1
TECHNICAL MANUALIndustrial Ni-Cd BatteriesStandard RangeMadeinGermany
®
...the opportunity to have the choice
2
Preface
TheGAZ®Ni-Cdbatteryconsistingofpocketplateelectrodesisoneofthemostreli-ablesystemsthatcanbefoundinthemarket,andoftentheonlyreasonablechoiceifabatteryoperatingunderextremeenvironmentalconditionsisrequested.NoothersystemisabletoprovidemorefavourablefeaturesthanGAZ®Ni-Cdpocketplatebat-teriessuchas:
· veryhighpowerrating
· lowinternalresistance
· reducedlossofcapacityatdeeptemperature
· noiceformationattemperaturesbelow0°C
· longlifetimeathightemperatures
· insensitiveagainstdeepdischarge
· longshelflife
· noelectrolytestratification
· insensitiveagainstmisuseandoptimisedforharshoperatingconditions.
Basedonmorethan100yearsofexperienceinthedesign,manufacturingandcon-tinuouslyimprovingandfurtherdevelopmentsintechniquesGAZ®Ni-CdbatteriesmadeinGermanywillprovidemaximumperformanceandsecurity independentofthemainelectricalsupply.Ourcompanypridesitselfonthehighstandardsofqualityforwhichitisknownandisabletocountwellknowncompaniesallovertheworldasitscustomers.
Thismanualwillanswermostofthemaintechnicalquestionsregardingourstand-ardpocketplatebatteries.
PublicationNo:EN-GAZ-TMSR-002November2010
3
Table of contents
1. DesignofaGAZ®Ni-Cdpocketplatecell........................................................................................................4 1.1 GAZ®VentingSystem............................................................................................................................5 1.2. GAZ®SafetyTerminal.............................................................................................................................5 1.3 Electrodeframe......................................................................................................................................6 1.4 Separators..............................................................................................................................................6 1.5 Positiveandnegativeelectrodeplate......................................................................................................6 1.6 Distanceplate.........................................................................................................................................7 1.7 Cellcases................................................................................................................................................7 1.8 Electrolyte...............................................................................................................................................72. Batteryrangeandapplications........................................................................................................................8 2.1 Batteryranges........................................................................................................................................8 2.2 Applicationsandchoiceofcelltype........................................................................................................93. ElectrochemistryofNi-Cdbatteries.................................................................................................................94. Operatingfeatures..........................................................................................................................................9 4.1 Capacity.................................................................................................................................................9 4.2 Cellvoltage............................................................................................................................................9 4.3 Internalresistance...................................................................................................................................9 4.4 Impactoftemperatureoncellperformanceandavailablecapacity......................................................10 4.5 Impactoftemperatureonlifetime........................................................................................................11 4.6 Short-circuitvalues...............................................................................................................................11 4.7 Opencircuitloss...................................................................................................................................12 4.8 Cycling.................................................................................................................................................12 4.9 Waterconsumptionandgasevolution.................................................................................................135. PrinciplesandmethodsofsizingofGAZ®Ni-Cd-batteriesforstandbyapplications.......................................14 5.1 Voltagewindow...................................................................................................................................14 5.2 Loadprofile..........................................................................................................................................14 5.3 Ambienttemperature...........................................................................................................................14 5.4 Rechargetimeandstateofcharge.......................................................................................................14 5.5 Ageing.................................................................................................................................................14 5.6 Floatingeffect-Voltagedepression......................................................................................................156. Charging ..................................................................................................................................................15 6.1 Constantvoltagecharge.......................................................................................................................15 6.2 Chargeacceptance...............................................................................................................................16 6.3 Chargeefficiency..................................................................................................................................17 6.4 Temperatureinfluence..........................................................................................................................18 6.5 Commissioning.....................................................................................................................................187. Installationandoperatinginstructions...........................................................................................................18 7.1.Receivingthebattery............................................................................................................................19 7.2.Storage.................................................................................................................................................19 7.2.1Unchargedandunfilledcells......................................................................................................19 7.2.2Chargedandfilledcells/dischargedandfilledcells....................................................................19 7.3. Installation............................................................................................................................................19 7.3.1Location.....................................................................................................................................19 7.3.2Ventilation.................................................................................................................................19 7.3.3Settingup..................................................................................................................................20 7.3.4Electrolyte..................................................................................................................................20 7.3.5Commissioning..........................................................................................................................20 7.3.5.1.Commissioningwithconstantcurrent...........................................................................21 7.3.5.2Commissioningwithconstantvoltage...........................................................................21 7.4.Charginginoperation..........................................................................................................................22 7.4.1Continuousbatterypowersupply(withoccasionalbatterydischarge)............................... 22 7.4.1.1Twolevelcharge...........................................................................................................22 7.4.1.2Singlelevelcharge.........................................................................................................22 7.4.2Bufferoperation.........................................................................................................................22 7.5. PeriodicMaintenance...........................................................................................................................22 7.5.1Equalisingcharge.......................................................................................................................22 7.5.2Electrolytecheckandtoppingup...............................................................................................22 7.5.3Replacingofelectrolyte..............................................................................................................23 7.5.4Electrolytetemperature..............................................................................................................23 7.6.Additionalwarningnotes.....................................................................................................................23
PublicationNo:EN-GAZ-TMSR-002November2010
4
1. Design of a GAZ® Ni-Cd pocket plate cell
Gas drying or fl ame arresting vent
Safety terminalRedundant leak protection minimizescarbonate formation.
Electrode edgeConnected to pole bolt by screwing or welding.
Electrode frameConsisting of electrode edge and side bars. Seals the plates and works as a current collector.
Corrugated perforated plas-tic separator Insulates the plates and allows free circulation of electrolyte.
Horizontal pocketsFormed by perforated steel strips containing the active material.
Distance platePrevents movement of the electrode pack.
PublicationNo:EN-GAZ-TMSR-002November2010
Publication No: EN-GAZ-TMSR-002 November 2010
5
1.1 GAZ® Venting System GAZ®batteriescanbeequippedwithanormalflip-topventoroptionallywithaspecialgasdryingaswellasaflamearrestingvent.
Mode of action of GAZ® gas drying or fl ame arresting vent
The originated charging gases (hydrogen and oxy-gen), which occur during the charging process ofNi-Cdbatteries,carryalsosmallelectrolytedropsoftheelectrolytesolution(aerosol).This leadstoaquickerdeclineoftheelectrolyte level incomparisontothenormal water decomposition during the overcharg-ingand,thus,resultsinshortmaintenanceintervals.Furthermore,astrongincrustationofthefillingventscanbetheresultduetothecreationofcarbonate.
By using the GAZ® gas drying or flame arrestingvents, this occurrence can be avoided. These ventscontaining small plastic particles on the large sur-face of which the electrolyte drops comprised areinthegasescapingfromthecellarecondensingtothe greatest possible extent and, therefore, remainwithinthecells.
