HAWKER Battery Handbook

Generic 29/7/99 3:25 pm Page 1
Hawker Batteries
Handbook
STANDBY BATTERIES TECHNICAL MANUAL

INTRODUCTION TO HAWKER
INTRODUCTION
The Hawker Group is the largest manufacturer of industrial batteries in the

world. It is a global energy business with manufacturing and assembly plants
in Europe, North America and Asia, and marketing operations in more than
100 countries. Its formation in 1991 brought together some of the most
respected names in the industry, companies with a reputation for innovation
and technical achievement. World-wide, they set the standard for battery
making continuously pushing forward the technology to deliver even more
effective power storage solutions.
Through its membership of Invensys plc, Hawker has the backing and
investment strength of the world’s premier automation and controls group.
Created from the merger of BTR plc and Siebe plc, Invensys is a global
electronics and engineering business of more than 500 companies, employing
120,000 people world-wide,
Batteries from Hawker Group companies provide primary and reserve

power in almost every aspect of human activity - telecommunications, power
generation and distribution, UPS systems, aerospace, defence, marine,
automotive and leisure. Working closely with specifiers, power equipment
manufacturers and end users, Hawker ensure that the most effective battery
solutions are always available.
1
PDF Issue No.1/Gen/July 99
GROUP PROFILE
As the world’s leading supplier of industrial batteries, we operate on all

continents with more than 20 state-of-the-art manufacturing plants, backed
by local sales, product and service support. Added to this our global network
of distributors and agents, means that we are currently active in over 100
countries.
Hawker is one of the largest players in the $3 billion world industrial battery
market, providing batteries and power supplies for Standby, Traction, Low and
Zero Emission Vehicles, Defence and Aviation and other Special applications.
Hawker has the resources needed to continuously invest in new plant and
product development to meet the world’s industrial power needs.
And all of this is available to you through your local Hawker Group company
listed in this document.
2
QUALITY
In terms of design and manufacture, the quality of every Hawker battery
benefits greatly from the amassed expertise and knowledge of the group,
backed by many decades of experience.
Today the Hawker group boasts some of the most modern battery
manufacturing facilities in the world. A structured quality management
system is in place which satisfies the requirements of ISO 9001 and
demonstrates that all customer requirements are identified and satisfied from
contract review, through manufacturing, to installation and service.
Computer controlled equipment and quality control techniques have been

introduced to ensure that reliable and cost effective products are
manufactured to meet the highest international standards.
The Hawker group has also invested heavily in state of the art computerised
test and metrology laboratories which carry out routine performance testing,
product characterisation testing and equipment calibration.
RESEARCH & DEVELOPMENT

As the world’s leading and most innovative industrial battery manufacturer,
Hawker naturally recognises the fundamental importance of research and
development. Our pre-eminent position in industrial lead-acid technology
results from many years’ R&D to ensure that our products set the standard by
which the competition is judged. This investment is continuing and Hawker
engineers and scientists are working on the next generation of batteries and
power conversion technology. We work very closely with our customers to
develop new products and the right solutions for their specific applications.
In this market Hawker occupies a unique position with pure lead valve
regulated lead acid (VRLA) batteries; a mainstream product using lead-
calcium-tin grids and Absorptive Glass Mat (AGM) separators; tubular and
rod-plate gel batteries; and a full range of traditional flooded battery types.
Current development is focused on the pure lead and lead-calcium-tin/AGM

batteries. Pure lead offers excellent service life and recent developments have
provided increased reliability, better performance for cyclic duty cycles and
higher integrity sealing systems. The range has been redesigned to meet
application requirements more precisely and further improvements are in
development, with some radical new products at a conceptual stage.
3
BATTERY DESIGN
TYPES OF BATTERIES AND THEIR USES
Flooded Lead Acid Batteries

