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Summary of Contents for Alpha alphacell gelcell series
- Page 1 AlphaCell GelCell Series ™ AlphaCell GelCell Battery Users Guide Storage, Maintenance, and Deployment Effective: April, 2013 Alpha Technologies...
- Page 2 Power ® Alpha Technologies...
- Page 3 Alpha representative. NOTE: 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.
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Page 4: Table Of Contents
Battery Evaluation Procedures ....................18 Battery Refurbishment Plan ....................19 Battery System Float Charging ......................20 Alpha Power Supply Charging Profile ..................21 Battery Symptoms and Solutions ......................22 Battery Parameters by Model Number ....................25 Warranty and Return Information ......................27 AlphaCell Limited Warranty.................... - Page 5 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.
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Page 6: Safety Notes
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. -
Page 7: Battery Maintenance Guidelines
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... -
Page 8: Storage
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 —... -
Page 9: Chemical And Mechanical Safety
WARNING! 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. -
Page 10: Introduction
Adherence to the procedures and practices detailed in this guide will not only insure the battery operates per specifications, 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: •... -
Page 11: Description
For example, in Fig. 3, two 36V 90Ah capacity strings are connected in parallel to provide a nominal 36V at 180Ah. WARNING! Alpha highly recommends fusing in single and parallel string configurations. (+), to power supply... -
Page 12: Preparing For Maintenance
100 amp momentary load test set • System load bank (DC if to be performed at the battery and AC if to be performed by loading a power supply output— contact your Alpha Sales Representative for purchasing information). • NO-Ox Corrosion Inhibitor •... -
Page 13: Periodic Maintenance Tasks And Schedule
3.0 Periodic Maintenance Tasks and Schedule The following tasks are to be performed on a monthly and quarterly schedule. The following maintenance procedure requires a fully functional status monitoring system capable of remotely measuring and recording the following data on a periodic basis: •... -
Page 14: Quarterly Preventive Maintenance
Quarterly Preventive Maintenance Required Equipment • True RMS Volt Meter with DC Amp Clamp • Midtronics Conductance Battery Tester Remote Status Monitoring Procedure Site Visit Ensure Power Supply is in Float Mode Battery String Record Information Float Current on Site Visit Record >0.5A Disconnect Monitor as per PM... - Page 15 Quarterly Preventive Maintenance, continued Procedure Verify the power supply is in Float mode. Use the DC Amp clamp to measure and record each individual battery string’s float current. 3. If the individual string float current is greater than 0.5 amps, replace the battery string. Measure and record the individual battery conductance and voltage on the Site Visit Record.
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Page 16: Alphacell Tm Battery Maintenance Log
AlphaCell Battery Maintenance Log Follow this sample when filling out the maintenance log (following page). Node / Location Power Supply Type Load (kW) Evaluation Procedure Evaluation Procedure Evaluation Procedure Conductance Vdc 24 Conductance Vdc @ Vdc 24 Float mhos @ Hour mhos @ 100A after... - Page 17 AlphaCell Battery Maintenance Log Node / Location Power Supply Type Load (kW) Evaluation Proce- Evaluation Procedure Evaluation Procedure dure #1 Conductance Vdc 24 Conductance Vdc @ Float mhos @ Hour mhos @ 100A after Hour 77°F 77°F/25°C 10 seconds Load 745-680-C0-002, Rev.
