Installation Ventilation Guideline Oerlikon

Installation / Ventilation guideline
The installation of a Compact-Power battery requires attention concerning mechanical and electrical safety, ventilation and cooling, inspection and control opportunities. In the planning phase an intensive dialog of the prospective user/customer with our Technical Sales department or our local Sales organization is highly desirable. Furthermore local standards, building codes, code of practice etc. should be consulted so to satisfy local laws and regulations. One of the most recent standards for the operation of stationary battery UPS plants is the European Standard EN 50091:1:1993.
To facilitate battery monitoring and inventory control each cell or monobloc is equipped with a bar code label on which a part number and a unique identification number is written in Bar Code Type 93.
Battery strings Operating position of Compact-Power cells and monoblocs The Compact Power cells and monobloc have the electrolyte completely absorbed in a glass mat (AGM) and can therefore be operated without modifications in any position. Never lift cells and monoblocs with the terminals. This could cause short circuits and damage to the sealing mechanism of the terminals. Observe the maximum torque for the terminal connections. For purpose of easy manual voltage monitoring and inspection and in case of cyclic charge/ discharge service the units should be operated in a horizontal position with the plate group lying flat. Racks for both layouts are available. In order to increase battery capacity or to increase redundancy multiple strings of batteries can be assembled. The following rules apply. A maximum of 4 identical battery strings is recommended The parallel connection of the strings shall be made only at the terminal connector or on the bus bar. The cables from the batteries to the point of parallel connection shall be of same electrical resistance. The cells and monoblocs should normally be of the same make, age and capacity.
OERLIKON STATIONARY BATTERIES LTD. AESCH BL DORNACHERSTR. 110 CH-4147 AESCH/BL SWITZERLAND PHONE +41 (0) 61 - 706 36 36 FAX +41 (0) 61 - 706 36 37 www.accuoerlikon.com e-mail: info@accuoerlikon.com Page 1/9 State September 6, 2004
Ventilation of battery installations Lead acid batteries and also VRLA types emit hydrogen under all operating conditions. The hydrogen can produce explosive atmospheres in the concentration range of 4 to 94 vol %. The ventilation requirements are described in local standards and code of practice. They should be adhered strictly so to ensure a safe operation and avoid loss of life and property. Never install any type of lead acid battery in hermetically closed environments! VRLA AGM cells and monoblocs emit approximately 30 cm3 hydrogen (NPT) per cell and Ah rated C10 capacity in 30 days under benign float conditions. In abusive conditons (higher voltages and temperatures) this value jumps to 300 cm3/cell/Ah/30 days. The Standards for battery ventilations assume a more pessimistic gas evolution scenario and require ventilation dimensioning based on hydrogen emission data as shown in the original text of the European Standard EN 50091:1:1993 below. Annex N (normative) of 50091:1:1993 Ventilation of battery compartments N. 1 Notes for guidance Batteries develop a certain amount of hydrogen gas by electrolysis. Gassing occurs particularly during overcharging and at the end of charging, and also during float charge of the battery. Battery gases escape via vent plugs or, for valve regulated lead-acid batteries, via pressure valves.
Mixtures of hydrogen and oxygen are explosive where the hydrogen component exceeds 4 % in a hydrogen/air composition. Ventilation of battery rooms and/or battery compartments shall ensure a sufficient dilution of hydrogen to avoid any danger of a hydrogen explosion. An excess of dilution is necessary for a corresponding degree of safety. Safety factors between 4-5 shall be applied generally; but on ships or for particular application, even larger safety factors (e.g. 10) may be prescribed. Gas generation in a vented flooded cell can be calculated from the overcharge current, since: 1 amp per hour of overcharge current will generate 0,45 1 of hydrogen at NT.
q = 0,45 x 10-3 m3/(Ah)