Since the battery was first designed way back in the 1880’s, many flooded lead
acid batteries still use the same basic principles of flat pasted plates immersed in
a dilute sulphuric acid electrolyte. This is still by far the most common form of
lead acid battery, although other types developed to improve efficiency or life
now include planté, tubular and rod types. Water has to be added at regular
intervals as it is lost during operation, although there are low maintenance
types which have excess electrolyte calculated to compensate for water loss
during the normal lifetime of the battery.
Valve Regulated Lead Acid Batteries

This development in battery technology originated in the late 1960’s. Here the
gases that are produced during operation are recombined which minimises the
water loss. The sealed lead battery provides high performance and long life. As
such it has become the accepted power source for ’clean’ applications including
computer backup systems, telecommunications and emergency power. It is also
becoming popular for cordless tools and appliances, electric vehicles and
applications requiring frequent discharges.
4
VALVE REGULATED LEAD ACID BATTERIES....

GAS RECOMBINATION EXPLAINED
When a charge current flows through a fully charged

conventional lead acid cell, electrolysis of water occurs to Liquid
02 H2
produce hydrogen from the negative plate and oxygen electrolyte
from the positive plate. This means that water is lost from
the cell and regular topping-up is needed.
However, evolution of oxygen gas and hydrogen gas S

does not occur simultaneously, because the efficiency of + --
recharge of the positive plate is not as good as the negative E
P N
plate. This means that oxygen is evolved from the positive O
P
E
plate before hydrogen is evolved from the negative plate. S G
I A
A
At the same time that oxygen is evolved from the T T
positive plate, a substantial amount of highly active spongy I R I
V V
lead exists on the negative plate before it commences
E A E
hydrogen evolution. Therefore, provided oxygen can be
transported to the negative plate, conditions are ideal for a P T P
rapid reaction between lead and oxygen: i.e. This oxygen is L L
A O A
electro-chemically reduced on the negative plate according T T
to the following scheme, E R E
2e - + 2H+ + 1/2 O2 H2O
and the final product is water. Conventional Cell

The current flowing through the negative plate drives
this reaction instead of hydrogen generation which would
occur in a flooded cell. This process is called gas
recombination.
If the process were 100% efficient, no water would be

lost from the cell. By careful design of the constituents
within the cell, gas recombination of more than 95% is
achieved. An efficient gas recombination cell can be made
using either Absorptive Glass Mat (AGM) separators or
gelled (gel) electrolyte.
5
ABSORPTIVE GLASS MAT (AGM)

To achieve a satisfactory gas recombination efficiency Electrolyte in Absorptive Glass Mat
it is necessary to provide a path between the positive
and negative plates. By providing this path, oxygen can
pass from the positive to the negative plate where it
A
reacts with the spongy lead negative active material.
G
In the AGM cell a special, highly porous micro-fibre + --
M
02
glass separator is used. By carefully controlling the P N
O E
saturation level and the exact balance between
S G
electrolyte quantity and porosity, a continuous path for S A
I
oxygen transport is obtained. This provides the T E T
02 I
optimum conditions for gas recombination and an I
P V
V
efficiency of over 95% is achieved. E
E A
The VRLA AGM battery can be used for all discharge R
P P
rates from switch closing/tripping and engine starting 02
L A L
which requires short duration high currents, to telecom A A
T T
and navigational systems requiring long, stable power T
E O E
occasionally for many days. The special separator used
in these batteries results in a very low resistance which R
makes them particularly good at delivering high
AGM Cell
currents.
GELLED ELECTROLYTE (GEL)

For gelled electrolyte cells, a mixture of sulphuric Gelled electrolyte
acid with finely dispersed silica is used to produce a gel.
By vigorously stirring, the thixotropic mixture stays
fluid so that it can be poured into the cells. The
M
mixture then stiffens and forms a firm gel. As the gel I
stiffens it shrinks and this leads to the formation of + C --
R
numerous micro-fine cracks through which the oxygen P
O
02 N
O E
generated at the positive plate is able to diffuse to the P
S O G
negative plate. I A
R
Because a conventional microporous separator is T O 02 T

