Alpha Alphacell gelcell series Bedienungsanleitung

AlphaCell™GelCell Series

AlphaCellTM GelCell Battery Users Guide

Storage, Maintenance, and Deployment

Effective: April, 2013

Alpha Technologies

Power

Alpha Technologies

745-680-C0-002, Rev. B1

AlphaCellTM GelCell Battery Users Guide

Storage, Maintenance and Deployment

745-680-C0-002, Rev. B1

Effective Date: April 2013

Alpha Technologies, Inc.

Contacting Alpha Technologies: www.alpha.com

For general USA sales information and customer service (7 AM to 5 PM, Pacic Time), call

1 800 863 3930

For complete technical support in the USA, call

7 AM to 5 PM, Pacic Time or 24/7 emergency support

1 800 863 3364

For Sales information and Technical Support in Canada, call

1 800 667 8743

Photographs contained in this manual are for illustrative purposes only. These photographs may not match

your installation.

Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If

there are questions regarding the safe operation of this product, please contact Alpha Technologies or your

nearest Alpha representative.

Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,

batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with

its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.

member of The Group

NOTE:

AlphaCellTM

GelCell Battery

Users Guide

Storage, Maintenance

and Deployment

745-680-C0-002, Rev.B1

Table of Contents

Safety Notes....................................................................................................................................................... 6

Battery Maintenance Guidelines......................................................................................................................... 7

Recycling and Disposal Instructions................................................................................................................... 7

Storage............................................................................................................................................................... 8

Electrical Safety.................................................................................................................................................. 8

Chemical and Mechanical Safety ....................................................................................................................... 9

1.0 Introduction.......................................................................................................................................... 10

1.1 Description..............................................................................................................................11

2.0 Preparing for Maintenance .................................................................................................................. 12

2.1 Required Tools and Equipment .............................................................................................. 12

3.0 Periodic Maintenance Tasks and Schedule......................................................................................... 13

3.1 Monthly Remote Status Monitoring ........................................................................................ 13

3.2 Quarterly Preventive Maintenance ......................................................................................... 14

3.3 AlphaCellTM Battery Maintenance Log .................................................................................... 16

3.4 Battery Evaluation Procedures ............................................................................................... 18

3.5 Battery Refurbishment Plan.................................................................................................... 19

4.0 Battery System Float Charging............................................................................................................ 20

4.1 Alpha Power Supply Charging Prole .................................................................................... 21

5.0 Battery Symptoms and Solutions ........................................................................................................ 22

6.0 Battery Parameters by Model Number ................................................................................................ 25

7.0 Warranty and Return Information ........................................................................................................ 27

7.1 AlphaCellTM Limited Warranty.................................................................................................. 27

7.2 Battery Maintenance Report for Return Authorizations .......................................................... 29

745-680-C0-002, Rev. B1

Figures and Tables

Fig. 1, Capacity vs Storage Time........................................................................................................... 8

Fig. 2, Series Connected String of Batteries ........................................................................................11

Fig. 3, Parallel String of Batteries .........................................................................................................11

Fig. 4, Flow Chart, Monthly Status Monitoring..................................................................................... 13

Fig. 5, Flow Chart, Quarterly Preventive Maintenance........................................................................ 14

Fig. 6 Flow Chart for Battery Refurbishment Plan ............................................................................... 19

Fig. 7, Charger Modes......................................................................................................................... 21

Table 1, Conductance values, new vs. suspect batteries .................................................................... 18

Table 2, Battery Symptoms and Solutions........................................................................................... 22

Table 3, Battery Parameters, Current Models (threaded insert terminals) .......................................... 25

Table 4, Battery Parameters, Legacy Models (threaded insert terminals)........................................... 26

Table 5, Battery Parameters, Legacy Models, (Lead ag insert terminals) ......................................... 26

Table 6, Warranty Periods for AlphaCellTM batteries ............................................................................ 28

745-680-C0-002, Rev.B1

Safety Notes

Review the drawings and illustrations contained in this manual before proceeding. If there are any questions

regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha

representative. Save this document for future reference.

To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following

symbols have been placed throughout this manual. Where these symbols appear, use extra care and

attention.

A WARNING presents safety information to PREVENT INJURY OR DEATH to the

technician or user.

WARNING!

The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or

equipment.

CAUTION!

A NOTE provides additional information to help complete a specic task or procedure.

NOTE:

The use of ATTENTION indicates specic regulatory/code requirements that may affect the placement of

equipment and installation procedures.

ATTENTION:

745-680-C0-002, Rev. B1

Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery

installation, maintenance, service, and replacement must only be performed by authorized

personnel.

WARNING!

Battery Maintenance Guidelines

• For optimal performance, inspect batteries every 3 months for:

Signs of battery cracking, leaking or swelling. The battery should be replaced immediately

by authorized personnel using a battery of the identical type and rating (match conductance,

voltages, and date codes as specied in this document).

Signs of battery cable damage. Battery cable should be replaced immediately by

authorized personnel using replacement parts specied by vendor.

Loose battery connection hardware. Refer to documentation for the correct torque and

connection hardware for the application.

• Do not attempt to remove the vents (valves) from the AlphaCell GelCell battery or add water. This is a

safety hazard and voids the warranty.

• Apply NO-OX grease on all exposed connections.

• When necessary, clean up any spilled electrolyte in accordance with all federal, state, and local

regulations or codes.

• Follow approved storage instructions.

• Always replace batteries with those of an identical type and rating. Never install untested batteries.