The additional feature of the GAZ® flame-arrestingventisthemicroporousdisconthetopwhichresultsin a diffused leakage of the charging gases. More-over, high local concentrations can be preventedwhichfinallyleadstoalowerriskofflammability.
According to IEC 60623 the total amount ofentrained potassium hydroxide shall be not morethan0.05mg/Ahduring2hoursovercharge.GAZ®batterieswiththespecialventingsystemimprovetherequiredvaluemanytimesoverto0.011mg/Ahdur-ing2hoursovercharge.
Plasticparticles
Gasdryingvent
Internal&externalsealingRedundantleakprotection
1.2 GAZ® Safety TerminalUse of the especially developed terminal design withredundantleakprotectionpreventsanyleakageofelec-trolyte.Dependingonthecellrangeandtypeterminalsaredesignedasfemaleormalethreadandpolarity iscoloredmarked.
PublicationNo:EN-GAZ-TMSR-002November2010
Publication No: EN-GAZ-TMSR-002 November 2010
6
1.3 Electrode frameTheelectrodeframeofGAZ®Ni-Cdbatteriesconsistsofarightandaleftsidebaraswellastheelectrodeedge,whichareconnectedbyweldingshapingtheelectrodeframe.
Theelectrodeframeoperatesasacurrentcollectorandalso seals the electrode plates. This procedure leadsto an electrode design with high mechanical robust-nessbutalsoensuresareliableserviceforthecompletelifetimeofthebattery.
1.4 SeparatorsTheseparationoftheelectrodesisensuredbyacorru-gatedperforatedplastic(M-andL-types)orplasticgridseparator (H-types). Theplasticgrid separator isusedforhighdischarge types (H-types) inorder toachieveasuperiorcellperformancecausedbyalowerinternalresistance,whichisverytypicalandnecessaryfortheirhighdischargecurrents.
Theseparatoralsoensuresalargespacebetweentheelectrodes,whichallowsfreecirculationoftheelectro-lyteandagooddissipationofthegasesgenerateddur-ingendofcharging.
1.5 Positive and negative electrode plate
Thenickel-cadmiumcelliscomposedofthepositiveplatescontainingnickelhydroxideandthenegativeplatescon-taining cadmiumhydroxide. Thepockets formed fromanickelplatedandperforatedsteeltape,theso-calledpockettape,infoldstripsoftheactivematerial.
The so originated electrode strips are mechanicallylinked together forming the electrode plate and areconsecutivelycuttosizeoftheappropriateplatewidthbasedonthecelltypeandrange.
Theplates thenareweldedormechanically linked totheplate frame (seepoint3) forming theelectrodes-theheartofthebattery–andassembledtotheplateblock.
ThebasisfortheextemelylongusefullifetimeandtheverygoodcyclelifefeaturesoftheGAZ®Ni-Cdpock-etplatebatteriesare the specialplatedesignswhosestructuralcomponentsaremadeofsteel.
Thispreventsthepossibilityofgradualdeteriorationbycorrosionandsincethealkalineelectrolytedoesnotre-actwithsteelthesubstructureofthebatteryremainsin-tactforthetotallifetimeofthebattery.Veryimportantanduniqueistheenfoldingoftheelectrochemicalactivemassesintheperforatednickelplatedsteelpockets,sothat the risk of sheddingor penetrationofmaterial isvery small and consequently also the risk of structuraldamagesandofsoftshortcircuitsiswellundercontrol.
The so originated electrode strips are mechanicallylinked together forming the electrode plate and areconsecutivelycuttosizeoftheappropriateplatewidth
Activematerial
Electrodestrip
Pockettape
Mechanicallylinked
Electrodestrips
Electrodestrips
PublicationNo:EN-GAZ-TMSR-002November2010
7
1.6 Distance plateThedistanceplateoperatesasanadditionalstabiliza-tiontopreventanymovementoftheelectrodes.Itisan additional feature for applications where vibra-tionsarepossible.
1.7 Cell casesThecellcasesaremadefromatranslucentpolypro-pyleneorpolystyrene,whichensuresavisualcontrolof theelectrolyte level. Theexeptional sturdyGAZ®cellcasesprovideasatisfactoryserviceforthetotallifetimeof thebatterybutalsowillhavea superiorfinish at every stage. The lid and the container arewelded or glued together forming an integrativecompound.
All GAZ® Ni-Cd cells have a single cell design thatprevents in the greatest possible extent any leak-age of the cell cases since they are made by injec-tionmoldingoutofonepiece.Therefore,theweldorglueseamsofthecellcasesandthelidsliesovertheelectrolyte level. The GAZ® single cell design elimi-natescompletelytheriskoffaultyweldedseamsonthesidesandonthebottomofthecellcases.Causedbythesinglecelldesignaneconomicalreplacementof faultycells ispossible,whereonly the faultycellcanbereplaced.
Aspecialflameretardentmaterial(acc.tostandardUL94V0)isalsoavailable,whichadmittedlybringsalongsomeimpairedproperties.Byusingthismaterialavi-sualcheckoftheelectrolyteisnolongerpossible.
1.8 ElectrolyteThe electrolyte used in GAZ® Ni-Cd batteries is a so-lution of potassium hydroxide and lithium hydroxidethatisoptimizedtogivethebestcombinationofper-formance, energy efficiency and a wide temperaturerangeofuse.
The concentration of the standard electrolyte allowsoperations between – 30°C and + 50°C. For specialoperationswithinverylowtemperaturesaspecialhighdensityelectrolytecanbeused.
It is an important property of the GAZ® battery, andindeedofallnickel-cadmiumbatteries,thattheelectro-lytedoesnotchangeduringchargeanddischarge.Itre-tainsitsabilitytotransferionsbetweenthecellplates,irrespectiveofthechargelevel.
Inmostapplicationstheelectrolytewillretainitseffec-tivenessforthelifeofthebatteryandwillneverneedreplacing.However,undercertainconditions,suchasextendeduseinhightemperaturesituations,theelec-trolytecanbecomecarbonated.
If this occurs the battery performance can be im-proved by replacing the electrolyte (see „Mainte-nanceandHandlingInstructions“).
400KVINTERCONNECTIONOFABUDHABIISLAND400/132/11kVGRIDSTATIONSE48ANDE19
PublicationNo:EN-GAZ-TMSR-002November2010
8
Cell type
LLowrateofdischarge
MMediumrateofdischarge
M/NMediumrateofdischarge
HHighrateofdischarge
KL…PKL…
KM…PKM…TP...T...
KM...P/N
KH...PKH...TSP...TS...