I U I
used in the gelled electrolyte cell, the internal resistance V S V
is slightly higher for these cells compared to AGM types. E E
S
Therefore, they are better suited to medium and long E
02
P P
rate discharges. Tubular plate cells with gelled P
L A L
electrolyte are particularly suitable for cyclic A R A
applications or where there is a need to supply power to T A 02 T
E T E
equipment for several hours. The rod plate offers a
O
compromise between tubular plate and pasted plate R
types by giving a higher power to weight and volume
GEL Cell
ratio than the tubular type but being more robust than
the pasted type because the design is more corrosion
resistant.
6
PLATE TYPES
There are various types of electrodes which are used in
lead-acid batteries. Each offers different characteristics
which makes it suitable for specific application.
Planté
The Planté plate is only used as a positive electrode and

is principally used for standby applications. It benefits
from being extremely reliable with 25 years or more life
and needs very little maintenance. The Planté uses pure
lead cast plates and has moderate to good energy
density. It has the unique ability to provide a minimum
of 100% capacity for its entire lifetime. Normally, the
end of life is determined when less than 80% capacity is
available.
Tubular
The tubular plate is also only used as a positive

electrode. Its principal use is for motive power
applications, but it is also used for standby applications.
It has a very good cycle life which means it can be
discharged heavily for up to 2000 times. It also has a
good float life, lasting up to 15 years.
Pasted Plate
The pasted plate electrode can be used both as a positive

or negative. It is mainly used for automotive and
standby applications. It has very good energy density
with thin (1mm - 0.039”) or thick (7mm - 0.27”) plates.
Pasted plate electrodes use pure lead, lead antimony,
lead calcium or pure lead tin grid alloys. Grids can either
be cast or punched and their life is dependant on the
grid alloy and plate thickness.
Rod Plate
Rod plate electrodes can be either positive or negative.

They are principally used for standby applications and
have a life of between 12 and 20 years. Very robust,
rod plate electrodes use lead antimony or lead-calcium
cast grids with moderate energy density.
7
VALVE REGULATED LEAD ACID PRODUCT ILLUSTRATIONS

GENERIC AGM BATTERY
1 High Conductivity Pillars 7 Container and Lid
Rolled thread for greater strength and conductivity. Manufactured from flame retardant ABS to give
protection against fire.
2 Gas Tight
Compressed neoprene rubber grommet for high 8 Separators
reliability. The finest borosilicate fibres ensure maximum
absorbtion of acid and provide a path for oxygen
3 Heat Sealed Lid to Container
recombination.
Welded for life to give leak proof seal.
9 Thick Group Bars
4 One Way Valve
Manufactured by state of the art cast-on-strap
Prevents oxygen from entering the cell and flame
process to give maximum conductivity and superior
retardant disk to give added integrity.
corrosion resistance for long life.
5 Thick Positive Plates
Manufactured from the highest purity primary 10 Pure Dilute Sulphuric Acid
For maximum performance and life.
lead/tin/calcium alloy for high performance and long
life, with active material from 99.99% pure primary 11 Through Partition Weld
lead. Minimum resistance and maximum on load voltage.
6 Negative Plates
Active material produced from 99.99% pure primary
lead for balanced performance and high
recombination efficiency. 1
4
3
11
7 6
5
8
10
8
TUBULAR GEL (OPzV) PRODUCT
1 Pressure Relief Valve

2 1
2 Coloured Polarity Rings
Blue = Negative 6
Red = Positive
7
3 Microporous Separator
4 Flat Pasted Plate - Negative
5 Positive Grid Coating
3
6 ABS Lid
4 8
7 Terminals with brass insert for
improved conductivity
8 Diecast Positive Grid Spines 9

5
9 ABS Container
9
FLOODED LEAD ACID PRODUCT ILLUSTRATION
1 Vent Plugs
Designed to eliminate spray but
give free exit of gasses. 1
2 Cell Lids
SAN material.
Completely sealed container 2
means no leakage.
3 Cell Pillars and Connectors

