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V3.4

Technical manual

VantageUltra-low maintenance batteries

1 Introduction 3

2 Benefits of the Vantage battery 4

3 Battery applications 5

4 Principles of the oxygenrecombination cycle 6

5 Construction features 75.1 Plate assembly 75.2 Separation 75.3 Electrolyte 85.4 Terminal pillars 85.5 Venting system 85.6 Cell container 8

6 Operating features 96.1 Capacity 96.2 Cell voltage 96.3 Internal resistance 96.4 Effect of temperature

on performance 96.5 Short-circuit values 106.6 Open circuit loss 106.7 Cycling 116.8 Water consumption 116.9 Gas evolution 11

7 Battery charging 127.1 Charging methods 127.2 Charge acceptance 137.3 Temperature effects 13

8 Special operating factors 148.1 Electrical abuse 148.2 Mechanical abuse 14

9 Battery sizing principles 15

10 Installation and operatinginstructions 16

10.1 Receiving the shipment 1610.2 Storage 1610.3 Installation 1610.4 Commissioning 1710.5 Charging in service 1810.6 Periodic maintenance 18

11 Refurbishment ofVantage batteries 19

12 Disposal and recycling 20

Contents

VANTAGE TECHNICAL MANUAL

1 Introduction

The nickel-cadmium battery is the most reliablebattery system available in the market today. Itsunique features enable it to be used in applicationsand environments untenable for other widelyavailable battery systems. With the advent of thevalve-regulated lead acid battery a new concept wasavailable to the customer, a battery that did notrequire water replenishment. However, this wasobtained at the cost of reliability. To give thecustomer a highly reliable battery of zero orultra-low maintenance Alcad has developed theVantage recombination pocket plate battery.

This publication details the design and operatingcharacteristics of the Alcad Vantage battery toenable a successful battery system to be achieved.A battery which in normal applications requires notopping-up but has all the well-proven advantagesof the nickel-cadmium pocket plate battery.

3 VANTAGE TECHNICAL MANUAL

2 Benefits of theVantage battery

Benefits of the Alcad valve-regulated Vantage battery are :

Complete reliability

Does not suffer from the sudden death failure dueto internal corrosion associated with the lead acidbattery.

Exceptional long life

It has all the design features associated with theconventional Alcad twenty plus year life batteries.

Ultra-low maintenance

Vantage can operate for up to twenty years withouttopping-up in normal applications. It can beengineered for severe applications to give prolongedultra-low maintenance with the option of waterreplenishment as and when required.

Wide operating temperature range

The normal Vantage operating temperature range is0˚C to + 40˚C (+ 32˚F to +104˚F). However, Vantagecan survive extremes of temperature from as low as– 50˚C to up to + 70˚C (– 58˚F to up to +158˚F).

Resistance to mechanical abuse

Vantage is designed to have the mechanical strengthfor use in both stationary and mobile applications.

High resistance to electrical abuse

Vantage will survive abuses which will destroy thevalve-regulated lead acid battery. In particular, it hasa resistance to overcharging, deep discharging, short-circuits, and accepts ripple currents up to 0.2 C5 A Ieff.

Low installation costs

Vantage can be used with existing charging systems,has minimal gas evolution without any corrosivevapours, uses corrosion-free polypropylene containersand has an easy bolted assembly system.

Well-proven pocket plateconstruction

Alcad has over 80 years of manufacturing andapplication experience with respect to thenickel-cadmium pocket plate product and thisexpertise has been built into the twenty plus years’design life of the Vantage product.

4VANTAGE TECHNICAL MANUAL

3 Battery applications

Offshore oil and gas

Emergency lighting

Fire and security systems

Railway signalling

Process control

Switchgear

Telecommunications

Mass transit

UPS

Vantage batteries are designed to meet the needsof applications requiring the traditional highreliability of nickel-cadmium pocket plate cellswithout the need to replenish with water. Theyare indeed the best solution for installations,whether they are UPS systems, emergency lightingsystems, telecommunications, where the risk offailure of the system is unacceptable. Vantagebatteries are also eminently suitable for “remote”applications such as offshore applications andswitching substations, where the system musthave total reliability without the need for batterymaintenance.


