lead crystal CNFJ Safety, Storage, Operations And Maitenance Manual
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lead crystal CNFJ Safety, Storage, Operations And Maitenance Manual

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SAFETY, STORAGE, OPERATIONS
AND MA IN TE NA NC E M ANU A L
|
MAY 2014
CNFJ / 3-CNFJ / 3-CNFT / 6-CNFJ / 6-HCNFJ / 6-CNFT
P U B L I C A T I O N

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  • Page 1 SAFETY, STORAGE, OPERATIONS AND MA IN TE NA NC E M ANU A L MAY 2014 CNFJ / 3-CNFJ / 3-CNFT / 6-CNFJ / 6-HCNFJ / 6-CNFT P U B L I C A T I O N...
  • Page 2 THIS MANUAL PROVIDES FULL INSTRUC- TIONS REGARDING SAFETY, STORAGE, OPERATION, AND MAINTENANCE FOR LEAD CRYSTAL® BATTERIES, AS WELL AS CERTAIN INSTALLATION CONSIDERATIONS. FAILURE TO OBSERVE THE PRECAUTIONS AS PRESENTED MAY RESULT IN DAMAGE TO EQUIPMENT, INJURY OR LOSS OF LIFE.

  • Page 3: General Safety Instructions

    Battery replacement by unauthorized personnel is prohibited. When replacing batteries, please use Lead Crystal® batteries of the same capacity and size as originals used in equipment. Do not misuse or mutilate Lead Crystal® Batteries.
  • Page 4 SYMBOLS FOR BATTERY USE AND OPERATIONS P L E A S E R E A D C H A P T E R 5 F O R F U R T H E R D E T A I L E D S A F E T Y G U I D E L I N E S NO OPEN SAFETY FLAMES...

  • Page 5: Table Of Contents

    Plates Special Manufacturing 2.1.8 CUSTOMER SERVICE Process Working Principle CHARGE AND DISCHARGE SPECIFICATIONS Charge Characteristics 12 Volt Lead Crystal® Batteries 3.1.1 6 Volt Lead Crystal® Batteries 3.1.2 2 Volt Lead Crystal® Batteries 3.1.3 Temperature compensation 3.1.4 Discharge Characteristics Battery Capacity 3.2.1...

  • Page 6: General Information

    AGM separator and a slow reaction to the electrodes. By its unique technology Lead Crystal® batteries have a high performance To overcome the fundamental flaws of the lead-acid and gel batteries, we have successfully developed five exclusive patented technological innovations in Lead Crystal®...
  • Page 7 The patented technology found in lead crystal batteries uses a special advanced technology formula, a new type of composite SiO2 electrolyte developed to completely replace traditional sulphuric acid solution.

  • Page 8: Product Specification And Model Identification Method P8

    A ND M A I N T E N A N C E M AN UA L APPLICATIONS Lead Crystal® batteries can be used in a wide range of applications where lead acid, Lead Gel batteries or AGM Batteries are used today, including, but not limited to: • Telecommunications, Communications Exchange And Transmission Systems;...

  • Page 9: Product Range P9

    PRODUCT RANGE BATTERY SIZE ARTICLE BATTERY FRONT RATED RATED AH WEIGHT NUMBER EAN CODE TERMINAL VOLTAGE (10 HOURS) (KG) TOTAL H 12 VOLT RANGE 6-CNFJ-7.2 0610696122070 2,30 6-HCNFJ-7.2 0610696122872 2,57 6-CNFJ-10 0610696122087 4,15 6-CNFJ-12 0610696122094 4,35 0610696122100 4,55 6-CNFJ-14 6-CNFJ-18...
  • Page 10 A ND M A I N T E N A N C E M AN UA L BATTERY SIZE ARTICLE BATTERY FRONT RATED RATED AH WEIGHT NUMBER EAN CODE TERMINAL VOLTAGE (10 HOURS) (KG) TOTAL H 6 VOLT RANGE 3-CNFJ-4 0610696122001 0,77 47,5 1,20 3-CNFJ-7,2 0610696122018 3-CNFJ-10 0610696122025 2,00 2,10 3-CNFJ-12 0610696122032 3-CNFJ-160 0610696122049 26,00...

  • Page 11: Product Standards P11

    ‘Safety, Storage, Operations and Maintenance’ manual applies. PRODUCT STANDARDS Lead Crystal® batteries are manufactured to meet the following national and international standards and are manufactured under the ISO 9001, ISO 14001 and GB/T 24001 system. • GB/T22473-2008 lead-acid energy storage battery • GB/T19638.2-2005 fixed type valve-controlled sealed battery...