Each one designed specifically for
the job. 3
Give minimum resistance -
maximum current flow.
4 Bar Guard
Safeguards against short circuits.
4
5 Negative Plates
Pasted grids. Provide perfect
balance with the positive to give
5
maximum performance.
6 Separators
Sintered micro p.v.c. gives
minimum resistance.
6
7 Planté Positive Plates
Pure lead. Ensures full initial
capacity and long life.
7
8 Plastic Containers
Transparent SAN.
Electrolyte level and cell condition
can be clearly seen.
Good electrolyte reserve to reduce
periods of maintenance.
8
10
BATTERY SIZING
BATTERY SIZING
All the Hawker product literature Method Conclusion: Use 24 - P cells

contains performance data in (1) minimum allowable volts per (b) at 5°C (41°F) by reference to
tabular format, which allows simple cell the table 1 below available
battery sizing calculations to be current output at 20°C is
42 volts
made. = 1.75 Vpc reduced by factor 0.9.
24 cells
(2) hence, cell performance Therefore at 5°C (41°F) - 2
Battery sizing at constant requirement is 102 amps hours output is reduced to, on
current discharge constant current to 1.75 Vpc; the P size, 110 amps x 0.9 = 99
Example A amps.
(3) by reference to constant current
To demonstrate constant current performance table relating to Hence the P cell size too small!
calculation and also the effect of 1.75 volts per cell level: Try the next largest cell size - Q.
temperature. (a) at 20°C (68°F) At 5°C (41°F) available current
A nominal 50V telecommunications output is 124 amps x 0.9 =
The P cell size is smallest
system using a 24 cell battery and 111.6 amps
available size to use (110 amps
requiring 102 amps constant current available) . Conclusion: Use 24-Q cells
will operate satisfactorily at a
minimum battery terminal volts
level of 42 volts.
Temperature Correction Factor to be applied to 20°C (68°F) data at:
Calculate the battery type required Discharge
rate 32°F 41°F 50°F 59°F 68°F 77°F 86°F 95°F 104°F
for 2 hours standby duration on the (duration)
basis of: 0°C 5°C 10°C 15°C 20°C 25°C 30°C 35°C 40°C
5 mins
(a) 20°C (68°F) operating
to 0.8 0.86 0.91 0.96 1 1.037 1.063 1.085 1.10
temperature 59 mins
(b) 5°C (41°F) operating
1 hour
temperature to 0.86 0.90 0.93 0.97 1 1.028 1.05 1.063 1.07
24 hours
CELL DISCHARGE CURRENTS (AMPERES PER CELL) AT 20°C (68°F) TO 1.75 VOLTS PER CELL
TYPE 1 1.5 2 2.5 3 4 5 6 7 8 9 10 12 24
A 12.7 9.3 7.4 6.3 5.4 4.3 3.5 3.1 2.7 2.4 2.1 1.97 1.66 0.85
B 19 13.9 11.2 9.4 8.1 6.4 5.3 4.6 4 3.6 3.2 2.95 2.49 1.27
C 25.3 18.5 14.8 12.5 10.7 8.5 7 6.1 5.3 4.8 4.2 3.93 3.32 1.7
D 31.7 23.2 18.6 15.6 13.4 10.7 8.8 7.7 6.7 6 5.3 4.9 4.15 2.1
E 38 27.8 22.3 18.8 16.1 12.8 10.6 9.1 7.9 7.1 6.4 5.9 4.99 2.54
F 52 37.6 30 25.2 21.6 17.2 14.4 12.4 10.8 10 9.2 8.4 7 3.6
G 65 47 37.5 31.5 27 21.5 18 15.5 13.5 12.5 11.5 10.5 8.8 4.5
H 71.3 51.6 41.4 34.9 30.4 24.2 20.1 17.5 15.6 14.1 12.8 11.7 9.9 5.1
I 83.2 60.2 48.3 40.7 35.4 28.3 23.5 20.4 18.2 16.4 14.9 13.7 11.5 6.0
J 95.0 68.8 55.2 46.6 40.5 32.3 26.9 23.4 20.8 18.8 17.1 15.6 13.2 6.8
K 119 86.0 69.0 58.2 50.6 40.4 33.6 29.2 26.0 23.5 21.3 19.5 16.5 8.5
L 131 94.5 75.9 64.0 55.7 44.4 36.9 32.1 28.6 25.8 23.5 21.5 18.1 9.4
M 143 103 82.8 69.9 60.8 48.4 40.3 35.0 31.2 28.2 25.6 23.4 19.8 10.2
N 143 103 82.8 69.9 60.8 48.4 40.3 35.0 31.2 28.2 25.6 23.4 19.8 10.2
O 166 120 96.6 81.5 70.9 56.5 47.0 40.9 36.4 32.9 29.9 27.3 23.1 12.0
P 190 138 110 93.1 81.0 64.6 53.7 46.7 41.6 37.6 34.1 31.2 26.4 13.7
Q 214 155 124 105 91.1 72.7 60.4 52.6 46.8 42.3 38.4 35.1 29.7 15.4
R 238 172 138 116 101 80.7 67.2 58.4 52.0 47.0 42.7 39.0 33.0 17.1
S 250 180 145 122 106 84.8 70.5 61.3 54.6 49.3 44.8 41.0 34.6 17.9
T 262 189 152 128 111 88.8 73.9 64.2 57.2 51.7 46.9 42.9 36.3 18.8
U 285 206 166 140 122 96.9 80.6 70.1 62.4 56.4 51.2 46.9 39.6 20.5
W 285 206 166 140 122 96.9 80.6 70.1 62.4 56.4 51.2 46.9 39.6 20.5
11
Battery sizing at constant The minimum cell voltage should be repeated to consider
power discharge therefore is the minimum a reduced number of cells as
battery voltage ÷ the maximum follows:
Example number of cells, which in this
using 116 cells:
To demonstrate constant power case
calculation. (2) minimum allowable volts
200V
A 70kVA rated inverter system = = 1.709 Vpc per cell
117 cells
requires a d.c. constant power input 200V
= = 1.724 Vpc
of 60.5kW in the voltage range 266 (3) Total d.c. power required is 116 cells
volts maximum, 197 volts 60.5kw, therefore using 117
minimum. cells (3) watts per cell required
watts per cell required 60,500 watts