4 Principles of theoxygen recombinationcycle

In a conventional flooded electrolyte pocket platenickel-cadmium battery water is lost from the batteryon overcharge due to the following reactions :At the positive plate40H- 2H20 + 02 + 4e- (Oxygen evolution)

At the negative plate4H20 + 4e- 2H2 + 40H- (Hydrogen evolution)

This corresponds to a theoretical loss of 36 g of waterfor 107 Ah of overcharge i.e. 0.335 cm3 per Ah. Hencea conventional cell requires periodic addition of water.The frequency of this operation depends upon thecumulative amount of charge received and theoperating temperature.

During the charging process evolution of oxygen beginsto occur a little before the positive plate reaches its fullycharged state and then becomes the main reactionwhen the fully charged condition is reached. However,the cadmium negative plate has a better chargeacceptance than the positive plate and hydrogen is notevolved until this plate is virtually fully charged.

The Vantage battery has been designed with anexcess of cadmium negative material to enhance thiseffect and ensure that oxygen evolution commencesprior to hydrogen evolution.The oxygen which is produced at the positiveplate surface is collected by the special porousseparator and thus not allowed to escape fromthe region between the plates. Somedisplacement of electrolyte within the separatoroccurs, thus generating extra unfilled pores forthe diffusion of oxygen directly to the adjacentcadmium negative plate.

As soon as the oxygen reaches the negative plateit reacts either chemically :

2Cd + 02 + 2H20 2Cd(OH)2 (A)

or electrochemically :

02 + 2H20 + 4e- 40H- (B)

Reaction (A) has the effect of chemicallydischarging some of the cadmium to cadmiumhydroxide. The current passing through the batteryis used to recharge this material.

Reaction (B) consumes the current directly. Thushydrogen evolution at the negative plate issuppressed because the preferred reaction is oxygenrecombination. Hence the total process of oxygengeneration and consumption is referred to as anoxygen recombination cycle.

The efficiency of this oxygen recombination processdepends upon the relationship between the rate atwhich oxygen is produced and the rate at which itcan be collected and transferred to the negativeplate surface. The rate of collection and transfer ofoxygen is controlled by the separator type and thecell design.

The rate at which oxygen is produced on overchargeis directly related to the charge current once thepositive plate has reached a full state of charge. Thecharge current in turn is controlled by the chargingvoltage level set on the charging equipment and theambient temperature. By controlling the chargevoltage high efficiencies can be obtained and in thisway the rate of water loss can be reduced to afraction of that from conventional batteries.

Though the efficiency of this oxygen recombinationis high it will never achieve 100% as smallquantities of oxygen will escape from the separatorbefore reaching and reacting at the negative plate.Thus a small quantity of hydrogen will ultimatelybe generated and hence a low rate of water losswill occur. The battery is designed to accommodatethis by provision of a generous electrolyte reserveboth above and around each cell pack within thebattery. This ensures a long service life without theneed to replenish with water too often.

The Vantage battery is fitted with a low pressurevent on each cell. On overcharge the cells have aninternal pressure above atmospheric pressure. Thevent provides an outlet for the release of smallquantities of hydrogen and non-recombinedoxygen and thus controls the internal pressure.When the pressure falls below the release pressureeither on open circuit or on discharge the ventreseals to prevent ingress of air and minimise self-discharge reactions.


5 Construction features

The construction of the Alcad Vantage cell is basedupon the Alcad pocket plate technology but withspecial features to enhance the low water usageby means of the recombination cycle.

5.1 Plate assembly

The nickel-cadmium cell consists of two groups ofplates, one containing nickel hydroxide (thepositive plate) and the other containing cadmiumhydroxide (the negative plate).

The active materials of the Alcad Vantage pocketplate are retained in pockets formed from nickel-plated steel strips double-perforated by a patentedprocess. These pockets are mechanically linkedtogether, cut to the size corresponding to the platewidth and compressed to the final platedimension. This process leads to a componentwhich is not only mechanically robust but alsoretains its active material within a steel boundarywhich promotes conductivity and minimiseselectrode swelling.

These plates are then welded to a current carryingbus bar which further ensures the mechanical andelectrical stability of the product.

The alkaline electrolyte does not react with steel,which means that the supporting structure of theVantage battery stays intact and unchanged forthe life of the battery. There is no corrosion and norisk of “sudden death”.

5.2 Separation

As described in section 4, the separator is a keyfeature of the Alcad Vantage battery. It ispolypropylene fibrous material which, afterexhaustive analysis of available separator material,was specially developed for this product to givethe features required.