  • Page 12: Advantages Summarised P12

    +65 Celsius • Lead Crystal® batteries can be charged below 0 degrees Celsius • Lead Crystal® batteries can be cycled more often (1500 @ 80% DOD) • Lead Crystal® batteries have very low gassing (IEC 60896-21/11) • Lead Crystal® batteries can be used in a partial state of charge • Lead Crystal®...

  • Page 13: Technical Specifications

    A ND M A I N T E N A N C E M AN UA L TECHNICAL SPECIFICATIONS Lead Crystal® batteries are a range of new products that were successfully developed based on existing batteries. It has better performance characteristics compared to a conventional batteries and is the result of new technical breakthroughs.

  • Page 14: Safety Valve P14

    SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L Partition 2.1.4 The partition is made of an ultra-fine fibre separator of high porosity, using cathode absorption technology to create gas recombination. The separator has good acid resistance and stability, which provides sufficient porosity and maintains the smooth passage of the gas while absorbing and storing sufficient volumes of electrolyte (to ensure the battery high performance).

  • Page 15: Working Principle

    SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L 2.2 WORKING PRINCIPLE DISCHARGE + 2H + Pb PbSO O + PbSO CHARGE DILUTE LEAD LEAD LEAD LEAD WATER SULPHURIC DIOXIDE SULPHATE SULPHATE...
  • Page 16 Lead Crystal® batteries use a new advanced type of AGM material as a separator. The AGM has much higher electrical conductivity, heat resistant and acid resistant abilities than standard AGM on the market.

  • Page 17: Charge And Discharge Specifications

    A ND M A I N T E N A N C E M AN UA L CHARGE AND DISCHARGE SPECIFICATIONS CHARGE CHARACTERISTICS See below charge characteristics for CNFJ, HCNFJ and CNFT Lead Crystal® Batteries. 12 volt Lead Crystal Batteries 3.1.1...
  • Page 18 A ND M A I N T E N A N C E M AN UA L Charger Settings Lead Crystal® Batteries are high-end products that work best with good quality battery chargers. Below settings for automated battery chargers are recommended to fully utilize the benefits of Lead Crystal®...

  • Page 19: Volt Lead Crystal® Batteries P19

    SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L 6 volt Lead Crystal Batteries 3.1.2 Charge Curves W W W . L E A D C R Y S T A L B A T T E R I E S . C O M...
  • Page 20 A ND M A I N T E N A N C E M AN UA L Charger Settings Lead Crystal® Batteries are high-end products that work best with good quality battery chargers. Below settings for automated battery chargers are recommended to fully utilize the benefits of Lead Crystal®...

  • Page 21: Volt Lead Crystal® Batteries P21

    SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L 2 volt Lead Crystal Batteries 3.1.3 Charge Curves W W W . L E A D C R Y S T A L B A T T E R I E S . C O M...
  • Page 22 A ND M A I N T E N A N C E M AN UA L Charger Settings Lead Crystal® Batteries are high-end products that work best with good quality battery chargers. Below settings for automated battery chargers are recommended to fully utilize the benefits of Lead Crystal®...

  • Page 23: Temperature Compensation P23

    SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L Temperature Compensation 3.1.4 The charge voltage has to be adjusted according to the change in ambient temperature according to below table. TEMPERATURE -40 -35 -30 -25 -20 -15 -10 -5 CYCLE CHARGE 2.66 2.64 2.62 2.60 2.58 2.56 2.54 2.52 2.50 2.48 2.47 2.47 2.45 2.45 2.43 2.41 2.39 2.37 2.35 2.33 2.31 2.29 2.27 FLOAT CHARGE 2.46 2.44 2.42 2.40 2.38 2.36 2.34 2.32 2.31 2.30 2.29 2.29 2.29 2.27 2.26 2.24 2.23 2.23 2.23 2.23 2.23 2.23 2.23...

  • Page 24: Battery Discharge Rate P24

    0.01C = 0.01 multiplied by the 10 hour rated capacity used for the discharge current (A) Figure 3.2 Generic curve of different discharge rates of a Lead Crystal® battery at 25°C. For discharge values of a specific battery model we revert to the constant current discharge tables in the datasheets.

  • Page 25: Influence Of Temperature On Capacity P25

    In Figure 3.3 you will notice the effect of temperature on the capacity of the CNFJ, HCNFJ and CNFT series lead crystal batteries. To calculate the capacity of the battery when the environmental temperature is not 25°C, the below...

  • Page 26: Discharge Voltage P26

    0.5C - 1C 1C - 3C Table 3.4 Termination voltage of Lead Crystal® batteries when discharged at different current. W W W . L E A D C R Y S T A L B A T T E R I E S . C O M...

