June 2004 SRX Ni-Cd batteries Type plastic and steel containers Installation and operating instructions Important recommendations connection to the load is also correct. ■ 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. 3.2. Check tightness of terminal connecting nuts. Torque applied should be: 1. Receiving the shipment 4.1. Discharged cells placed into service immediately after delivery or after less than one year of storage: 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. Remove the plastic transport seals. The battery is then ready for installation. The battery must never be used electrically with the plastic transport seal in place as this can cause permanent damage. 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 discharged and filled may be stored for many years before it is installed. ■A battery delivered charged (80%) must not be stored more than 3 months (including transport). 3. Installation Remove the transport seals and close the vent plugs. 3.1. Verify that cells are correctly interconnected and that battery • 10 ± 2 N.m for cells SRX 22 P/FR to 80 P/FR, SRX 50 C, • 15 ± 2 N.m for cells SRX 900 P to 2200 P, SRX 90 FR to 220 FR, SRX 220 F3, SRX 175 LP/LFR, SRX 720 to 3700, SRX 90 to 250 (SRX 100 excl.), SRX 2500 P-LC, • 30 ± 3 N.m for cells SRX 100. The connectors and terminal nuts should be corrosion-protected by coating with a thin layer of neutral vaseline or anti-corrosion oil agreed by Saft. 3.3. Electrolyte The electrolyte to be used is E13. 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 to 5 mm above the plate tops with distilled or deionized water. 4. Commissioning ■ Constant current charge: • 8 h at 0.2 C5 A Caution: during charging, the battery box must be open. ■ Constant potential charge: • 1.55 V/cell for 20 h, with the current limited to 0.2 C5 A Charge at constant current is recommended. The battery is ready for use. 4.2. Cells stored more than 1 year: a) charge 10 h at 0.2 C5 A b) discharge at 0.2 C5 A down to 1.0 V/cell c) charge 8 h at 0.2 C5 A The battery is ready for use. 4.3. Charged cells (80%) shipped and/or stored at temperatures > +30°C (>+86°F), and/or ≥ 3 months from date of charge: a) charge 10 h at 0.2 C5 A b) discharge at 0.2 C5 A down to 1.0 V/cell c) charge 8 h at 0.2 C5 A The battery is ready for use. 5. Charging in service 5.1. Cycling application The battery is cycled up to 20% DOD (Depth Of Discharge) per day. ■ Single level charge: 1.45 - 1.55 V/cell, at +20°C (+68°F) 1.47 V/cell is recommended. ■ Two level charge: • High level: 1.45 - 1.60 V/cell at +20°C (+68°F) • Float level: 1.38 - 1.40 V/cell at +20°C (+68°F) 5.2. Stand-by application Battery is on float and discharged only in emergency situation. ■ Single level charge: 1.41 - 1.43 V/cell at +20°C (+68°F) ■ Two level charge: • High level: 1.43 - 1.50 V/cell at +20°C (+68°F) • Float level: 1.38 - 1.40 V/cell at +20°C (+68°F) For use at temperature outside +10°C to +30°C (+50°F to +86°F), the charge voltage correcting factor is: • – 2 mV/°C/cell (–1.1 mV/°F/cell) if charging voltage < 1.45 V/cell at +20°C (+68°F) • – 3 mV/°C/cell (–1.7 mV/°C/cell) if charging voltage between 1.45 and 1.55 V/cell at +20°C (+68°F) For higher charging voltages, consult Saft. To minimise the water usage, Saft recommends the use of low charging voltages. 