Using this separator and plastic spacing ribs, thedistance between the plates is carefully controlledto give the necessary gas retention to provide thelevel of recombination required.

Low pressureflame-arresting vent

Terminal pillars

Plate group bus bar

Polypropylenecell container

Polypropylenefibrous separator

Pocket plate


Plate tab

Protective coverin line with

EN 50272-2 (safety)with IP2 level.

Alcad cells fulfil allrequirements specified by IEC 60623 and 62259.

By providing a large spacing between the positiveand negative plates and a generous quantity ofelectrolyte between plates, the possibility of thermalrunaway is eliminated.

5.3 Electrolyte

The electrolyte used in Vantage, which is a solutionof potassium hydroxide and lithium hydroxide, isoptimised to give the best combination ofperformance, life and energy efficiency over a widetemperature range.

The concentration is such as to allow the cell to beoperated down to – 20˚C(– 4˚F) (for operatingtemperature, see section 2) and it is not necessary tochange the electrolyte during the life of the cell.

The electrode material is less reactive with thealkaline electrolyte (nickel-cadmium secondarybatteries) than with acid electrolytes (lead acidsecondary batteries). Furthermore, during chargingand discharging in alkaline batteries the electrolyteworks mainly as a carrier of oxygen or hydroxyl ionsfrom one electrode to the other; hence thecomposition or the concentration of the electrolytedoes not change noticeably. In the charge/dischargereaction of the nickel-cadmium battery, thepotassium hydroxide is not mentioned in the reactionformula. A small amount of water is producedduring the charging procedure (and consumedduring the discharge). The amount is not enough tomake it possible to detect if the battery is charged ordischarged by measuring the density of theelectrolyte.

Once the battery has been filled with the correctelectrolyte at the battery factory, there is no need tocheck the electrolyte density periodically.

5.4 Terminal pillars

Short terminal pillars are welded to the plate busbars using a well-proven battery constructionmethod. These posts are manufactured from steelbar, internally threaded for bolting on connectorsand are nickel-plated.

The terminal pillar to lid seal is provided by acompressed visco-elastic sealing surface held in placeby compression lock washers. This assembly isdesigned to provide satisfactory sealing throughoutthe life of the product.

5.5 Venting system

Vantage is fitted with a low pressure flame-arrestingvent for each cell of the battery. This vent operatesas a one way valve which will allow the release ofsmall quantities of hydrogen and non-recombinedoxygen if the internal pressure exceeds a fixedsafety value. The nominal operating pressure of thevent is 0.2 bar.

When the pressure falls below the release pressurethe vent reseals to prevent ingress of air.

The sealing vent has an integral flame-arrestingporous disc to prevent any possibility of any externalignition from spreading into the Vantage cell.

5.6 Cell container

Vantage is built up using the well-proven Alcadbattery construction. The tough polypropylenecontainers are welded together by heat sealing.Additional end walls are welded on to constrain thesmall internal pressure changes created by therecombination process and the low pressure vent.

The assembly of the blocks is completed by a clip oncover enclosing the top of the Vantage block, givinga non-conducting, easy to clean, top surface.


6 Operating features

6.1 Capacity

The Vantage battery capacity is rated in ampere-hours(Ah) and is the quantity of electricity at + 20°C (+ 68°F)which it can supply for a 5 hour discharge to1.0 V/cell after being fully charged. This figure is inagreement with the IEC 60623 standard.

According to the IEC 60623 (Edition 4), 0.2 C5 Ais also expressed as 0.2 It A. The reference testcurrent (It) is expressed as :

Cn Ah1 h

where :Cn is the rated capacity declared by the

manufacturer in ampere-hours (Ah),and

n is the time base in hours (h) for which the rated capacity is declared.

In practice, Vantage is used in floating conditions andso the tabular data is based upon cell performanceafter several months of floating. This eliminatescertain correction factors which need to be usedwhen sizing batteries with conventional fully chargedopen cell data (see section 9 Battery sizing principles).

6.2 Cell voltage

The cell voltage of nickel-cadmium cells results fromthe electrochemical potentials of the nickel and thecadmium active materials in the presence of thepotassium hydroxide electrolyte. The nominal voltageis 1.2 V.

6.3 Internal resistance

The internal resistance of a cell varies with thetype of service and the state of charge and is,therefore, difficult to define and measure accurately.