N.2 Application to lead acid batteries Flooded cell batteries A conventional flooded lead-acid battery cell of 100 Ah nominal capacity will require a charge retention current in the range of 20 mA to 100 mA, depending on temperature, quality of electrolyte and ageing at a floating voltage of circa 2,23 V/cell. But where unusual conditions, e.g. overheating or overvoltage, exist the level of hydrogen generating current will be much higher. In the interests of safety, one should assume a maximum current flow of I = 1 A/100 Ah during floating at 2,23 V/cell and twice this value during equalizing charging close to the overvoltage level of 2,4 V/cell.
With batteries where the electrode lead alloy reduces gassing, one may assume the half of the above values, for battery cells with catalytic recombination of hydrogen and oxygen (recombination plugs) one may calculate with a quarter of the above values.
s n
is the factor of safety, e.g. s = 5; is the number of battery cells;
I = 2 A/100 Ah - Conventional flooded cell batteries; I = 1 A/100 Ah - Flooded battery cells with low antimony alloy; I = 0,5 A/100 Ah - Flooded battery cells with recombination plugs; I = 0,2 A/100 Ah- Valve regulated lead-acid batteries;
Valve regulated batteries (gel or absorbed electrolyte)

Valve regulated lead-acid batteries (maintenance free lead-acid batteries with oxygen recombination in the cells) still will generate hydrogen, escaping from the cell pressure valves. Here one may calculate with a hydrogen generating current of 0,025 A/l00 Ah at a floating voltage of circa 2,27 V/cell and 0,2 A/100 Ah at an overvoltage of circa 2,40 V/cell. N.3 Ventilation requirements (normative) To allow for equalization (boost charging) and in the case of valve regulated batteries, operation over a wider range of ambient temperatures the factors of I shall use the 2,4 V/cell figures. The necessary ventilation air flow for a battery compartment shall be calculated by the following formula: Q=vxqxsxnxIxC where:
is the battery nominal capacity, in Ah. It is permitted to simplify the formula for Q by introducing the resultant value of v x q x s = 0,054 m3/Ah.
Q = 0,054 x n x I x C
Q is the air flow, m3/h This amount of ventilation air flow shall preferably be ensured by natural air flow, otherwise by enforced ventilation. Inlet and outlet apertures shall allow for a free access of air flow. The mean speed of air shall be in the region of 0,1 m/s.
Q v
is the ventilation air flow, in m3/h; is the necessary dilution of hydrogen (100- 4) / 4 = 24;
q = 0,4510-3 m3/Ah generated hydrogen;

With this amount of natural air flow, the battery compartment shall contain air inlet and air outlet apertures with a free area of K1= 28 h x cm2/m3 A > = K1 x Q A is the aperture, in cm2; K1: 28 h x cm2/m3 or A > = K2 x n x I x C
Example A battery with 108 cells of a VRLA type with 650 Ah (C10) requires an air flow of:
Q = 240.00045 m3/Ah51080.2 A/ 100 Ah650 Ah=7.5 m3/h