Intercityandurbantransport X X X X
Substations&signalling X X X X
UPS X X X X
Offshore&onshoreoil&petrochemicalrefineries X X X X
Emergencylighting X
Telecommunication X X
Photovoltaic X
Dieselstart X
Shipequipment X X X X
Electricity,gas&waterproduction&distribution X X X X
Emergencysupply X X X
Alarmequipment X
2.1 Battery ranges
InordertoenableGAZ®batteriestoofferanappropri-atesolutioninaccordancewiththecustomer’srequire-mentsandtohaveachoiceforanybatteryapplicationexistingon themarket,GAZ®Ni-Cdbatteriesarede-signedinfourdifferentperformanceranges.
ThisGAZ®cell typehasbeenespeciallydesigned forlow ratesofdischargeover longperiods,where thecurrent is relatively low incomparisonwiththetotalstoredenergy.Thedischargescangenerallybeinfre-quentand the recommendeddischarge time for theKL…Prangeis1hourto100hours.
TheGAZ®M-typebatteryhasbeenespeciallydesignedfor“mixedloads”thatincludeamixtureofhighand
lowratesofdischarge.Itisusedforfrequentandin-frequentdischargesandtherecommendeddischargetimeis30minto120min.
This GAZ® cell type is a further developed M-type,which because of a special perforation higher dis-chargecurrentsforspecialapplicationsupto1hour.It isespeciallyusedforUPSandsimilarapplicationsand the recommendeddischarge time is 10min to60min.
TheGAZ®H-typebatterywasdesignedforhighcur-rent discharging over short discharge periods. Therecommendeddischargetimeforthiscellrangeis1sto30min.
KL …P
KM …P TP
KM …P/N NON-STOP
KH …P TSP
2. Battery range and applications
PublicationNo:EN-GAZ-TMSR-002November2010
9
2.2 Applications and choice of cell type
GAZ®Ni-Cdbatteriescoverawiderangeofapplicationsandareusedinalmosteverysector,nomatterifitisaprivate,industrial,commercial,governmentalormilitaryone.Thetableonpage8onwhichsomeexamplescanbefoundrepresentsonlyasmalloverviewintheextend-edfieldofapplications.Therefore,itistobeunderstoodasgeneralinformation.
3. Electrochemistry of Ni-Cd batteries
Oxidationofcadmiumatthenegativeelectrode
Reductionoftrivalentnickelionstobivalentattheposi-tiveelectrode
Duringchargingthebothreactionsarereversed.
The complete reaction is:
negative electrode
positive electrode
cell reaction
4. Operatingfeatures
4. Operating features
4.1 Capacity
Thecapacityofnickel-cadmiumbatteriesisratedinam-pere-hours(Ah)andisthequantityofelectricityat+20°C(±5°C)whichcansupplyfora5hourdischargeafterbe-ingfullychargedfor7.5hoursat0.2C
5.Thesefigures
andproceduresarebasedontheIEC60623standard.
Accordingto IEC60623,0.2C5Aisalsoexpressedas
0.2ItA.ThereferencetestcurrentItisexpressedas:
ItA=
Cn istheratedcapacitydeclaredbythemanufacturerinampere-hours(Ah)
n isthetimebasedinhours(h)forwhichtheratedcapacityisdeclared
4.2 Cell voltage
ThecellvoltageofaNi-Cdcellistheresultoftheelec-trochemicalpotentialsofthenickelandthecadmiumac-tivematerialsincooperationofthepotassiumhydroxideelectrolyte.Therefore,thenominalvoltageforthiselec-trochemicalcoupleis1.2V.Fromtheelectrochemistryofthereactiongivenabove(seepoint3),thefreevoltageof1.3VisgivenfortheNi-Cdcell.Thisvoltageisalsoobserveddirectlyafterchargingofthecell.
4.3 Internal resistance
TheinternalresistanceofaNi-Cdcellisverydifficulttomeasureandtodefinesince itvarieswithdiffer-ent temperature and state of discharge. The inter-nalresistancealsodependsonthecelltypeandsizeasitincreasesforlowerstateofcharge.Apartfromthis the internal resistanceofafullydischargedcellcarries no weight. Reducing the temperature alsoincreases the internal resistance. The correct valuesregardingthespecialconditionscanbeprovidedbyourtechnicalstaff.
Cd Cd 2+ + 2 e¯
Ni3+ + e¯ Ni2+
Cd + 2 OH¯ Cd(OH)2 + 2 e¯
2 NiOOH + 2 H2O + 2 e¯ 2 Ni(OH)2 + 2 OH¯
2 NiOOH + Cd + 2 H2O 2 Ni(OH)2 + Cd(OH)2
Cn Ah
1 h
PublicationNo:EN-GAZ-TMSR-002November2010
10
When sizingand choosingabattery the variations inambient temperature and their influence on the cellperformancehavetobetakenintoconsideration.
Low ambient temperature conditions reduce the cellperformance, buton theotherhandoperationswith
highertemperaturesaresimilartothoseatnormaltem-peratures.Theeffectoflowtemperaturesisincreasingwithhigherratesofdischarge.
Thevalues,whichhavetobetakenintoaccount,canbefoundinthefollowinggraph.
4.4 Impact of temperature on cell performance and available capacity
TMTypical GAZ® NiCd-cell performance variation with temperature
Temperaturein°C
%o
fra
ted
capa
city
at
25°C
120
100
80
60
40
20
0
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
5-hourdischargerate5-hourdischargerate
PublicationNo:EN-GAZ-TMSR-002November2010
11
Aswitheverybatterysystemanincreasedtempera-ture always reduces the expected service lifetimeandalthoughtheGAZ®Ni-Cdbatteryisdesignedtoreachalifetimeofover20yearsthisisalsothecase.Thefollowinggraphisincludedtodemonstratethatthe reduction in lifetime of a GAZ® Ni-Cd battery
is many times lower than for a lead acid battery.ForNi-Cdbatteries thenormaloperatingtempera-tureisbasedat+20°C(±5°C)and,therefore,spe-cial considerations have to be taken into accountwhen dimensioning a Ni-Cd battery for high tem-peratureapplications.
4.6 Short-circuit values
Theshort-circuitvaluesofaGAZ®Ni-Cdpocketplatebattery depend on and vary from cell range to cellrange.Thespecialvaluescanbeprovidedbyourtech-nicalstaffonrequest.
4.5 Impact of temperature on lifetime
Lifetime of batteries at higher temperatures as percentage of +25°C lifetime
Temperaturein°C
Perc
enta
geo
f+
25°C
life
time
[%]
100
90
80
70
60
50
40
30
20
10
0
25 30 35 40 45 50 55
Ni-CdbatteriesLeadacidbatteries
PublicationNo:EN-GAZ-TMSR-002November2010
12
The GAZ® Ni-Cd battery is designed to obtain ahuge number of cycles in stationary standby opera-tions.Theimportantfactandbasisforthenumberofcycles the battery is able to provide is the depth ofdischarge.Thelessdeeplyabatteryisdischargedthe
greaterthenumberofcycles it iscapabletoprovidebeforebeingunabletoachievetheminimumdesignlimit.Onthegraphbelowtypicalvaluesfortheeffectofdepthofdischargeon theavailable cycle life canbefound.