Under full load conditions, there is = = 522 watts per
60500 watts cell
approximately 3 volts drop = = 517 watts per
116 cells
between battery terminals and cell
117 cells
inverter due to cable resistance. (4) Hence, cell performance
Calculate the optimum battery size (4) Hence cell performance requirement is 522 watts to
required for 20°C (68°F) operation requirement is 517 watts to 1.724 Vpc at 20°C (68°F).
for a 5 minutes standby period. 1.709 Vpc at 20°C (68°F).
(5) by reference to the Constant
Method (5) by reference to the Constant Power performance table
(1) The maximum number of cells Power performance table relating to 1.73 volts per cell
required is calculated from the relating to 1.71 volts per cell level:
maximum battery voltage ÷ the level: P cell size is now too small - it
cell float voltage. Therefore in will only provide 507 watts per
G cell size is the smallest
this case the maximum number cell to 1.73 volts per cell level.
available size to use on the
of cells
basis that the battery comprises THEREFORE, the initial
266V
= = 117 cells 117 cells in series. calculation gives optimum
2.27 Vpc
NB! In order to check the battery size for the duty
(2) The minimum battery voltage is optimisation of battery selection specified.
the minimum system voltage (because available performance Conclusion: Use 117 G cells
plus the voltage drop due to of 524 watts per cell is in excess
cable resistance, which in this of required performance 517
case is 266V + 3V = 200V. watts per cell), the calculation
CONSTANT POWER DISCHARGE (IN WATTS PER CELL) AT 20°C (68°F) TO 1.73 VOLTS PER CELL CONSTANT POWER DISCHARGE (IN WATTS PER CELL) AT 20°C (68°F) TO 1.71 VOLTS PER CELL
CELL STANDBY TIME MINUTES CELL STANDBY TIME MINUTES
TYPE 5 10 15 20 25 30 35 40 45 50 55 TYPE 5 10 15 20 25 30 35 40 45 50 55
A 120 86 65 54 46 40 36 32 29 27 25 A 124 87 66 54 46 40 36 32 29 27 25
B 180 129 98 81 69 60 54 48 44 41 38 B 186 130 99 81 69 60 54 48 44 41 38
C 240 172 131 108 92 80 72 64 59 55 51 C 248 173 132 108 92 80 72 64 59 55 51
D 300 215 163 135 115 100 90 80 73 68 63 D 310 217 165 135 115 100 90 80 73 68 63
E 360 258 196 162 138 120 108 96 88 82 76 E 372 260 198 162 138 120 108 96 88 82 76
F 406 306 244 208 181 160 146 134 122 112 106 F 420 312 245 209 183 161 147 135 123 113 106
G 507 382 304 259 226 200 182 167 152 140 132 G 524 389 306 261 228 201 183 168 153 141 132
H 578 444 361 304 263 231 207 187 170 156 144 H 596 453 366 308 265 233 207 187 170 156 144
I 675 518 421 355 307 270 241 218 198 182 168 I 695 529 427 359 309 271 242 218 198 182 168
J 771 592 482 406 350 308 275 249 227 208 192 J 795 604 489 410 353 310 276 249 227 208 192
K 964 740 602 507 438 386 344 311 283 260 240 K 993 755 611 513 442 388 345 311 283 260 240
L 1061 814 662 558 482 424 379 342 312 286 264 L 1093 831 672 564 486 427 380 342 312 286 264
M 1157 888 722 608 526 463 413 373 340 312 288 M 1192 906 733 615 530 465 414 373 340 312 288
N 1189 902 730 613 529 465 414 374 340 312 289 N 1222 919 740 619 532 466 415 374 340 312 289
O 1388 1053 851 715 617 542 483 436 397 365 337 O 1425 1073 863 722 621 544 484 436 397 365 337