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Page 18: Battery Evaluation Procedures
3.4 Battery Evaluation procedures for AlphaCell™ GXL, GXL-HP and Gold-HP batteries To help identify batteries approaching end of life in an operating power system, test #1 should be performed at each maintenance interval. For batteries not installed in an operating power system, test #2 or #3 may be performed. For accuracy, tests must be performed on fully charged batteries. -
Page 19: Battery Refurbishment Plan
3.5 Battery Refurbishment Plan Battery Refurbishment Plan Batteries Returned from Site. Measure and document 24 hour Open Circuit Voltage (OCV). Must occur within 24 hours of removal from charger) Does battery meet the minimum Measure conductance values Conductance per Table 1? Does battery meet Measure Measure... -
Page 20: Battery System Float Charging
4.0 Battery System Float Charging Battery System Float Charging Voltage Encountering temperature extremes When you encounter temperature extremes, temperature compensate the float charging voltage. The temperature compensation coefficient is -0.0028 V/C per °F (-0.005 V/C per °C). For example if the normal battery temperature is 90°F (13° above 77°F) you should reduce the average float charging voltage range by 0.036 V/C (13°... -
Page 21: Alpha Power Supply Charging Profile
Battery System Float Charging, continued NOTE: The following information specifically pertains to Alpha XM Series 2 Power Supplies. 4.1 Alpha Power Supply Charging Profile BULK charge is a “Constant Current” charge. This current is the maximum the charger is capable of delivering: 10A for 615, 906/915/915HV, and 922/922HV. As the charge is returned to the batteries, their voltage increases to a specific threshold (2.27VDC per cell). -
Page 22: Battery Symptoms And Solutions
5.0 Battery Symptoms and Solutions Problem with Symptom Possible Causes Possible Result Corrective Actions Reduced operat- ing time at 77°F Eventual failure to support the Replace battery system (25°C) with Normal life cycle load followed by potential for when at 70% of rated smooth voltage shorted cells capacity or before... - Page 23 Battery Symptoms and Solutions, continued Problem with Symptom Possible Causes Possible Result Corrective Actions Overcharging causes System float voltage > excessive gassing and Reset the charger output Charger output set 2.3V/C average 77°F drying out of electrolyte voltage to recommended incorrectly (25°C) and contributes to potential...
- Page 24 Battery Symptoms and Solutions, continued Type Symptom Possible Causes Possible Result Corrective Action • Failure to support load. If an internal arc occurs during A battery or connection in series discharge, can ignite gasses Replace battery with string is open. Verify via the float Float current to internal to cell.
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Page 25: Battery Parameters By Model Number
6.0 Battery Parameters by Model Number Model Number Parameter 220 GOLD-HP 220GxL 195 GOLD-HP 195GxL Terminal Type Threaded Insert Threaded Insert Threaded Insert Threaded Insert Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt Annual Retorque Inch-Lb / N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m... -
Page 26: Table 4, Battery Parameters, Legacy Models (Threaded Insert Terminals)
Battery Parameters by Model Number, continued Model Number Parameter 215 GOLD HP 210GxL 190 GOLD HP 180GxL Terminal Type Threaded Insert Threaded Insert Threaded Insert Threaded Insert Bolt Size 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt 1/4"-20 UNC Bolt Annual Retorque Inch-Pounds / N•m 110In-lb / 12.4N•m 110In-lb / 12.4N•m... -
Page 27: Warranty And Return Information
ALPHA SHALL NOT BE LIABLE FOR, AND USER SHALL INDEMNIFY AND SAVE ALPHA HARMLESS FROM ANY CLAIMS AND LIABILITIES ARISING OUT OF THE USE, MAINTENANCE, TRANSPORTATION, OR INSTALLATION OF ANY EQUIPMENT WARRANTED HEREUNDER. - Page 28 7.1 AlphaCell™ Standard Limited Warranty, continued The table below indicates the warranty periods for AlphaCell Batteries used with Alpha approved power supplies and enclosures. Battery Model Description Mfg Date Warranty Warranty Warranty US/Canada International International Standard Northern Climates 220GOLD -HP...
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Page 29: Battery Maintenance Report For Return Authorizations
Alpha Customer Service (800) 421-8089, or fax# (360) 671-4936 This form, in conjunction with Alpha's Battery Evaluation Procedure is intended as a method of collecting data critical to the efficient processing of your warranty battery claims. Record battery float voltage while the battery is still connected to the system. - Page 30 This page intentionally blank...
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- Page 32 Fax: +357 25 359 595 Visit us at www.alpha.com Due to continuing product development, Alpha Technologies reserves the right to change specifications without notice. Copyright © 2013 Alpha Technologies. All Rights Reserved. Alpha® is a registered trademark of Alpha Technologies. 745-680-C0-002 Rev. B1 (04/2013)
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