Thestateofchargeofacellonopencircuitslowlyde-creasesduetoitsself-discharge.Thisdecreaseisquiterapidduringthefirsttwoweeksandthenstabilizesatabout2%permonthat+20°C. Ingeneral the self-
dischargeofaGAZ®Ni-Cdbatteryisaffectedbyvarioustemperatures.Theopencircuit loss is reducedat lowtemperatures, while the self-discharge is significantlyincreasedathighertemperatures.
4.7 Open circuit loss
4.8 Cycling
TM
Self discharge of GAZ® NiCd-accumulators (fully charged)
Months
Loss
of
capa
city
[%]
40°C20°C0°C
40°C20°C20°C0°C0°C
60
50
40
30
20
10
0
0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0
Cycle life versus depth of discharge expressed as a percentage of the rated capacity (20°C)
Cha
rge-
disc
harg
ecy
cles
Depthofdischarge[&]
15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
8000
7000
6000
5000
4000
3000
2000
1000
0
PublicationNo:EN-GAZ-TMSR-002November2010
13
At the final stage of the charging procedure of aGAZ® Ni-Cd battery the provided electrical energycannot be fully absorbed but is absolutely neces-sarytoreachthefullychargedstateofthecells.Thedifference between absorbed and provided energyleadstoabreakdownoftheelectrolyte’swatercon-tentintooxygenandhydrogen(electrolysis).Thislosshastobecompensatedbytoppingupthecellswithpuredistilledwater.
Thewaterlossdependsonthecurrentusedforover-charging.Abatteryonstandbyoperationwillcon-sume less water than a battery that is cycled con-stantly, i.e. which is charged and discharged on aregularbasis.
Intheory,thequantityofwaterusedcanbefoundbyFaraday’s equation that eachamperehourofover-chargebreaksdown0.336cm3ofwater.
However, in practice, the water usage will be lessthanthis,astheoverchargecurrentisalsoneededtocounteractself-dischargeoftheelectrodes.
Theoverchargecurrentisafunctionofbothvoltageandtemperature,sobothhavean influenceontheconsumptionofwater.Thetablebelowgivestypicalwaterconsumptionvaluesoverarangeofvoltages.
Example:
AcellKM110Pisfloatedat1.41V/cell
Theelectrolytereserveforthiscellisapprox.400cm³
FromthetablebelowaGAZ®cellat1.41Vpercell
willuse0.25cm³/monthfor1Ahofcapacity
ThatmeansaKM110Pwilluse
0.25cm³/monthx110Ah=27.5cm³/month
andtheelectrolytereservewillbeusedin
400cm³/27.5cm³/month=14.5months
Thegasevolutionisafunctionoftheamountofwaterelectrolyzedintohydrogenandoxygenandispredomi-nantlygivenoffattheendofthechargingperiod.Thebatterydoesnotgiveoffanygasduringanormaldis-charge.Duringelectrolysistheamountof1Ahproduces684cm³ofgasmixtureand thisgasmixture is in theproportionof2/3hydrogenand1/3oxygen.Thus1Ahproducesabout456cm³ofhydrogen.
4.9 Water consumption and gas evolution
Chargingvoltage[V/cell]
Loss of water for GAZ® cells and different charging voltages (app.) 20°C
Loss
of
wat
er[c
m²/
mon
tha
ndA
h]
2.5
2
1.5
1
0.5
0
1.40 1.41 1.42 1.43 1.44 1.45 1.46 1.47 1.48 1.49 1.50 1.51 1.52 1.53 1.54 1.55
PublicationNo:EN-GAZ-TMSR-002November2010
14
5. Principles and methods of sizing of GAZ® Ni-Cd-batteries for standby applications.
AllGAZ®Ni-Cdbatteriesusedforstandbyfloatingap-plicationsaresizedaccordingtotheinternationalsizingmethodIEEE1115.Wehavedevelopedaspecialcalcu-lationprogramwhichisavailableovertheInternetandallowsustoupdateitregularlywithoutbotheringourcustomers. Itprovidesthepossibility tocalculatewithmultipledischarges,andtoincludethetemperaturede-ratingfactoraswellastheageingfactorofthebattery.AsignificantfeatureandadvantageoftheGAZ®Ni-Cdbatteryincomparisontotheleadacidbatteryisthatitcanbefullydischargedwithoutanyinconveniencetothelifetimeorrechargeofthebattery.Further,itisanadvan-tagetodischargethebatterytothelowestpracticalval-uetoextractthemaximumenergythebatteryisabletoprovideinordertofindoutthemostbeneficialsolution.Themostimportantsizingparametersare:
5.1 Voltage window
Thisistheminimumandmaximumvoltageacceptableforthesystem.Themaximumvoltageprovidesthevolt-agethatisavailabletochargethebattery,whereas,theminimumvoltagegivesthe lowestvoltageacceptabletothesystemtothatthebatterycanbedischarged.
5.2 Load profile
Theloadprofile istheelectricalperformancerequiredby the system from thebattery for theparticular ap-plication. Itcanbeexpressed intermsofamperesforcertain durationor inwatts for certain duration. Therequirementsmightvaryforexamplefromjustonedis-chargetomultipledischargesofacomplexnature. Inordertocalculatetheappropriatedbatterysizepleasetakeintoconsiderationpoint5.1voltagewindow.
5.3 Ambient temperature
Theambienttemperaturewillhaveinanycaseaninflu-enceonthesizingofthebattery(seepoint4.4Impactoftemperatureoncellperformanceand4.5Impactoftemperatureonlifetime).
5.4 Recharge time and state of charge
Someapplicationsmightrequireafulldischargecycleof the battery after a certain time after the previousdischarge.Thefactorstobetakenintoaccountdependonthedepthofdischarge,therateofdischargeaswellasthechargingconditions.