P 1586 1203 973 817 705 620 552 499 454 417 385 P 1629 1226 986 826 709 622 553 499 454 417 385
Q 1784 1353 1094 919 793 697 622 561 511 469 433 Q 1832 1379 1110 929 798 699 623 561 511 469 433
R 1982 1504 1216 1021 881 774 691 623 567 521 481 R 2036 1532 1233 1032 887 777 692 623 567 521 481
S 2082 1579 1277 1073 925 813 725 654 596 547 505 S 2138 1609 1295 1084 931 816 726 654 596 547 505
T 2181 1654 1338 1124 969 852 760 685 624 573 529 T 2240 1685 1356 1135 975 855 761 685 624 573 529
U 2379 1804 1459 1226 1057 929 829 748 681 625 578 U 2443 1839 1479 1238 1064 933 830 748 681 625 578
V 2379 1804 1459 1226 1057 929 829 748 681 625 578 V 2443 1839 1479 1238 1064 933 830 748 681 625 578
12
ENVIRONMENT
ENVIRONMENT
The Hawker Group is committed to the environment in all that we do. We seek to conserve
natural resources, promote the more efficient use of energy, minimise water use, reduce
waste, reduce emissions and increase the recycling and re-use of materials. Our policy is to
operate in an environmentally responsible manner designed to meet all applicable legislation
and one that strives to further reduce any adverse effects of its operations upon the
environment.
Manufacturing
Hawker manufacturing plants throughout the world employ state of the art production
processes which are more efficient and environmentally-benign. A programme of continuous
development and investment ensures that all Hawker plants are as environmentally friendly
as it is possible to make them.
Recognition
Companies in the Hawker Group are working towards the international environmental
standard ISO14001 which has already been awarded to Hawker Energy Products Inc in the
USA.
Environmental Awards
Our commitment to the environment can be seen by the fact that Hawker companies have
won awards for envionmental excellence.
Hawker Energy Products Inc, for example, has won awards recognising the treatment of
waste water at their battery plant for three years running. The company has been able to
minimize water use and maximise water reuse, while at the same time doubling
manufacturing capacity.
Recycling
Hawker is working with other companies and trade organisations to look into, and make
recommendations about, the most effective means of recycling batteries. The majority of lead
acid batteries, including those produced by Hawker, are already efficiently recycled, primarily
to remove the valuable lead.
Hawker provides a complete disposal service for both standby and traction batteries following
installation of new or replacement batteries. We also operate a sealed lead recycling
programme, which recycles all components of Hawker VRLA batteries - metals, plastics and
acids.
Many Hawker factories operate programmes to recycle process waste back into the
manufacturing operation wherever possible. For example, the waste water which is recovered
at the effluent plant is re-used for cooling and cleaning. We also recover the waste lead slurry
from pasting departments. The slurry is then sent to a smelter for recycling.
13
HEALTH AND SAFETY GUIDELINES

