage and actual use of the battery. Never let the electrolyte level fall below the minimum level mark. Use only distilled or deionized water to top-up. If charge at constant current : operation must be carried on charged cells with a rest time of minimum of 2 hours. If charge at constant voltage on the train, the topping-up can be carried out at any time. SRA/SRA LT/SRA HT Ni-Cd Batteries ■ atteries not equipped with a water B filling system (typical frequency of topping-up is every 6 months): No electrolyte level measurement is necessary if you use a Saft cell-topper, which allows the correct level to be obtained by a simple nozzle setting. See nozzle lengths in Table A. If a cell-topper is not available, the electrolyte level must be measured. Insert a transparent glass or plastic tube (alkali resistant, 5 to 6 mm in diameter) vertically into the cell vent until it touches the top of the plates. Close the top end of the tube by putting a finger on it and remove it from the cell. The height of the liquid in the tube indicates the electrolyte level. Cell type Level (mm) high low SRA 75 to 140 66 15 SRA 160 to 375 75 15 SRA LT 75 to 140 66 15 SRA LT 160 to 375 59 15 SRA HT 70 to 130 66 15 SRA HT 150 to 350 75 15 ■Batteries equipped with water filling system (typical frequency of topping-up is every 12 months): •Remove transport seals and connect hydraulic tubing between cells up to a maximum of 50 cells. • Make sure that the tubes are completely inserted for a good seal. • The hydraulic connection of cells must be in parallel to the electrical connection, in order to avoid voltage differences of more than 1.2 V between two hydraulically connected cells. • The hydraulic connection must be horizontal in order to avoid siphoning. • The water filling circuit output must not be too close to electrical equipment, electrical circuit, and metallic structure. • Water filling circuit input must be connected to the self-closing inlet. • Topping-up can be performed by gravity or using adapted pump with a flow rate of 0.7 l/min at a relative pressure of 0.3 bar maximum. Table A: Cell type SRA 75 SRA 90 SRA 110 SRA 125 SRA 140 SRA 160 SRA 190 SRA 220 SRA 260 SRA 280 SRA 310 SRA 340 SRA 375 SRA LT 75 SRA LT 90 SRA LT 110 SRA LT 125 SRA LT 140 SRA LT 160 SRA LT 190 SRA LT 220 SRA LT 260 SRA LT 280 SRA LT 310 SRA LT 340 SRA LT 375 SRA HT 70 SRA HT 85 SRA HT 105 SRA HT 115 SRA HT 130 SRA HT 150 SRA HT 175 SRA HT 200 SRA HT 245 SRA HT 265 SRA HT 290 SRA HT 315 SRA HT 350 C5 Ah (Ah) 0.2 C5 A (A) 75 90 110 125 140 160 190 220 260 280 310 340 375 15 18 22 25 28 32 38 44 52 56 62 68 75 185 285 280 335 335 575 570 645 765 900 900 1085 1085 59 59 59 59 59 54 54 54 54 54 54 54 54 75 90 110 125 140 160 190 220 260 280 310 340 375 15 18 22 25 28 32 38 44 52 56 62 68 75 185 285 280 335 335 415 410 465 555 650 645 785 780 59 59 59 59 59 39 39 39 39 39 39 39 39 70 85 105 115 130 150 175 200 245 265 290 315 350 14 17 21 23 26 30 35 40 49 53 58 63 70 185 285 280 335 335 575 570 645 765 900 900 1085 1085 59 59 59 59 59 54 54 54 54 54 54 54 54 For detailed maintenance, please refer to the maintenance manual of the battery. • Keep the battery clean using only water. Do not use a wire brush or solvents of any kind. Vent plugs can be rinsed in clean water. ■Maintenance • Check the torque of all terminal screws. Coat with grease or neutral vaseline all the terminal nuts and cell connectors. Periodic maintenance should be carried out at least every 5 years. • Check charger settings. It is very important that the recommended charging voltage remains unchanged. 7. Periodic maintenance operations (not including the topping-up operation): Saft Industrial Battery Group Doc N° 21881-2-1113 Data in this document is subject to change without notice and becomes contractual only after written confirmation. 12, rue Sadi Carnot 93170 Bagnolet - France Tel: +33 1 49 93 19 18 Fax: +33 1 49 93 19 64 Société par Actions Simplifiée au capital de 31 944 000 RCS Bobigny B 383 703 873 www.saftbatteries.com Le Révérend Imprimeur - Printed in France - 1k Electrolyte reserve (cm3) Topper nozzle (mm) High water consumption of the battery is usually caused by improper voltage setting of the charger. 8. Changing electrolyte It is not necessary to change the electrolyte during the life time of the cells. 9. Environment To protect the environment all used batteries must be recycled. Contact your local Saft representative for information.