5.5 Ageing
Itmightberequiredthatavaluehastobeaddedtoen-surethecorrectserviceofthebatteryduringthelifetime.Thevaluetobeuseddependsonthedischargerateofthebatteryandontheconditionsunderwhichiscarriedout.Ourexpertsorpartnersareabletohelpyouchoosetherightbatteryforyourspecialrequirements.
computed values according to IEEE Std 1115-2000
period load
(amperes)
change in load
(amperes)
duration of period (minutes)
time to end of section (minutes)
capacity rating
factor at t Min Rate (Kt)
temperature derating factor for t Min (Tt)
required section
(rated amp hrs)
section 1
1 100.00 100.00 600 600 9.8590 1.1351 1119.0692
section 1 total: 1119.0692
range: KL 150-1700 P design margin factor: 1.10
endvoltage per cell: 1.05 Vpc aging factor: 1.25
temperature: 5°C to 50°C use floating derating factor:
max section size: 1119.07 Ah
1.00 (use: Yes)
computed cellsize: 1538.72 Ah
use the cell: KL 1620 P
user: Peko
order number: 002062
date: 2008-09-30 15:36:02
Your data was saved successfully. Please contact GAZ with order number 002062.
PublicationNo:EN-GAZ-TMSR-002November2010
15
WhenaGAZ®Ni-Cdbatteryoperatesatafixedfloat-ingvoltageoveracertainperiodoftime,adecreaseinthevoltagelevelofthedischargecurveoccurs.Itbegins after one week and reaches its peak in ap-proximately3months.Since thiseffect reduces thevoltage levelof thebattery it canbe consideredasreducingtheperformanceandautonomyofthebat-terytoo.Therefore,itisnecessarytotakethiseffectintoconsiderationwhensizingaGAZ®Ni-Cdbattery.TheGAZ®calculationprogramgivesthepossibilityto
includethisfactorintothecustomers´calculation.
Thefloatingeffectisareversibleeffectandcanonlybeeliminatedbyafulldischarge/chargecycle.Pleasenote that it cannot be prevented by just a boostcharge. The GAZ® battery sizing program providestheoptiontocalculatewithandwithoutthisfloatingeffectsothatthecustomerisabletoseetheaddedvalues.Ourrecommendationisalwaystoincludethisfactorwhensizingabattery.
6. Charging
TheGAZ®Ni-Cdbattery cangenerallybe chargedbyallnormalmethods.Usually,batteriesinparallelopera-tionwithchargerandloadarechargedwithconstantvoltage. For operations where the battery is chargedseparatelyfromtheload,chargingwithconstantcur-rentispossible.Overchargingwillnotdamagethebat-terybutwillleadtoanincreaseofwaterconsumption.
6.1 Constant voltage charge
Thecommonmethodtochargeabatteryinstationaryapplicationsiscarriedoutbyaconstantvoltagesystemandtherecommendedsolutionistouseatwo-ratetypethat is able to provide a constant voltage charge andalowerfloatingvoltageorsingleratefloatingvoltage.The two level charger has an high voltage stage tochargethebatteryproperlyafteradischargefollowed
by a lower voltagefloat level charge. This results in aquickchargeofthebatteryandinrelativelylowwaterconsumptionduetothelowlevelfloatcharge.
Two level charge
Boostcharge: 1.55–1.70V/cell
Floating 1.40–1.42V/cell
Ahighvoltagewillincreasethespeedandefficiencyofrechargingthebattery.
Inrealityoftensinglelevelchargercanbefound.Thisissurelyacompromisebetweenavoltagehighenoughtochargethebatteryandlowenoughtohaveadequatewaterconsumption.
Single level charge
1.45–1.50V/cell
Forcommissioningthebatteriespleaseseepoint7.3.5.
5.6 Floating effect - Voltage depression
Floating derating factor in accordance of discharge time
Time[sec]Time[min]Time[hours]
Floa
ting
dera
ting
fact
or
FloatingderatingfactorforKM-typestoanendvoltageof1.10V/cell
1.10
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
1 5 30 60 5 10 15 20 30 1 1.5 2 3 5
Example:
YoucandischargethecellKM110Pfor30minuteswithacurrentof91Ampereto1.10V
accordingdischargetable.Thisvalueisvalidafterfullycon-
stantcurrentcharging.Ifyouchargethecellatfloat
chargingyouhavetoreducethedischargetimewithfactor0.74.Thatmeansthedischargetime
is22.2minutesonly.
ThisfactwillbeconsideredbytheGAZ®batterycalculation
programautomaticallyifthisoptionischosen.
PublicationNo:EN-GAZ-TMSR-002November2010
16
A discharged GAZ® Ni-Cd cell will take its time toreachafullstateofcharge.Onthetablesbelowthe
timeneededtoachieveacertainstageofchargecanbefound.
6.2 Charge acceptance
Chargingtime[hours]
Time to reach state of charge at charging voltages for fully discharged GAZ® Ni-Cd cells (M-Range: current Limit 0.2 C5A)
Vol
tage
per
cel
l[V
]
1.7
1.65
1.6
1.55
1.5
1.45
1.4
1.65
1.55
1.45
5
FULLYCHARGED
95%CHARGED
90%CHARGED
85%CHARGED
80%CHARGED
75%CHARGED
1 2 3 4 5 6 78 910 20 30 40 50 100 200 300 400500 1000
Chargingtime[hours]
Vol
tage
per
cel
l[V
]
1 2 3 4 5 6 78 910
Time to reach state of charge at charging voltages for fully discharged GAZ® Ni-Cd cells (L-Range: current Limit 0.2 C5A)
FULLYCHARGED
95%CHARGED
90%CHARGED
85%CHARGED
80%CHARGED
75%CHARGED
20 30 40 50 100 200 300 400500 1000
1.7
1.65
1.6
1.55
1.5
1.45
1.4
PublicationNo:EN-GAZ-TMSR-002November2010
17
6.3 Charge effi ciency
Thechargeefficiencydependsmostlyonthestateofchargeof thebatteryandtheambienttemperatureaswellasthechargingcurrent.Formuchofitschargeprofile the GAZ®Ni-Cd battery is charged at a highlevelofefficiency.Butifthebatteryapproachesafullychargedconditionthechargingefficiencydecreases.
Chargingtime[hours]
Vol
tage
per
cel
l[V
]
1.7
1.65
1.6
1.55
1.5
1.45
1.4
1 2 3 4 5 6 78 910
Time to reach state of charge at charging voltages for fully discharged GAZ® Ni-Cd cells (H-Range: current Limit 0.2 C5A)
FULLYCHARGED
95%CHARGED
90%CHARGED
85%CHARGED
80%CHARGED
75%CHARGED
20 30 40 50 100 200 300 400500 1000
PublicationNo:EN-GAZ-TMSR-002November2010
18
The electrochemical behaviour of the battery becomesmore active if temperature increases, i.e. for the samefloatingvoltagethecurrentincreases.Ifthetemperaturedecreases the reverse occurs. Increasing the current in-creasestheconsumptionofwaterandreducingthecur-rentcouldleadtoaninsufficientcharging.
For standby application it is normally not necessary tocompensatethechargingvoltagewiththetemperature.In order to reduce the water consumption it is recom-
mendedtocompensateitatelevatedtemperatureasforexamplefrom+35°Conbyuseofthenegativetempera-turecoefficientof−3mV/K.