The most practical value for normal applications isthe discharge voltage response to a change indischarge current.

The internal resistance per 1/C5 of a Vantage cell atroom temperature when measured after floatcharging at normal temperature is 80 mΩ for VN 8to VN 48 cells and 100 mΩ for VN 71 to VN 476 cells;e.g. for a Vantage cell type VN 8 (8 Ah) the internalresistance is 80x1/8 = 10 mΩ.

The above figures are for fully charged cells. Forlower states of charge the values increase.

For cells 50% discharged the internal resistance isabout 20% higher and when 90% discharged it isabout 80% higher. The internal resistance of a fullydischarged cell has very little meaning.

Reducing the temperature also increases the internalresistance and, at 0˚C (+ 32°F), the internal resistanceis about 40% higher than at room temperature.

6.4 Effect of temperature onperformance

Variations in ambient temperature affect theperformance of Vantage and this needs to be takeninto account when sizing the battery.

Low temperature operation has the effect ofreducing the performance but the highertemperature characteristics are similar to those atnormal temperatures. The effect of temperature ismore marked at higher rates of discharge.

It A =


The factors which are required in sizing a battery tocompensate for temperature variations are given ina graphical form in Figure 1 for the normalrecommended operating temperature range of0˚C to + 40˚C (+ 32°F to +104°F).

For use at temperatures outside this range contactAlcad for advice.

6.5 Short-circuit values

The typical short-circuit value in amperes for a Vantagecell is approximately 15 times the ampere-hourcapacity. The Vantage battery is designed to withstanda short-circuit current of this magnitude for manyminutes without damage.

6.6 Open circuit loss

The state of charge of Vantage on open circuitslowly decreases with time due to self-discharge.In practice this decrease is relatively rapid during thefirst two weeks but then stabilises to about 2% permonth at + 20˚C (+68°F).

The self-discharge characteristics of a nickel-cadmiumcell are affected by the temperature. At lowtemperatures the charge retention is better than atnormal temperature and so the open circuit loss isreduced. However, the self-discharge is significantlyincreased at higher temperatures.

The open circuit loss for Vantage for the standardtemperature and the extremes of the normal operatingrange is shown in Figure 2 for a one year period.


6.7 Cycling

Vantage is an ultra-low maintenance product andtherefore is used generally in standby and notcontinuous cycling applications. Nevertheless, it isdesigned using conventional pocket plate electrodetechnology and has therefore an equivalent cyclingcapability to the standard product.

If Vantage is used in a deep cycling applicationwhich requires a fast recharge, there will besignificant gas evolved and the ultra-lowmaintenance properties of the product will beseverely reduced. However, there are cyclingapplications where Vantage can be beneficial.This will depend on the frequency and depth ofdischarge involved.

6.8 Water consumption

The Vantage battery works on the oxygenrecombination principle and therefore has a muchreduced water consumption. In practice, for therecommended charging voltages, Vantage has a levelof recombination of 85% to 95%. This compares tothe level of recombination found in equivalentvented pocket plate cells of 30% to 35%. ThusVantage has a water usage reduced by a factor of upto 10 times of that of an open flooded cell. Thismeans that at suitable charging voltages andtemperatures, Vantage will not need waterreplenishment for about 20 years.

However, not all needs are the same and Vantage isdesigned to allow water replenishment underdifferent and more difficult charging conditions.Figure 3 gives a comparison of different waterreplenishment times under different float voltages at+ 20˚C (+ 68°F).

6.9 Gas evolution

The gas evolution is a function of the amount ofwater electrolysed into hydrogen and oxygen whichis not involved in the recombination cycle. Theelectrolysis of 1 cm3 of water produces about1865 cm3 of gas mixture and this gas mixture is inthe proportion of 2/3 hydrogen and 1/3 oxygen. Thusthe electrolysis of 1 cm3 of water produces about1243 cm3 of hydrogen.

As stated in section 6.8 Water consumption, undernormal recommended float conditions Vantage has arecombination level of 85% to 95% and so theamount of water which is electrolysed into gas issmall. Typically a Vantage cell will electrolyse about0.002 cm3 of water per Ah of cell capacity per day.This value will be smaller or larger depending on thefloat voltage value. Thus a typical value of gasemission would be 3.5 cm3 per Ah of cell capacityper day, or 2.5 cm3 of hydrogen per Ah of cellcapacity per day.