• Do not charge batteries in a sealed container. Each individual battery should have at least 1/2 inch of

space between it and all surrounding surfaces to allow for convection cooling.

• All battery compartments must have adequate ventilation to prevent an accumulation of potentially

dangerous gas. Never place batteries in a sealed enclosure. Extreme caution should be used when

maintaining and collecting data on the battery system.

Recycling and Disposal Instructions

• Spent or damaged batteries are considered environmentally unsafe as they contain lead and dilute

sulfuric acid. They should not be "thrown away" with common refuse.

• Always recycle used batteries in accordance with federal, state, provincial, and local regulations. The

Alpha Group provides recycling services. Call 800 863 3930 or contact your local Alpha representative.

745-680-C0-002, Rev.B1

32ºF (0ºC)

50ºF (10ºC)

ºF

)

6ºF (

0ºC

)

4ºF

(

Storage Time (Months)

Residual Capacity (%)

Fig. 1, Capacity vs. Storage Time

During storage please note:

• The self-discharge rate is related to ambient temperature. The lower the temperature, the less

the discharge. Batteries should be stored in a clean, ventilated, and dry location with an ambient

temperature of 32ºF to 68ºF (0ºC to 20ºC).

• It is important to track open circuit voltage which is related to the density of the electrolyte. If

the open circuit voltage is lower than 12.6V or the batteries have been stored beyond the limits

shown in Figure 1, the batteries should be charged to avoid damage caused by self-discharge.

• All batteries should be fully charged before storage. Record the storage date and next

supplemental charge date in a maintenance record and on the battery.

• Upon battery deployment, verify all batteries within each string measure in the range of

+/- 0.3Vdc of the string average.

Electrical Safety

• Lethal voltages are present within the power supply and electrical enclosures. Never assume that

an electrical connection or conductor is not energized. Check circuits with a volt meter prior to any

installation or removal procedure.

• Observe circuit polarities.

• Always use the buddy system when working under hazardous conditions.

• Ensure no liquids or wet clothes contact internal components.

• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input

power is disconnected.

• Use an insulated blanket to cover exposed portions of the battery system when performing extended

maintenance that could result in personal or equipment contact with the energized conductors.

• Certain types of rectier circuits used in charging the battery may not include a line isolating transformer.

In these cases extreme caution should be used when maintaining and collecting data on the battery

system.

The product warranty is void if the batteries are not stored and recharged in accordance with these guidelines.

NOTE:

Important Storage Practices

All lead acid batteries experience self-discharge while in open circuit storage. This causes circuit

voltage and capacity to decrease (see Fig.1). This is especially true if the batteries are stored for

long periods of time at higher temperatures. Storage of the batteries in the shaded area of Figure

1 is not recommended, as higher temperatures combined with longer periods of storage will result

in diminished residual capacity — hence a shorter battery lifespan.

745-680-C0-002, Rev. B1

Chemical Hazards

Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contains dilute sulfuric acid,

which is harmful to the skin and eyes. Emissions are electrolytic and are electrically conductive and corrosive.

To avoid injury:

• Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel

knowledgeable of batteries and the required safety precautions.

• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. To avoid

battery contact, remove all metallic objects, (such as rings or watches), from your person.

• Batteries produce explosive gases. Keep all open ames and sparks away from batteries.

• Use tools with insulated handles, do not rest any tools on top of batteries.

• Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects

or other reproductive harm. Battery post terminals and related accessories contain lead and lead

compounds. Wash hands after handling (California Proposition 65).

• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your

company’s approved chemical exposure procedures.

• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with

a solution of one pound (454g) bicarbonate of soda to one gallon (3.8l) of water. Report a chemical spill

using your company’s spill reporting structure and seek medical attention if necessary.

• Always replace batteries with those of an identical type and rating (match conductance, voltages, and

date codes as specied in this document).

• Never install old or untested batteries.

• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have

developed on your body.

• Use special caution when connecting or adjusting battery cabling. An improperly or unconnected battery

cable can make contact with an unintended surface that can result in arcing, re, or a possible explosion.

• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by authorized

personnel using a battery of identical type and rating.

Mechanical Safety

• Keep hands and tools clear of fans.

• Fans are thermostatically controlled and will turn on automatically.

• Power supplies can reach extreme temperatures under load.

• Use caution around sheet metal components, especially sharp edges.

• Depending on the model, batteries can weigh anywhere from 25 to 100 pounds (11kg to 45kg). Exercise

care when handling and moving batteries. Use proper handling equipment.

WARNING!

745-680-C0-002, Rev.B1

The purpose of this guide is to provide the user with the necessary information to maintain batteries in storage

and deploy batteries in Alpha Powering systems, as well as perform battery testing, install replacements and

recycling.

This manual guides you through periodic maintenance checks and troubleshooting of the AlphaCell GelCell

batteries of 50 through 107 ampere hours capacity.

Adherence to the procedures and practices detailed in this guide will not only insure the battery operates per

specications, but also provides the proper backup for the Alpha Powering system in which it is installed.

To achieve these goals, this guide will address the following topics:

• The storage and maintenance of new battery inventory.

• Deployment of AlphaCell batteries into Alpha Power systems.

• Proper preventiative maintenance practices for AlphaCell batteries.

• Replacement and recycling of AlphaCell batteries.

• Warehousing, testing, and redeployment of reuseable AlphaCell assets.

• How to keep proper maintenance records for troubleshooting and/or Warranty claims.

1.0 Introduction

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