For operation at low temperatures, i.e. below 0°C,thereisariskofpoorcharginganditisrecommend-edtoadjustthechargingvoltageortocompensatethechargingwiththetemperature(-3mV/K,start-ingfromanambienttemperatureof+20°C).
6.5 Commissioning
Agoodfirstchargeisessentialtopreparethebatteryforitslongservicelifetime.Aboveallitisimportantfor discharged cells since they are in a totally dis-chargedstage(seepoint7.3.5Commissioning)
6.4 Temperature infl uence
Float Voltage with Temperature Correction
Temperaturein°C
Floa
tV
olta
ge[V
/cel
l]
U-Float
-25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
1.56
1.54
1.52
1.50
1.48
1.46
1.44
1.42
1.40
1.38
1.36
1.34
1.32
1.30
PublicationNo:EN-GAZ-TMSR-002November2010
19
7. Installation and operating instructions
7.1. Receiving the battery
Thecellsarenottobestoredinpackaging,therefore,unpack the battery immediately after arrival. Do notoverturn thepackage. Thebattery cells are equippedwithablueplastictransportplug.Thebatterycanbedelivered
- Filled and charged – thebatteryisreadyforin-stallation.Replacethetransportplugbytheventcapincludedinouraccessoriesonlybeforeuse
- Filled and discharged – replace the transportplugby theventcap included inouraccessoriesonlybeforeuse
- Unfi lled and discharged – do not remove thetransportpluguntilreadytofillthebattery
Thebatterymustnotbechargedwiththetransportpluginthecellsasthiscandamagethebattery.
7.2. Storage
Theroomsprovidedforstoringthebatteriesmustbeclean,dry,cool(+10°Cto30°C-incompliancewithIEC60623)andwellventilated.Thecellsarenottobe stored inclosedpackagingandmustnotbeex-posedtodirectsunlightorUV-radiation.
If the cells are delivered in plywood boxes, open the boxes before storage and remove the pack-ing material on the top of the cells. If the cells are delivered on pallets, remove the packing material on the top of the cells.
7.2.1 Uncharged and unfi lled cells
Providedthecorrectstorageconditionsaremetthenthe cells and batteries can be stored for long peri-odswithoutdamage if they aredeeply discharged,drainedandwellsealed.Itisveryimportantthatthecellsaresealedwiththeplastictransportplugtightlyinplace.Itisnecessarytocheckafterreceiptandatleasteveryyear.Leakyplugsallowthecarbondioxidefromtheatmospheretoinfiltratethecell,whichwillresult incarbonationoftheplates.Thatmayimpairthecapacityofthebattery.
7.2.2 Charged and fi lled cells/ discharged and fi lled cells
Filledcellscanbestored12monthsatthemostfromthetimeofdelivery.
Storageoffilledcellsatatemperatureabove+30°Cresultsinlossofcapacity.Thiscanbeapproximately5%per10degrees/yearwhen the temperatureex-ceeds +30°C. It is very important that the cells aresealedwiththeplastictransportplugstightlyinplace.Thisistocheckafterreceiptofgoods.Incaseoflossofelectrolyteduringtransport,refillthecelluntilthe“MIN”markwithelectrolytebeforestorage.
7.3. Installation
EN50272-2:2001“Accumulatorsandbatteryinstal-lations,stationarybatteryinstallations”isbindingforthesettingupandoperationofbatteryinstallations.Fornonstationaryinstallationsspecificstandardsarevalid.
7.3.1 Location
Install the battery in a dry and clean room. Avoid in any case direct sunlight and heat. The battery will give the optimal performance and maxi-mum service life if the ambient temperature lies between + 10°C and + 30°C.
7.3.2 Ventilation
During the last part of charging the battery gases(oxygenandhydrogenmixture)areemitted.Atnor-malfloatchargethegasevolution isverysmallbutsomeventilationisnecessary.
Specialregulationsforventilationmightberequiredinyourareaforcertainapplications.IfnoregulationsarefixedinyourareaDINEN50272–2:2001shouldbemet.
PublicationNo:EN-GAZ-TMSR-002November2010
20
7.3.3 Setting up
Alwayspayattentiontotheassemblydrawings,circuitdiagramsandotherseparateinstructions.Thetransportplugs have to be replaced by the vent caps includedin the accessories. If batteries are supplied “filled andcharged”,theelectrolytelevelshouldbechecked,andifnecessary,toppedoffasdescribedinpoint3.4.
Cellconnectorsand/orflexiblecablesshouldbecheckedtoensuretheyaretightlyseated.Terminalnuts,screwsand connectors must be tightly seated. If necessarytightenwithatorquespanner.
Torque loading for:
M10:8NmM16:20NmM20:25Nm
Female thread:
M8:20–25NmM10:25–30Nm
The connectors and terminals should be corrosion-pro-tectedbycoatingwiththinlayerofanticorrosiongrease.
7.3.4 Electrolyte
The electrolyte forGAZ® Ni-Cdbatteries consists of di-lutedcausticpotashsolution(specificgravity1.20kg/litre±0.01kg/litre)witha lithiumhydroxidecomponent, inaccordancewithIEC60993.Thecausticpotashsolutionispreparedinaccordancewithfactoryregulations.Thespe-cificgravityoftheelectrolytedoesnotallowanyconclu-siontobedrawnonthechargingstateofthebattery.Itchangesonlyinsignificantlyduringcharginganddischarg-ingandisonlyminimallyrelatedtothetemperature.
- Battery delivered unfilled and discharged-iftheelectrolyteissupplieddry,itistobemixedac-cordingtotheenclosedmixinginstruction.Removethe transportplugs fromthecell justbeforefilling.Fillthecellsupto20mmabovethelowerlevelmark“MIN”.Steelcasedcellshavetobefilleduptothetopedgeoftheplates.Whenusingbatteryracksfillcellsbeforeputtingup.Onlyusegenuineelectrolyte.
- Battery delivered filled and charged or discharged-checkelectrolytelevel.Itshouldnotbelessthan20mmbelowtheupperlevelmark“MAX”see5.2.
- “OnlyusegenuineelectrolytesuppliedbyGAZ®“.
7.3.5 Commissioning
Agoodcommissioningisveryimportant.Thefollow-inginstructionsarevalidforcommissioningat20°Ctill 30°C. For different conditions please contactmanufacturer.Chargeatconstantcurrent isprefer-able.IfasitetestisrequestedithastobecarriedoutinaccordancewithtoIEC60623.
According to IEC 60623, 0.2 C5A is also expressed
as0.2ItA.