7 Battery charging

In order to ensure that the ultra-low maintenanceproperties of the Vantage battery are achieved, it isnecessary to control the charge input to the batteryto minimise the rate of water loss during the life ofthe product.

It is important therefore that the recommendedcharge conditions are complied with. However,Vantage is unique in recombination valve-regulatedsystems in allowing the possibility of replenishmentof water in severe applications where excessive waterloss is unavoidable.

7.1 Charging methods

Vantage batteries may be charged by the followingmethods :

a) Two level constant potential charging

The initial stage of two-rate constant potentialcharging consists of a first charging stage to amaximum voltage of 1.45 ± 0.01 V/cell.

Alternatively, if a faster rate of recharge is required,a voltage limit of 1.55 V/cell with a current limit of0.1 C5 A can be used. However, if frequent rechargesare required this will increase the rate of water lossand gas generation.

After this first stage the charger should be switchedto a second maintenance stage at a float voltage of1.42 ± 0.01 V/cell. After a prolonged mains failurethe first stage should be reapplied manually orautomatically.

b) Single level float charging

Vantage batteries are float charged at1.42 ± 0.01 V/cell from a fully discharged conditionto a high state of charge. This is detailed insection 7.2 and about 80% of the capacity will beavailable after 16 hours of charge.

Temperature compensation may be required asdescribed in section 7.3.


7.2 Charge acceptance

The performance data sheets for Vantage are basedupon several months’ floating and so are for fullyfloat charged cells.

A discharged cell will take a certain time to achievethis and Figure 4 gives the capacity available for thetwo principal charging voltages recommended forVantage, 1.42 V/cell and 1.45 V/cell, during the first30 hours of charge from a fully discharged state.

If the application has a particular recharge timerequirement then this must be taken into accountwhen calculating the battery (see section 9 Batterysizing principles).

7.3 Temperature effects

The recombination efficiency of the Vantage cell isdependent on the floating current and this, in itself,is a function of the floating voltage. Thus the floating

voltages chosen for Vantage are carefully optimisedat an ambient temperature of + 20˚C (+68°F)between the current required to charge the cell andthe level of current required to give the ultra-lowmaintenance features.

As the temperature increases then theelectrochemical behaviour becomes more active andso, for the same floating voltage, the currentincreases. As the temperature is reduced then thereverse occurs. Increasing the current increases thewater loss and reducing the current creates the riskthat the cell will not be sufficiently charged. Thus asit is clearly important to maintain the same currentthrough the cell, it is necessary to modify the floatingvoltage as the temperature changes. The change involtage required, or “temperature compensation”, isgiven in Figure 5. If these values cannot be exactlymet with a particular system then temperaturecompensation value is – 3 mV/ ˚C/cell (–1.7 mV/ ˚F/cell).


8 Special operatingfactors

8.1 Electrical abuse

8.1.1 Ripple effects

The nickel-cadmium battery is tolerant to high ripplefrom standard charging systems. Vantage acceptsripple currents up to 0.2 C5 A Ieff.

8.1.2 Over-discharge

If more than the designed capacity is taken out ofa battery then it becomes over-discharged. This isconsidered to be an abuse situation for a battery andshould be avoided.

In the case of lead acid batteries this will lead tofailure of the battery and is unacceptable.

The Vantage battery is designed to make recoveryfrom this situation possible.

8.1.3 Overcharge

Overcharge of a recombination battery leads to anexcessive use of water.

In a restricted electrolyte battery, such as valve-regulated lead acid, this loss of electrolyte isirreversible and will lead to premature failure ofthe battery.

In the case of Vantage, with its generous electrolytereserve, a small degree of overcharge will notsignificantly alter the maintenance period. In thecase of excessive overcharge, a situation which willimmediately destroy a valve-regulated lead acidbattery, Vantage can be refurbished as described insection 11.

8.2 Mechanical abuse

8.2.1 Shock loads

The Vantage block battery concept has been tested toIEC 68-2-29 (bump tests at 5 g, 10 g and 25 g) andIEC 77 (shock test 3 g), where g = acceleration.

8.2.2 Vibration resistance

The Vantage block battery concept has been testedto IEC 77 for 2 hours at 1 g, where g = acceleration.

