21778_2_GB 01/02/12 09:05 Page1 January 2012 Tel.X Ni-Cd batteries TLX 80, TLX 100, TLX 150 and TLX 180 Installation and operating instructions 1. Safety ■ 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. ■ Tel.X batteries may be stored for up to one year, without special maintenance. ■ If you fully charge the battery (according to chapter 6.6), do not store the batteries for more than 2 months. 5. Preparation for transportation ■ ■ ■ Remove all rings, watches and other items with metal parts before working on the battery. Make use of original packing cases if possible. Otherwise protect the batteries from being damaged and short-circuited. Transport batteries upright and secured to prevent tipping. For transportation over public roads, each box or pallet must carry a "hazardous material" label and any other indication required by local transport authorities. ■ Use insulated tools. 6. Installation ■ Avoid static electricity and take measures for protection against electric shocks. 6.1. General ■ Discharge any possible static electricity from clothing and/or tools by touching an earth-connected part "ground" before working on the battery. Only trained and certified personnel should assemble and install Tel.X battery strings. ■ Local regulations related to battery compartment ventilation (e.g. Telcordia GR-487-CORE) should be carefully observed. Saft will not be responsible for the non-observance of these regulations. ■ Refer to Saft's “Tel.X batteries for telecom networks - Installation and operation manual” for complete instructions. ■ Batteries can be charged according to “In Service Charging” prior to installation. See chapter 6.6. ■ In case of abnormal events or operating outside recommended procedures, measuring the cell Open Circuit Voltage (OCV) is recommended to check for normal cell condition before installation. See paragraph “Troubleshooting and abnormal operation”. 6.2. Operating environment ■ Tel.X batteries are shipped filled with electrolyte. A connection kit should also be included. Make sure all items are received by checking the material list included on each string layout sheet. Do not top up batteries with water before, during or after initial installation. ■ 3. Unpacking and inspection ■ ■ Before installation, measure the OCV of each battery module and note the values. The sum of all modules will later be used to compare with battery string voltage once assembled. ■ Where applicable, place trays in position to allow installation with battery modules. ■ Temporarily position the battery modules in final position in accordance with the provided layout diagram. Make sure to orient the positive and negative terminals correctly. ■ Use only the accessory kit parts provided. ■ When a string barcode label is used, orient the module that has the affixed label so it can be accessed in its final position in the application. ■ When installing a cable, torque the terminal bolts to 10 ± 1 N.m (96 ± 9 in.lbs). ■ Apply generous amounts of NoOx, supplied with the accessory kit, to all terminal connections made before and after applying torque. ■ For tight spaces and to use a front accessible connection, make sure to install all back cable connections, first, while blocs are staged outside. To prevent inadvertent short circuit, make sure the loose cable end is insulated. ■ The modules can then be slid into place (in their trays if provided) and all front connections, cabled from the back, can subsequently be made. Tel.X batteries are delivered filled with electrolyte. 2. Important recommendations ■ The step by step procedures will vary with application and layout, but the following should be observed: For tight spaces and to use a front accessible connection, make sure to install all back cable connections, first, while blocks are staged outside. To prevent, inadvertent short circuit, make sure the loose cable end is insulated. 6.3. Recommended tools The following tools will facilitate installation: ■ Insulated 10 mm socket ■ ■ Insulated torque wrench capable of 10 ± 1 N.m (96 ± 9 in.lbs) Do not at this stage connect the system’s power cables. ■ ■ Multi meter (VDC) 4. Storage ■ ■ Store the batteries in standard warehouse conditions. Crimper, 6 AWG, non-insulated lug (optional) Connect each battery module using the accessory kit parts in accordance with the string layout diagram. ■ After completing terminal connections and NoOx application, make sure to install the battery top covers. ■ Battery module handles should remain in place unless it is obstructing module placement or connection. In that case remove them. ■ ■ ■ Check for damage or electrolyte spillage. Report any abnormalities to the shipping company as well as to Saft. Do not store in direct sunlight or expose to excessive heat. Store the batteries in a temperature range of – 20°C to + 35°C (– 4°F to + 95°F). Heat shrink gun (optional) 6.4. String assembly Battery configurations vary depending on the application. A battery string layout is provided with each string. 