October 2010 MRX Ni-Cd batteries Installation and operating instructions Important recommendations I Make sure that the plastic strapping and front plates remain in place during storage (for blocks delivered without metallic frames). I Never allow an exposed flame or spark near the batteries, particularly while charging. I Never smoke while performing any operation on the battery. I Do not expose to direct sunlight or excessive heat. I For protection, wear rubber gloves, long sleeves, and appropriate splash goggles or face shield. I I The electrolyte is harmful to skin and eyes. In the event of contact with skin or eyes, wash immediately with plenty of water for a minimum of 15 minutes. If eyes are affected, flush with water, and obtain immediate medical attention. Battery delivered discharged may be stored for many years before installation. For battery delivered charged (80%) please refer to 5.3 and 5.4. I Remove all rings, watches and other items with metal parts before working on the battery. I Use insulated tools. I Avoid static electricity and take measures for protection against electric shocks. I 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. Generally MRX batteries are shipped discharged and filled with electrolyte. An accessory kit should also be included. I Make sure all items have been received by comparing with the packing list. I Check for damage or electrolyte spillage. Report any irregularities to the carrier and Saft. I Never operate the battery with coloured transport seals inserted on the outlet and inlet of each module as this will damage permanently the battery. 3. Installation Remove the transport seals. 3.1. Battery configuration varies depending on the requirement. I Block battery directly fitted inside a battery box. I Block battery to be installed by customer in battery box designed by Saft. In this case, the block battery is delivered with two front plates and plastic strapping used for shipment and handling. Front plates and plastic strapping must be removed just before battery installation. Don't remove the front plates and plastic strapping if the battery is stored. I Block battery to be managed directly by the customer. In this case the block batteries are delivered in light self-keeping cradles. Never remove this assembly. 3.2. Verify that cells are correctly interconnected and battery is correctly connected to the load. 3.3. Check torque of terminal connecting screws. Torque must be: 10 ± 2 N.m Connections and terminal screws must be protected against corrosion by coating with a thin layer of neutral vaseline or anti-corrosion oil agreed by Saft. 2. Storage 4. Water filling system installation Store the battery indoors in a dry, clean, and cool location (0°C to +30°C / +32°F to +86°F). Remove transport seals and connect hydraulic tubing between block battery according to the battery drawing delivered by Saft. Saft's Water Filling Systems follows specific rules, please respect carefully Saft's battery drawing for installation. Make sure that the pipes are completely inserted to ensure a good tightness. Hydraulic connection of cells is in parallel to the electrical connection in order to avoid voltage differences of more than 1.2 V between two cells connected by this method. The hydraulic connection must be horizontal in order to avoid any siphon. The water filling circuit outlet must not be located close to electrical equipment, and electrical circuit or metallic structure. Water filling circuit input must be connected to the self-closing inlet. When installed, check the water filling circuit for continuity (no obstruction) and tightness (no leaks) using a pressure test (a kit may be supplied by SAFT). 5. Commissioning Caution: during constant charging operations, the battery box must be open. 5.1. Discharged block-battery put into operation immediately after delivery or after less than one year of storage: a) charge at constant current: at 0.2 C5 A for 8 h b) charge at constant voltage: 1.55 V/cell for 20 h with the current limited at 0.2 C5 A Charge at constant current is recommended. The battery is ready for use. MRX Ni-Cd batteries 5.2. Discharged block battery stored more than 1 year: a) charge at 0.2 C5 A for 10 h b) discharge at 0.2 C5 A down to 1.0 V/cell Between discharge and the following charge, the battery must be kept in open circuit for 8 hours or battery temperature down to ≤ +30°C (≤+86°F). c) charge at 0.2 C5 A for 8 h The battery is ready for use. 5.3. Charged block-battery (80%) shipped and stored at temperatures below +30°C (+86°F), less than 3 months from date of charge: the battery is ready for use. 5.4. Charged block-battery (80%) shipped and stored at temperatures above +30°C (+86°F) or stored more than 3 months from date of charge: a) charge at 0.2 C5 A for 10 h b) discharge at 0.2 C5 A down to 1.0 V/cell c) charge at 0.2 C5 A for 8 h to +86°F), the charge voltage correcting factor is: – 3 mV/°C/cell (– 1.7 mV/°F/cell) if the charging voltage is ≥ 1.45 V at +20°C (+68°F) For any other charging voltages, consult Saft. To minimise the water consumption, Saft recommends the use of low charging voltage. 7. Topping-up Before topping up operation, the water filling circuit of the battery must be checked for tightness (no leaks) using a pressure test (a kit may be supplied by SAFT). Use only distilled and deionized water for topping-up. Connect distilled water tank to the self-closing inlet. Topping-up is completed when an excess of 1 litre of water is measured at the outlet of the water filling circuit. The battery is ready for use. Topping-up can be performed by Saft's gravity kit or by using Saft's water filling stations. 6. Charging in service 8. Periodic maintenance On-board application (railway) The battery is cycled up to 20% Depth Of Discharge (DOD) per day. In addition to the topping-up, a periodic maintenance shall be carried out at least every 5 years. For detailed maintenance, please refer to the maintenance manual of the battery. I • Single level charge: 1.45 to 1.55 V/cell at +20°C (+68°F) 1.47 V/cell is recommended Stationary application The battery is on float and discharged only in case of emergency. • Single level charge: 1.41 to 1.43 V/cell at +20°C (+68°F) • Dual level charge: - High level: 1.43 to 1.50 V/cell at +20°C (+68°F) - Float level: 1.38 to 1.40 V/cell at +20°C (+68°F) I Keep the battery clean using only water. Do not use a wire brush or solvents of any kind. I Check torque of all terminal screws. Coat with grease approved by Saft or neutral vaseline all terminal screws and connections. I Voltage compensation For use at temperature range outside +10°C to +30°C (+50°F I Saft Industrial Battery Group I Check charger settings. It is very important that the recommended charging voltage remains unchanged. High water consumption by the battery is usually caused by improper voltage setting of the charger. Doc N° 21119-2-1010 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. Table A: Cell type Rated capacity Charge current Ah Amp MRX 70 70 14 MRX 80 80 16 MRX 90 90 18 MRX 100 100 20 MRX 115 115 23 MRX 130 130 26 MRX 145 145 29 MRX 160 160 32 MRX 180 180 36 MRX 200 200 40 MRX 230 230 46 MRX 260 260 52 MRX 280 280 56 MRX 300 300 60 MRX 350 350 70 MRX 400 400 80 MRX 460 460 92 MRX 520 520 104 I 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 (generally every 2 years). It depends on the charging voltage and actual use of the battery. Refer to section 7 concerning topping-up. 9. No change of electrolyte required Thanks to the sintered/plastic bonded electrode technology, it is not necessary to change the electrolyte during the life of the battery. 10. Recycling To protect the environment, all used batteries must be recycled. Contact your local Saft representative for information.