6. Topping-up ■ Batteries not equipped with water filling system: 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. SRX Ni-Cd batteries high low SRX 720 to 3700 Level (mm) 50 5 SRX 22 P/FR to 80 P/FR 55 5 SRX 900 P/90 FR to 2200 P/220 FR 55 5 SRX 175 LP/LFR 50 5 SRX 90 to 250 45 5 SRX 50 C 50 5 SRX 220 F3 44 5 SRX 2500 P-LC 70 5 ■ Batteries equipped with water filling system: • 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. 7. Periodic maintenance Table A: Cell type: In nickelled steel container SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX 720 800 900 1000 1200 1300 1500 1700 1900 2200 2500 3000 3700 Capacity C5 Ah (Ah) Charge current 0.2 C5 A (A) 73 81 90 103 115 130 145 170 195 220 250 300 375 Electrolyte per cell Solid Liquid (kg) (l) Length of cell topper nozzle (mm) 14.6 16.2 18.0 20.6 23.0 26.0 29.0 34.0 39.0 44.0 50.0 60.0 75.0 0.34 0.31 0.40 0.37 0.40 0.46 0.52 0.52 0.61 0.73 0.77 0.89 1.04 1.1 1.0 1.3 1.2 1.3 1.5 1.7 1.7 2.0 2.4 2.5 2.9 3.4 55 55 55 55 55 55 55 55 55 55 55 55 55 10.0 18.0 20.0 23.0 29.0 34.0 39.0 50.0 0.16 0.37 0.37 0.39 0.52 0.48 0.59 0.78 0.53 1.2 1.2 1.3 1.7 1.6 1.9 2.6 55 50 50 50 50 50 50 50 4.4 5.0 6.2 7.4 9.2 10.4 12.0 14.0 16.0 18.0 20.6 23.0 26.0 31.0 34.0 38.0 44.0 35.0 44.0 50.0 0.11 0.10 0.15 0.25 0.23 0.21 0.24 0.21 0.21 0.46 0.43 0.40 0.46 0.55 0.67 0.61 0.73 0.61 0.71 0.50 0.38 0.35 0.51 0.84 0.76 0.70 0.80 0.71 0.91 1.5 1.4 1.3 1.5 1.8 2.2 2.0 2.4 2.0 2.4 1.5 65 65 65 65 65 65 65 65 65 55 55 55 55 55 55 55 55 45 45 50 Cell type: In stainless steel container SRX SRX SRX SRX SRX SRX SRX SRX 50 C 90 100 115 145 170 195 250 50 90 103 115 145 170 195 250 Cell type: In plastic container SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX SRX 22 P/FR 25 P/FR 31 P/FR 37 P/FR 46 P/FR 52 P/FR 60 P/FR 70 P/FR 80 P/FR 900 P/90 FR 1000 P/100 FR 1200 P/115 FR 1300 P/130 FR 1500 P/155 FR 1700 P/170 FR 1900 P/190 FR 2200 P/220 FR 175 LP/LFR 220 F3 2500 P-LC 22 25 31 37 46 52 60 70 80 90 103 115 130 155 170 190 220 175 220 250 ■ Maintenance operations (not including the topping-up operation): Periodic maintenance should be carried out every two years. • 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 when dirty. • Check that all connectors are tight. Coat with grease or neutral vaseline all terminal nuts and cell connectors. • Check charger settings. It is of great importance that the recommended charging voltage remains unchanged. High water consumption of the battery is usually caused by improper voltage setting of the charger. Saft Industrial Battery Group ■ Topping-up operation: Check the electrolyte level. Never let the level fall below the minimum level mark. Use only distilled or deionized water to top-up. Frequency of topping-up must be determined for each battery. It depends on charging voltage and real utilization of the battery. Refer to section 6 concerning topping-up. 8. Changing electrolyte Due to the sintered electrode plastic bonded technology, it is not necessary to change the electrolyte during the life time of the cells. Doc N° 21123.2 - 0604 12, rue Sadi Carnot 93170 Bagnolet - France Tel: +33 1 49 93 19 18 Fax: +33 1 49 93 19 64 Société anonyme au capital de 31 944 000 € RCS Bobigny B 383 703 873 www.saftbatteries.com Pragma - Printed in France - 2k Data in this document is subject to change without notice and becomes contractual only after written confirmation. 9. Environment To protect the environment all used batteries must be recycled. Contact your local Saft representative for information.