8.2.3 External corrosion

Vantage nickel-cadmium cells are manufactured indurable polypropylene, all external metalcomponents are nickel-plated and these componentsare protected by an anti-corrosion oil and a rigidplastic cover.


9 Battery sizingprinciples

Vantage is designed to be easy to use and specifyand so the published data is based on cells whichhave been on float for several months, i.e. the datareflects the practical situation.

Thus in a situation at normal ambient temperaturewithout any specific requirement with regard torecharge time the published data can be useddirectly to size the battery. However, if there arerequirements with regard to recharge time ortemperature then this will modify the result.

Examples

A standby system is to be sited in a building with anambient temperature of + 20˚C (+ 68˚F) and thetemperature will always lie between + 15˚C and+ 25˚C (+ 59˚F and + 77˚F). It has a maximum voltageof 130 V and a minimum voltage of 95 V andrequires a backup of 105 Amperes for 2 hours.

In this case a simple 1.42 V/cell single level chargerwithout temperature compensation can be used.

Number of cells = 130/1.42 = 91 and the finalvoltage will be 95/91 = 1.04 V/cell.

The Vantage data shows that the VN 238 gives109 Amperes for 2 hours to 1.05 V/cell and so thebattery would be 91 cells of VN 238.

However, if for this example there was a restrictionthat the battery must give 80% of its performanceafter 10 hours from a totally discharged state thencertain modifications need to be made to thecalculation.

If the single level 1.42 V/cell charger is retained, thenfrom Figure 4 it can be seen that after 10 hoursabout 74% of the capacity is available and so thebattery size will have to be increased by the factor80/74 or, in other words, 8%. Thus for a current of113 Amperes (105 Amperes + 8%) to 1.05 V/cell thebattery required is 91 cells of VN 285 as this gives131 Amperes to 1.05 V/cell.

From Figure 4, it can be seen that a voltage of1.45 V/cell gives 80% of the capacity after 10 hoursand so there is no need to increase the cell capacityto compensate for the charge. However, the batteryhas to be recalculated as, with the same voltagewindow, the higher charge voltage will modify theend of discharge voltage.

Thus, the number of cells = 130/1.45 = 89and so the end of discharge voltage becomes95/89 = 1.07 V. The Vantage performance tablesgive for 2 hours discharge at 117 Amperes to1.10 V/cell the VN 285, and so in this case thebattery is 89 cells of VN 285.

In this situation it is advisable to use a dual ratecharger.

In principle it is always better to go to the lowestcharge voltage as this gives the lowest end ofdischarge voltage, and generally a smaller cellcapacity for the same duty, and gives the bestmaintenance interval.

Temperatures outside the standard range are treatedin precisely the same way using Figure 1 for thede-rating factors.

When treating temperatures it is important to notethat low temperatures reduce the performance(Figure 1) and so the battery size must be increasedto accommodate this.

This section is intended to give general guidelines inbattery sizing. For advice on special batteryapplications contact Alcad.


10 InstaIIation andoperating instructions

Important recommendations

Never allow an exposed flame or spark nearthe batteries, particularly while charging.

Never smoke while performing any operationon the battery.

For protection, wear rubber gloves, longsleeves, and appropriate splash goggles orface shield.

The electrolyte is harmful to skin and eyes.In the event of contact with skin or eyes,wash immediately with plenty of water.If eyes are affected, flush with water, andobtain immediate medical attention.

Remove all rings, watches and other itemswith metal parts before working on thebattery.

Use insulated tools.

Avoid static electricity and take measures forprotection against electric shocks.

Discharge any possible static electricity fromclothing and/or tools by touching an earth-connected part “ground” before working onthe battery.

10.1 Receiving the shipment

Unpack the battery immediately upon arrival. Do notoverturn the package. Check the packages and cellsfor transport damage.

The battery is shipped filled and charged, and isready for immediate use.

10.2 Storage

Store the battery indoors in a dry, clean, coollocation (0°C to + 30°C/+ 32°F to + 86°F) and well-ventilated space on open shelves.

Storage of a filled battery at temperatures above+ 30°C (+ 86°F) can result in loss of capacity. This canbe as much as 5% per 10°C (18°F) above + 30°C(+ 86°F) per year.

Do not store in direct sunlight or expose toexcessive heat.

Vantage batteries are supplied filled with electrolyteand charged. They can be stored in this conditionfor a maximum of 12 months.

Never drain the electrolyte from the cells.