21778_2_GB 01/02/12 09:05 Page2 Tel.X Ni-Cd batteries ■ Use lugs and sealable heat shrink provided in the installation kit, when necessary, for connecting power cables to the battery terminals. ■ Make sure that the cables are properly secured and supported. ■ Measure the battery string overall voltage and compare this with the sum of all the module OCV’s measured previously. If values show a discrepancy of 1.0 V or more, verify the polarity, position and connection of each module. Reassemble as required. ■ ■ ■ ■ Temperature compensated voltage control is not recommended. Disengage temperature compensation circuit if activated. Make sure the output of the rectifier is adjusted between 1.43 to 1.45 VPC; i.e, the DC bus voltage should be between 54.4 to 55.1 VDC for 38 cells. Note the polarity of the battery terminals and verify the polarity of the power cables before connecting these to the battery. Look for polarity markings. DO NOT color match. Using standard practice and rectifier manufacturers recommendations as a guideline, connect the power cables to the string terminals and secure hardware: M6 Terminal Torque 10 ± 1 N·m (96 ± 9 in·lbs). Constant voltage charging is recommended and should be done at 1.43 to 1.45 VPC per cell (54.4 to 55.1 VDC per 38 cell string). ■ In order to re-charge fully in 24 hours, the minimum current available for each battery string should be C8/10. See Table A for values. ■ Temperature compensated voltage control is not recommended. Check with rectifier manufacturer for instructions. ■ In case we need to check the IEC capacity (IEC 60623) the following procedure must be applied: ■ ■ Measure rectifier output voltage and make sure it is adjusted correctly. See paragraph “In Service Charging”. ■ Re-torquing the terminal bolts is not recommended. The hardware is constructed from nickel plated steel and stainless steel which requires no torquing maintenance. 7.4. Floating current monitoring ■ • Make sure that the string is discharged fully and each cell is at the same SOC. 8. Troubleshooting and abnormal operation Table B: Type Maximum Float Current (A) C5Ah C5/5A TLX 80 83 16.6 TLX 100 103 20.6 TLX 150 152 TLX 180 185 It is recommended to measure the cell open circuit voltage if: ■ Stored at too high or too low of temperature. 30.4 ■ Stored for too long of time. 37.0 ■ Batteries visibly OK but shipping crate excessively damaged. • Continue charging for a minimum of 30 hours (a maximum of 1 week). • Apply the load mentioned in the Table B and discharge to a cut-off of 1.0 V per cell (measured at the string terminals) and verify that the 5 hr of runtime are delivered. Nominal capacity (C8Ah) C8/10 (A) TLX 80 75 7.5 0.38 7. Maintenance and Inspection TLX 100 97 9.7 0.49 7.1. Watering TLX 150 140 14.0 0.70 TLX 180 172 17.2 0.86 Watering is not required over the operational life of the Tel.X. To measure the cell OCV: ■ Gain access to the cell terminals by removing the battery top covers. Set aside for re-use. ■ Using a DMW measure each cell and check that each is greater than or equal to 1.10 VPC per cell. ■ If a cell is below 1.10 VDC per cell, set the battery module aside and call Saft for further instructions. 9. Removal and recycling ■ Make sure appropriate packing materials are available. ■ Make sure each cell cap is installed to prevent spillage. ■ All local laws and regulations must be respected when removing, transporting and storing used batteries. ■ Contact your local Saft representative for instructions on recycling. 7.2. Cleaning ■ Apply approved corrosion preventative compound on string terminals. ■ If a battery must be connected to a live system (adding additional capacity), it must be necessary to charge the batteries prior to the installation to minimize the inrush current. Saft Industrial Battery Group 12, rue Sadi Carnot 93170 Bagnolet - France Tel: +33 1 49 93 19 18 Fax: +33 1 49 93 19 64 www.saftbatteries.com When the battery is ageing, it is advisable to check the float charging current. The battery requires action if the float current is higher than 5 mA/Ah when charging at 1.43 V/cell. See Table A for values. A current clamp with an accuracy of ± 0.025 Amps is a way to measure the floating charge. • Charge at constant voltage with a maximum voltage set point of 1.65 V per cell and current limit of C5/5A as mentioned in the table B: • Maximum 30 minute pause is allowed. Table A: Type 7.3. Periodic inspection and control 6.6. In Service Charging 6.5. Connecting power It is good practice to visually inspect the string during periodic site visits. Vacuuming or dusting with a soft brush is adequate if the string is dirty. A wet rag may be used, but do not use any detergent, chemicals or cleaning aids. Do not use metal brushes or hard bristles. Doc N° 21778-2-0112 Data in this document is subject to change without notice and becomes contractual only after written confirmation. Société par Actions Simplifiée au capital de 31 944 000 € RCS Bobigny B 383 703 873 Le Révérend Imprimeur - Printed in France - 3k