Battery ventilation has also the function of avoiding heat stagnation within the cells and monoblocs which can lead, if unchecked, to thermal runaways. The amount of heat produced by a VRLA battery is approximately 0.09 W per 100 Ah C10 and cell. For dimensioning purposes and to take in account conditions of excessive float current a value of 3 to 5x 0.09 W/100 Ah/ cell should be considered. Accu Oerlikon has foreseen air gaps between unit and is fixing the cell to cell or monobloc to monobloc distance with appropriate lengths of rigid intercell connectors. In cabinet installations or with the use of flexible connectors a gap of at least 10 mm between adjacent units and walls shall be present. Operating temperatures Compact-Power cells and monoblocs can be operated from -30 C to +40 C. At low temperatures charge acceptance and capacity decreases. At high temperatures premature aging and dangers, in connection with other factors, of thermal runaway exist. Compact-Power cells and monoblocs achieve their design life of up to 15 years float service at the European Standard Stationary Battery reference temperature of +20 C (+68 F). An operating temperature above this value shortens the service life accordingly.
K2 = 1,51 cm2/A
NOTE 1. Natural ventilation is applicable where the electrical power for hydrogen generation keeps below cer tain limits. Otherwise the ventilation air outlets would exceed acceptable dimensions. The limits for natural ventilation depend on the battery capacity and the number of cells, and also on the battery technology (vented cells, valve regulated cells), and the battery charging voltage applied. The above calculation method will result in a sufficient degree of safety against explosion, assuming hot (>300 C) or sparking components are kept at adequate distance from battery vent plugs or gas pressure outlets. In battery rooms, a distance of 500 mm may be regarded as ensuring sufficient safety. In battery compartments or cabinets, it is permitted to reduce this distance depending on the level of ventilation. NOTE 2. These requirements are under consideration by CENELEC/TC 21 X. An example of calculation of the ventilation as required by the European Standard EN50091:1:1993 is shown below.
Theoretical considerations and practical experience has shown that every 10C temperature rise above the 20 C reference temperature halves the service life. The service life is thus 100 % at 20 C, 75 % at 25 C, 50 % at 30 C and 25 % at 40 C. At temperatures below the reference value of 20 C an increase of service life can be expected. However under this condition reduced capacity (-0.6 to -1% per C) and reduced charge acceptance occurs. The high temperature life reduction factor is widely employed by battery manufacturer to test in an accelerated way the VRLA battery designs. In these life tests a test temperature of 55 C, 60 C or 80 C is widely employed. Oerlikon Stationary Batteries Ltd. uses 60 C with 2.28 Vpc float. Under these conditions a CompactPower cell or monobloc service life of >45 weeks to 80 % of rated capacity, when monitored with 10 minute high rate discharges, is routinely obtained. This amounts to a 20 C service life of >14 years. See also the US Bellcore publication Technical Reference TR-NWT-001200,1,1992 Generic requirements for accelerated life testing of valve regulated lead acid batteries at high temperatures. For the battery installation planner and operator following points are of interest: Reduce energy input into the battery by adjusting the float voltage according to the Compact-Power operating instructions. Provide adequate ventilation and, if necessary and economically viable, cooling.
Protect battery against radiant heat and warm exhaust air. Assure in multitier battery installations a homogeneous temperature within the battery string (T of <3 C) Avoid excessive AC currents in the battery circuits. They cause Joule heating of the battery and can cause extremely rapid battery aging. If needed install DC line filters. Oerlikon Stationary Batteries Ltd. furnishes selfadhesive LC temperature strips to be attached to the walls of suitable and representatively positioned cells and monoblocs in a battery. These Kelvin-Arrhenius Monitors give, like a speedometer, the actual service life expectancy in percent of the +20 C (+68 F) life based on the 10 C/half life rule. Electromagnetic compatibility / AC power interaction with the battery Lead acid batteries are pure DC power sources and are not sensitive to normal electromagnetic disturbances, and therefore no immunity tests shall be required. Free standing CompactPower cells, monoblocs and batteries electrically isolated from any associated electrical system are for all pratical purposes electromagnetically inert, and therefore the requirements for electromagnetic compatibility shall be deemed to be satisfied. It should be noted that rechargeable cells and batteries are part of an electrical sytem, and the manner in which they are used could invoke the requirements of electromagnetic compatibility upon that system.
In such cases, the requirements of electromagnetic compatibility shall be accomodated by the design of the system (Draft European Standard prEN50226:1995). Excessive AC currents imposed by exterior circuits onto VRLA cell and monobloc batteries can raise the battery temperature, due to Joule heating, to levels which cause very rapid aging. For an optimum service life it is recommended that the rms AC current flowing shall not exceed of 5 A per 100 Ah C10 capacity. In no case shall the negative sine wave of the AC ripple current cause a reversal of the charging current. This causes battery capacity cycling and premature aging. Fuse protection for the battery All exposed metal parts of a battery are live and so there is a danger of injury from electric shock and of accidental short circuits. Be carefull with non insulated tools, bracelets and rings. Touch the battery on the plastic surfaces only.
Compact-Power cells and monoblocs have very low internal resistance and can deliver large short circuit currents. These currents have been determined with the two current level pulse method according to the International Standard IEC 896-2,1996. Compact Power units can withstand their own short circuit current for 1 minute. Battery installations should be protected according the equipment power output and cross-section of the installed cables. The fuse or disconnecting equipment used must be capable to interrupt the current within 10s of the onset of the short circuit condition. Eventual magnetic forces arising from the short circuit current flow have to be considered. Fuse blowing or switch operation shall not causes a possible ignition of electrolysis gases. The short-circuit current ISC of Compact-Power batteries is determined according to International Standard IEC 896-2. The following formula is used: ISC = (U1) (I2) - (U2) (I1) / U1-U2 R I = U1 - U2 / I2 - I1
Type 12 CP 25 12 CP 26 12 CP 39 12 CP 50 12 CP 52 12 CP 65 12 CP 100 12 CP 150
Short-circuit ISC at 20 C [A 1000 1230 1730 1900 2200 2560 3400 5000
Internal resistance Ri at 20 C charged 100 % [mOhm 12.50 10.00 7.00 6.30 5.50 4.80 3.60 2.40
Type 6 CP 60 6 CP 80 6 CP 100 6 CP 115 6 CP 135 6 CP 155
Short-circuit ISC at 20 C [A] 1780 2220 2630 3020 3400 3760
Internal resistance Ri at 20 C charged 100 % [mOhm] 3.40 2.70 2.30 2.00 1.80 1.60
4 CP 185 4 CP 205 4 CP 225
5430 5900 6390
0.74 0.69 0.60
2 CP 180 2 CP 240 2 CP 300 2 CP 345 2 CP 405 2 CP 465
4120 5120 6070 6970 7840 8680
0.48 0.39 0.32 0.28 0.25 0.23
2 CP 450 2 CP 550 2 CP 650 2 CP 800 2 CP 900 2 CP1000
7690 9090 10500 13300 15400 18200
0.26 0.22 0.19 0.15 0.13 0.11
Storage prior to installation Compact-Power cells and monoblocs have a self discharge rate of 0.1 % per day at 20 C (68 F) and can therefore be stored for prolonged periods of time.
Recharge as directed on the packaging. Keep different battery batches separate. Installation and operation All Compact-Power battery deliveries carry a detailed installation and operating guide. The following points are reminded. Before connecting the battery to the charger or busbar or any electrical circuit check the polarity of each unit in the string and of the whole string. Place the Kelvin-Arrhenius-Monitors. Pay attention to live electrical parts. Start-up the electrical equipment according to the manufacturers specifications. Check the voltage applied to the battery as soon as feasible and after 3-6 weeks of first operation. Measure average room and battery temperature and adjust float voltage according to the operating instructions when the ambient temperature is expected to be permanently outside the +18 to +25 C (+64 to+77 F) range. Keep the battery installation clean. Use only a damp cloth to clean cells and monoblocs. Never use solvents and chemicals. Watch for live electrical parts and do not clean with dry dusters so to avoid electrostatic discharges/ sparks.
Remaining capacity at 10h rate as a function of open circuit storage time