• When deliveries are made in cardboard boxes,store without opening the boxes.

• When deliveries are made in plywoodboxes, open the boxes before storage. Thelid and the packing material on top of thecells must be removed.

10.3 Installation

10.3.1 Location

Install the battery in a dry and clean room. Avoid directsunlight and heat.

The battery will give the best performance andmaximum service life when the ambient temperatureis between +10°C to + 30°C (+ 50°F to + 86°F).

The Vantage valve-regulated recombination batterycan be fitted onto stands, can be floor-mounted orcan be fitted into cabinets.

Allow sufficient space over the battery to ensureeasy access during assembly.

Alcad offers a wide selection of stands to suit mostapplications.

It is desirable to have easy access to all blocks on astand-mounted battery and they should be situatedin a readily available position. Distances betweenstands, and between stands and walls, should besufficient to give good access to the battery.

The overall weight of the battery must be consideredand the load bearing on the flooring taken intoaccount in the selection of the battery accommodation.In case of doubt, contact Alcad for advice. Wheninstalling Vantage batteries in a cabinet or on astand the following simple procedures should beadopted.


First, place the blocks in the correct positionaccording to the electrical layout ensuring thatthey are correctly series connected i.e. red positiveterminal to negative terminal.

Start with the lowest shelf to ensure stability.

Fit the inter-block connectors and, on tieredarrangements, the inter-tier connector.

Connect positive and negative terminals of eachbattery to the correct polarity main battery leadsmaking sure that these are well-secured.

Tighten all bolts firmly with the spanner suppliedto the recommended torques given in 10.3.3.Do not use excessive force.

Fit the lid covers.

10.3.2 Ventilation

During the last part of charging,the battery isemitting gases (oxygen and hydrogen mixture). Atnormal float charge, the gas evolution is very smallbut some ventilation is necessary.

Note that special regulations for ventilationmay be valid in your area depending on theapplication.

Under normal floating conditions the Alcad Vantagebattery gives off up to10 times less gas than aconventional open cell. Thus the need for ventilationis much reduced and in many cases no specialventilation requirements other than normal roomventilation are required. The quantity of hydrogengiven off is given in section 6.9 Gas evolution.However, if the Vantage battery is commissioned inthe final location or if the maximum recommendedcharge current of 0.1 C5 is used then the quantity ofgas given off will be increased.

A typical figure for room ventilation is about 2.5 airchanges per hour and under such conditions it issatisfactory to install 700 watt hours of batterycapacity per cubic metre if the final charge current isat 0.1 C5 A.

Care should also be taken with cubicle installationsto ensure sufficient ventilation and battery spacing toprevent overloading and, hence, excess water usage.

10.3.3 Mounting

Verify that cells are correctly interconnected with theappropriate polarity. The battery connection to loadshould be with nickel-plated cable lugs.

Recommended torques for terminal bolts are :

• M 6 = 11 ± 1.1 N.m

• M 8 = 20 ± 2 N.m

• M 10 = 30 ± 3 N.m

The connectors and terminals should be corrosion-protected by coating with a thin layer of anti-corrosion oil.

10.3.4 Electrolyte

When checking the electrolyte levels, a fluctuation inlevel between cells is not abnormal and is due to thedifferent amounts of gas held in the separators ofeach cell. The level should be at least 15 mm abovethe minimum level mark and there is normally noneed to adjust it.

Do not open or remove the low pressure vents.

10.4 Commissioning

Verify that the ventilation is adequate duringthis operation.

10.4.1 Cells stored up to 6 months

A commissioning charge is normally not requiredand the cells are ready for immediate use. If fullperformances are necessary immediately (forexample capacity test), a commissioning charge isrecommended as mentioned in section 10.4.2.

10.4.2 Cells stored more than 6 months and up to1 year

A commissioning charge is necessary :

• Constant current charge :16 h at 0.1 C5 A recommended (see Installationand Operating Instructions sheet).

• Constant potential charge :1.65 V/cell for a minimum of 30 h with currentlimited to 0.1 C5 A (see Installation and OperatingInstructions sheet).

If these methods are not available, then charging may becarried out at lower voltages, 1.50 V/cell for 72 hoursminimum.