ThereferencetestcurrentItisexpressedas:
ItA=
Example:
0.2ItAmeans 20Afora100Ahbatteryor
100Afora500Ahbattery
7.3.5.1 Commissioning with constant current
Battery delivered unfilled and discharged – afteraperiodof5hoursfromfillingtheelectrolyteinthebat-teryshouldbechargedfor15hoursattheratedcharg-ingcurrent0.2I
tA.Approximately4hoursaftertheend
ofchargingtheelectrolytelevelshouldbeadjustedto
Cn Ah
1 h
1)cellcontainer2)cellconnector3)springwasher4)nut5)connectorcover
1)cellcontainer2)cellconnector3)springwasher4)screw5)connectorcover
nut connection
screw connection
PublicationNo:EN-GAZ-TMSR-002November2010
21
the upper electrolyte level marking “MAX” by usingonlygenuineelectrolyte.Forcellswithsteelcasestheelectrolyte level should be adjusted to the maximumlevel according to the “Instruction for the control ofelectrolytelevel”.During the charge the electrolyte level and temperature should be observed, see point 7.5.4. The electrolyte level should never fall below the “MIN” mark.
Battery delivered filled and discharged-thebatteryshouldbechargedfor15hoursattheratedchargingcurrent0.2I
tA.Approximately4hoursaftertheendof
chargingtheelectrolytelevelshouldbeadjustedtotheupper electrolyte level marking “MAX” by using dis-tilledordeionizedwaterinaccordancewithIEC60993.Forcellswithsteelcasestheelectrolytelevelshouldbeadjusted to themaximum level according to the“In-struction for the controlof electrolyte level”.During the charge the electrolyte level and temperature should be observed, see point 7.5.4. The electro-lyte level should never fall below the “MIN” mark.
Battery delivered filled and charged and stored for more than 12 months-thebatteryshouldbechargedfor15hoursattheratedchargingcurrent0.2I
tA.Ap-
proximately4hoursaftertheendofchargingtheelec-trolytelevelshouldbeadjustedtotheupperelectrolytelevel marking “MAX” by using distilled or deionizedwater in accordance with IEC 60993. For cells withsteel cases theelectrolyte level shouldbeadjusted tothemaximumlevelaccordingtothe“Instructionforthecontrol of electrolyte level”.During the charge the electrolyte level and temperature should be ob-served see point 7.5.4. The electrolyte level should never fall below the “MIN” mark.
Battery delivered filled and charged-a 5 hourscharge at the rated charging current 0.2I
tA must be
carriedoutbeforeputting thebattery intooperation.Approximately4hours after theendof charging theelectrolytelevelshouldbeadjustedtotheupperelec-trolytelevelmarking“MAX”byusingdistilledordeion-izedwaterinaccordancewithIEC60993.Forcellswithsteel cases theelectrolyte level shouldbeadjusted tothe maximum level according to the “Instruction forthe control of electrolyte level”. During the charge the electrolyte level and temperature should be observed, see point 7.5.4. The electrolyte level should never fall below the “MIN” mark.
7.3.5.2 Commissioning with constant voltage
If the charger´s maximum voltage setting is too low tosupplyconstantcurrentchargingdividethebattery intotwopartstobechargedindividually.
Battery delivered unfilled and discharged-after aperiodof5hoursfromfillingtheelectrolyte inthebat-teryshouldbechargedfor30hoursattheratedchargingvoltageof1.65V/cell.Thecurrentlimitshouldbe0.2I
tA
maximum.Approximately4hoursaftertheendofcharg-ingtheelectrolytelevelshouldbeadjustedtotheupperelectrolyte levelmarking“MAX”byusingonlygenuineelectrolyte.Forcellswithsteelcasestheelectrolyte levelshouldbe adjusted to themaximum level according tothe“Instructionforthecontrolofelectrolytelevel”.Dur-ing the charge the electrolyte level and temperature should be observed, see point 7.5.4. The electrolyte level should never fall below the “MIN” mark.
Battery delivered filled and discharged-the bat-teryshouldbechargedfor30hoursattheratedcharg-ing voltage of 1.65 V/cell. The current limit should be0.2I
tAmaximum.Approximately4hours after theend
of charging the electrolyte level should be adjustedto the upper electrolyte level marking “MAX” by us-ing distilled or deionized water in accordance with IEC60993. For cells with steel cases the electrolyte levelshould be adjusted to the maximum level accordingto the “Instruction for the control of electrolyte level”.During the charge the electrolyte level and tempera-ture should be observed, see point 7.5.4. The electro-lyte level should never fall below the “MIN” mark.
Battery delivered filled and charged and stored for more than 12 months-thebatteryshouldbechargedfor30hoursattheratedchargingvoltageof1.65V/cell.Thecurrentlimitshouldbe0.2I
tAmaximum.Approximately
4hours after the end of charging the electrolyte levelshouldbeadjusted to theupper electrolyte levelmark-ing“MAX”byusingdistilledordeionizedwater in ac-cordancewith IEC60993.Forcellswithsteelcases theelectrolytelevelshouldbeadjustedtothemaximumlevelaccordingtothe“Instructionforthecontrolofelectrolytelevel”. During the charge the electrolyte level and temperature should be observed, see point 7.5.4. The electrolyte level should never fall below the “MIN” mark.
Battery delivered filled and charged-/a 10 hourschargeattheratedchargingvoltageof1.65V/cellmustbecarriedoutbeforeputtingthebatteryintooperation.Thecurrent limitshouldbe0.2I
tAmaximum.Approxi-
mately4hoursaftertheendofchargingtheelectrolytelevel should be adjusted to the upper electrolyte levelmarking“MAX”byusingdistilledordeionizedwaterin accordance with IEC 60993. For cells with steelcasestheelectrolytelevelshouldbeadjustedtothemaximumlevelaccordingtothe“Instructionforthecontrolofelectrolytelevel”.During the charge the electrolyte level and temperature should be observed, see point 7.5.4. The electrolyte level should never fall below the “MIN” mark.
PublicationNo:EN-GAZ-TMSR-002November2010
22
7.4. Charging in operation
7.4.1 Continuous battery power supply (withoccasionalbatterydischarge)
Recommended charging voltage for ambient tem-peratures+20°Cto+25°C
Do not remove the vent caps during float-, boostchargeandbufferoperation.Thecurrentlimitshouldbe0.3I
tAmaximumingeneral.
7.4.1.1 Two level charge
Floating 1.40–1.42V/cell
Boostcharge: 1.55–1.70V/cell
Ahighvoltagewillincreasethespeedandefficiencyofrechargingthebattery.
7.4.1.2 Single level charge
1.45–1.50V/cell
7.4.2 Buffer operation
Wheretheloadexceedsthechargerrating.
1.45–1.55V/cell
7.5. Periodic Maintenance
Thebatterymustbekeptcleanusingonlywater.Donot use a wire brush or solvents of any kind. Ventcapscanberinsedincleanwarmwaterifnecessarybutmustbedriedbeforeusingthemagain.