  • Page 27: Transport, Storage And Installation

    Dangerous Goods code (special provision 238). BATTERY STORAGE Arrival All Lead Crystal® batteries have been fully charged prior to shipping to activate the crystallization of the electrolyte in the batteries. Precautions have been taken to pack the battery units, individual cells or cabinets containing batteries for shipment to ensure their safe arrival.
  • Page 28 A ND M A I N T E N A N C E M AN UA L Storage Lead Crystal® batteries should be stored in a clean, well- ventilated and dry environment. Avoid direct exposure of Lead Crystal® batteries to the sun.

  • Page 29: Battery Installation P29

    Due to the use of our unique crystal composite electrolyte and alloy grid plate technology, the self-discharge consumption of Lead Crystal Batteries is efficiently reduced. At a constant 25°C environmental temperature Lead Crystal Batteries can be kept on a shelf for up to two years without constant top up charging.
  • Page 30 SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L DO NOT lift any cell by the terminal posts as this will void the warranty. Always lift the batteries by the supplied handles or from the bottom of the batteries in the event that the battery is not designed or supplied with the required lifting handles.
  • Page 31 M8 (F4) 7.8 - 9.8Nm Table 4.2 Torque Settings of Lead Crystal® Batteries. W W W . L E A D C R Y S T A L B A T T E R I E S . C O M...
  • Page 32 SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L • When making parallel connections with multiple batteries, connect the batteries in series first and then in parallel. To ensure good heat distributing conditions, maintain 10mm or more space between batteries;...

  • Page 33: Operations And Maintenance

    BATTERY LIFE AND TEMPERATURE The best application temperature for the Lead Crystal® battery is 15°C - 25°C. Operating temperature range is the battery meter. When the ambient temperature is at a constant 40°C the battery cycle life decreases with 23%.
  • Page 34 15°C - 25°C Table 3-2 Operating temperatures Lead Crystal Batteries. BATTERY MAINTENANCE Lead Crystal Batteries are maintenance free, but accurate battery inspection and maintenance ensures or improves battery life. Battery handling and maintenance should be performed- or supervised by personnel who have professional knowledge about batteries and precautionary measures.
  • Page 35 A ND M A I N T E N A N C E M AN UA L Avoid constant over-charging or over-discharging of Lead Crystal Batteries. When batteries are discharged, the termination voltage should be set according to the discharging current requirement.

  • Page 36: Quarterly Maintenance P36

    SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L The following maintenance process by Lead Crystal® batteries series is recommended. Quarterly Maintenance 5.3.1 • Keep the battery room clean.

  • Page 37: Safety

    Lead Crystal® batteries authorised distributor or dealer to clarify any of the noted safety precautions. SAFETY EQUIPMENT AND CLOTHING When working with a Lead Crystal® Battery system, be sure you have the necessary tools and safety equipment, including but not limited to: • Insulated tools • Rubber gloves...

  • Page 38: Sulphuric Acid Burns P38

    SAFETY PRECAUTIONS Sulphuric Acid Burns 6.3.1 Lead Crystal® Batteries are sealed batteries with an electrolyte that solidifies into a non-dangerous white crystalline powder. Although there is no direct acid danger, Lead Crystal® Batteries do contain <5% sulphuric acid. Since sulphuric acid can cause burns and other serious injuries, below guidelines have to be observed.

  • Page 39: Explosive Gases P39

    Eliminate any potential of sparks, flames or arcing. IN CASE OF FIRE: To extinguish a fire in a battery room containing Lead Crystal® batteries, use a CO2, foam or dry-chemical extinguishing medium. Do NOT discharge the extinguisher directly onto the battery. The resulting thermal shock may cause cracking of the battery case/cover.
  • Page 40 SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L Remove all jewellery that could produce a short circuit. BEFORE working on the system: 1. Disconnect ALL loads and power sources to the battery. Use appropriate lockout/tag out procedures.
  • Page 41 IF YOU HAVE ANY QUESTIONS CONCERNING SAFETY WHEN WORKING WITH THE BATTERY SYSTEM, CONTACT YOUR NEAREST LEAD CRYSTAL® BATTERIES AUTHORISED DISTRIBUTOR OR DEALER TO CLARIFY ANY OF THE NOTED SAFETY PRECAUTIONS. W W W . L E A D C R Y S T A L B A T T E R I E S . C O M...

  • Page 42: Customer Service

    Lead Crystal® batteries authorised distributors and dealers Should you require installation supervision, service, parts, accessories or maintenance; Lead Crystal® batteries has a service organization by means of her authorised distributors and dealer network to assist with your questions. Please call your nearest Lead Crystal® batteries authorised distributor for more information.
  • Page 43 SAFETY, STORAGE, OPERATIONS A ND M A I N T E N A N C E M AN UA L Contacting Betta Batteries Please contact us through the following methods in the event of application issues: AFRICA Unit 7 Summit Square � Corporate Park North � Randjiespark Ext 100, Midrand Gauteng �...

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