10.5 Charging in service

The recommended charging voltages for continuousparallel operation, with occasional batterydischarges, are :

for two level charge :

• float level :1.42 ± 0.01 V/cell

• high level :1.45 ± 0.01 V/cell

for single level charge :1.42 ± 0.01 V/cell

For use at temperatures outside the range of+15°C to + 25°C (+ 59°F to + 77°F), the correctingfactor for charge voltage is –3 mV/°C/cell(– 1.7 mV/°F/cell).

10.6 Periodic maintenanceVantage is an ultra-low maintenance battery andrequires the minimum of maintenance. As a periodicmaintenance, the following is recommended :

Keep the battery clean using only water. Do notuse a wire brush or solvents of any kind.

Check visually the electrolyte level. The topping-upis recommended when the electrolyte level reachesthe minimum level mark but must be carried outbefore it reaches the warning level. Use onlydistilled or deionized water to top-up. Experiencewill tell the time interval between topping-up.

Note:Once the battery has been filled with the correctelectrolyte at the battery factory, there is no needto check the electrolyte density periodically.Interpretation of density measurements is difficultand could be misleading.

Check every two years that all connectors aretight. The connectors and terminal bolts should becorrosion-protected by coating with a thin layer ofanti-corrosion oil.

Check the charging voltage. It is important thatthe recommended charging voltage remainsunchanged. The charging voltage should bechecked at least once yearly. High waterconsumption of the battery is usually caused byimproper voltage setting of the charger.


11 Refurbishment ofVantage batteries

Refurbishment of the Vantage battery isrecommended when the electrolyte level reaches theminimum level mark on the cell but must be carriedout before it reaches the warning level on the cell.

Refurbishing of the Vantage battery in fully chargedconditions is carried out as follows –

Isolate the battery from the power supply and theload. Remove the terminal cover.

With the terminal cover removed, the tops of theindividual cells of the Vantage battery will be inview.

Confirm that an adequate protective finish(recommended anti-corrosion oil) remains onterminal bolts and connectors. Replenish ifnecessary.

Carefully loosen the flame-arresting low pressurevents by using a specific tool to release any gaspressure and then remove each vent completelyand retain for refitting.

Top-up each cell with distilled or deionized waterto the specified maximum level. Alcad can supplyspecial topping-up equipment on request.

Wipe any small spillage on cells using a cleancloth. Replace the vents taking care to tightenthem correctly i.e. until resistance against a stop isexperienced, and ensure that the seating rubberhas not been disturbed out of position. If there isany doubt about the quality of the sealing ringreplace with a new vent assembly.

Replace the terminal cover.

The refurbished Vantage cell is now ready forre-commissioning :- discharge the battery at 0.2 C5 A down to

1.00 V/cell.- recharge the battery according to section 10.4

Commissioning.

Note: Before proceeding with any batteryrefurbishment please ensure that the ImportantRecommendations given in the Vantage Installation andOperating Instructions sheet ‘V4’ are complied with.


12 Disposal andrecycling

In a world where autonomous sources of electricpower are ever more in demand, Alcad batteriesprovide an environmentally responsible answer tothese needs. Environmental management lies at thecore of Alcad’s business and we take care to controlevery stage of a battery's life cycle in terms ofpotential impact. Environmental protection is our toppriority, from design and production through end-of-life collection, disposal and recycling.

Our respect for the environment is complemented byan equal respect for our customers. We aim togenerate confidence in our products, not only from afunctional standpoint, but also in terms of theenvironmental safeguards that are built into their lifecycle. The simple and unique nature of the batterycomponents make them readily recyclable and thisprocess safeguards valuable natural resources forfuture generations.

In partnership with collection agencies worldwide,Alcad organises retrieval from pre-collection pointsand the recycling of spent Alcad batteries. Alcad’scollection network can be found on our web site :

www.alcad.com

Ni-Cd batteries must not be discarded as harmlesswaste and should be treated carefully in accordancewith local and national regulations. Your Alcadrepresentative can assist with further information onthese regulations and with the overall recyclingprocedure.


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Alcad Limited

SwedenTelephone: +46 491 68 100Facsimile: +46 491 68 110

Alcad Sales Offices

United KingdomTelephone: +44 1279 772 555Facsimile: +44 1279 420 696

Middle EastTelephone: +357 25 871 816Facsimile: +357 25 343 542

AsiaTelephone: +65 6 7484 486Facsimile: +65 6 7484 639

USATelephone: +1 203 234 8333Facsimile: +1 203 234 8255

www.alcad.com

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