Compact-Power batteries are activated/filled by Oerlikon Stationary Batteries Ltd. to the specific customer orders from a dry charged status and carry a recharge date reminder on the packaging. A good storage practice requires to Avoid storage in ambients with a relative humidity greater then 90 % Avoid elevated temperatures and direct sunshine. Optimum storage temperatures are -15 C (5 F) to +30 C (86 F). Avoid atmospheres with chemical contaminants and keep surroundings clean. Do not load other merchandise on top of unprotected batteries.
Do not smoke or entertain open flames in a battery room. Keep the access to the room or the interior of cabinets limited to qualified personnel. Post warning signs and keep aisle room sized for safe escape according to local laws and regulations. Battery monitoring The monitoring of vital operating parameters of lead acid batteries has made significant advances with new electronics and the price reduction of such devices. Watch for the coming IEC guideline (1997) for stationary lead acid battery monitoring. The use of a monitor has to be decided case by case. Accu Oerlikon suggests to monitor the battery performance according to the details of the Compact-Power operating instructions. For an adequate surveillance monitor and record at least cell and monobloc voltages and battery and temperature once every 6 months. Adjust, if necessary the battery float voltage. battery capacity with partial or complete test discharges every year or according to local standards.
The monitoring of the internal resistance or conductance of cells and monoblocs with a commercial conductance meter (Hewlett Packard, Hioki, Midtronics, Albr, and similiar) can provide a quick qualitative view of the battery capacity instead of a more complex to organize capacity test. However the correlation conductance vs. capacity is not yet as firm so to supplant the capacity test completely (see INTELEC1993-94-95 Conference Proceedings).

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Installation / Ventilation guideline