Checkregularly(approx.every6months)thatallcon-nectors,nutsandscrewsaretightlyfastened.Defec-tiveventcapsandsealsshouldbereplaced.Allmetalpartsofthebatteryshouldbecorrosion-protectedbycoatingwithathinlayerofanti-corrosiongrease.Do not coat any plastic part of the battery, for ex-ample cell cases!
Checkthechargingvoltage. Ifabattery isconnect-ed inparallel it is importantthattherecommendedcharging voltage remainsunchanged. The chargingcurrentinthestringsshouldalsobecheckedtoen-sureitisequal.Thesecheckshavetobecarriedoutonceayear.Highwaterconsumptionofthebatteryisusuallycausedbyimpropervoltagesettingofthecharger.
7.5.1 Equalising charge
It is recommended to carry out an equalisingchargeonceayeartomaintaincapacityandtosta-bilisethevoltagelevelsofthecells.Theequalisingchargecanbecarriedoutfor15hoursat0.2I
tAor
with theboost charging stage in conformitywiththe characteristic curve of the available chargingimplement. The electrolyte level is to be checkedafteranequalisingcharge.
Inordertoequalizethefloatingderatingeffect itisrecommendedtochargethebatteryonceayearfor15hoursattheratedchargingcurrent0.2I
tA.
Thendischargethebatterydownto1.0V/cellandchargeagainfor8hoursattheratedchargingcur-rent0.2ItA.
7.5.2 Electrolyte check and topping up
Checktheelectrolytelevelandneverletthelevelfallbelowthelowerlevelmark“MIN”.UseonlydistilledordeionizedwatertofillthecellsinaccordancewithIEC60993.Experiencewill tell thetime intervalbe-tween topping-up. Refilling with electrolyte is onlypermissible if spilledelectrolytehas tobe replaced.Ifduringrefillingelectrolytehasbeensplashedontothecellcoverorbetweenthecellcasescleanthisoffandthendrythearea.SeeMSDSforhowtoproperlyclean-upspilledmaterial.
NOTE: Once the battery has been filled with the correct electrolyte either at the factory or dur-ing the battery commissioning, there is no need to check the electrolyte density periodically. Interpretation of density measurements is dif-ficult and could lead to misunderstandings.
PublicationNo:EN-GAZ-TMSR-002November2010
23
7.5.3 Replacing of electrolyte
Inmoststationaryapplicationstheelectrolytewillretainitseffectivenessforthetotallifetimeofthebattery.However,underspecialbatteryoperatingconditions, if the electrolyte is found to be car-bonated,thebatteryperformancecanberestoredby replacing the electrolyte. Only use genuine electrolyte supplied by GAZ®!
Itisrecommendedtochangetheelectrolytewhenreaching a carbonate content of 75 g/litre. It ispossibletotesttheelectrolyteintheworkslabo-ratory.Forthisaminimumquantityof0.2litresofelectrolyte in a clean glass or polyethylene con-tainer should be sent in, paying strict attentionto the valid dangerous goods regulations. Expe-diently the sampleofelectrolyte is takenhalfanhour after charging has ended and from severalcellsofthebattery.Itispointlesstotakethesam-plesimmediatelyaftertoppingup.Theelectrolytesampleandthecellsshouldbeclosedimmediatelyaftertheelectrolytehasbeentaken.
CAUTION – caustic potash solution is corrosive! Safety regulations shall be applied, goggles and gloves shall be used!
7.5.4 Electrolyte temperature
Thetemperatureoftheelectrolyteshouldneverex-ceed45°Cashighertemperatureshaveadetrimen-taleffectonthefunctionanddurationof thecells.Inthecourseofcharginganelectrolytetemperatureof≤35°Cshouldbeaimedfor.Onexceeding45°Cthechargingshouldbetemporarilyinterrupteduntiltheelectrolytetemperaturefallsdownto35°C.Thetemperaturemeasurementsare tobemadeononeofthecellsinthemiddleofthebattery.
Low ambient or electrolyte temperatures down to–25°Cdonothaveanydetrimentaleffectonthebat-tery;theyjustcauseatemporaryreductionincapac-ity.
7.6. Additional warning notes
GAZ®Ni-Cdbatteriesmustnotbeusedorstoredinthesameroomasleadacidbatteries.Inadditiontothisthecharginggasesfromleadacidbatteriesmustbekeptaway fromNi-Cdbatteriesby suitablepre-cautionssuchasventilationorhermetic isolationoftherooms.ToolsforleadacidbatteriesmustnotbeusedforNi-Cdbatteries
Donotplaceelectrically conductiveobjects suchastoolsetc.onthebattery!
Risk of short circuit and fire: No rings or metalbraceletsshouldbewornduringtheassemblyofthebattery–Risk of injury!
Openthedoorsofthebatterycabinetduringcharg-ingsothatthecharginggasescanescape.Thecharg-inggasesfrombatteriesareexplosive.Donotallowopenfireoremberinthevicinityofthebattery!
Risk of explosion: Caution–causticpotashsolutioniscorrosive!
Causticpotashsolutionisusedaselectrolyte.Causticpotashsolutionisahighlycorrosiveliquidwhichcancauseseveredamagetohealthifitcomesintocon-tactwiththeeyesortheskin(riskofblinding).Ifevensmallquantitiesareswallowedthereisapossibilityofinternalinjuries.
When working with electrolyte and on cells, rubber gloves, safety goggles with side guards and protective clothing must always be worn!
Contact with the eyes:Flushoutimmediatelywithcopiousamountsofwaterfor10–15minutes.
Ifnecessaryconsultaneyeclinic.
Contact with the skin: Remove splashed clothingimmediately andwash the affected skin areaswithcopiousamountsofwater.Foranydiscomfortscon-sultadoctor.
Swallowing:Rinseoutthemouthimmediatelywithcopious amounts of water and keep drinking largeamountsofwater.Donotprovokevomiting.Callanemergencydoctorimmediately.
In the event of injuries:Rinsethoroughlyforalongperiodunderrunningwater.Consultadoctorimme-diately.
PublicationNo:EN-GAZ-TMSR-002November2010
GAZ Geräte- und Akkumulatorenwerk Zwickau GmbH
ReichenbacherStraße62/68D-08056Zwickau
Postfach200457D-08056Zwickau
Telefon:+49(0)375/86-0Telefax:+49(0)375/86-440
ANENERSYSCOMPANYPublicationNo:EN-GAZ-TMSR-002November2010Copyright2008GAZ®GmbHallrightreserved
©2008EnerSys.Allrightsreserved.AlltrademarksandlogosarethepropertyofEnerSysanditsaffiliatesunlessotherwisenoted.