HEALTH AND SAFETY GUIDELINES
Batteries are powerful sources of electrical energy and The guidelines are in 2 sections:
as such, should be handled with care and respect. The
guidelines below are meant for general reference and SYMBOLS and HANDLING BATTERIES
although refer to lead acid battery technology, do not
differentiate between the various types of lead acid SYMBOLS
batteries available. As such you should:
You will see all or some of the following symbols
ALWAYS consult the relevant instruction manual (depending on the battery type) on the batteries
before installation or service of your themselves. Ensure that you are aware of the meaning
batteries. of each symbol.
ALWAYS refer to safety recommendations required Note operating instructions

by national/international standards in your
local country. Explosive gas
ALWAYS ensure that only authorised personnel Shield eyes

carry out work on batteries.
Pb Batteries contain lead
This objective of this guide is:
Keep away from children
To demonstrate the potential hazards that
may arise when using lead acid batteries. Never dispose of old batteries as domestic
waste
To outline the precautions you should take
to minimise such hazards. Battery acid
To indicate the action that you should take Batteries are recyclable - please follow your
in the event of an accident or emergency local recycling regulations
situation.
No smoking, no naked flames, no sparks
Warning - Electric energy / high voltages
14
HANDLING BATTERIES Ingestion

Do NOT induce vomiting, but make the patient
1. SULPHURIC ACID drink as much water or milk of magnesia as
possible and seek immediate medical attention.
Batteries contain sulphuric acid (dry charge batteries
prior to filling with acid excluded) which may leak for a Spillages
number of reasons and may be given off as droplets
and/or a fine mist during charging. Small spillages can quite simply be dealt with by
swilling away with plenty of water. For larger spillages,
Nature of the Hazard absorb onto an inert material e.g. earth, sand or
vermiculite. Neutralise the mixture with soda ash and
Battery acid is a poisonous and corrosive liquid which arrange for disposal by a registered waste carrier.
will cause burns and irritation to the skin and eyes and
could burn clothing. Disposal
Precautions Suitable acid resistant, labelled containers should be

used.
1 Always handle batteries with care and keep
upright. See also Section 6.
2 Do not overfill batteries.
3 Always charge in a well ventilated area. Note - Additional Information
4 Always use eye protection (must comply with
national / international standards) and protective The above section applies particularly to flooded, wet
clothing where there is any risk from splashes. batteries such as wet planté, tubular and flat plate cells,
5 Always keep away from children. where dilute sulphuric acid circulates freely within the
6 Keep an eyewash bottle available at all times. cell/battery.
Accident or Emergency Action/Treatment Valve regulated AGM (absorptive glass mat) types such
as Powersafe, Espace, XT™, SBS and Cyclon® from the
Skin Contact Hawker Group, are classed as non hazardous. This is
Cool the burned area with large amounts of because in VRLA AGM cells, the dilute sulphuric acid is
water. Do this for at least 10 minutes but do not absorbed in a special, highly porous micro-fibre glass
allow this process to delay the calling of an separator. This, together with high density pillar seals
ambulance or the removal of the patient to and hermetic container-to-lid bonding, ensures that acid
hospital, if possible. Remove any contaminated is unable to leak out.
clothing. Do not remove any clothing which is
sticking. Gelled electrolyte cells (such as the OPzV type
manufactured by the Hawker Group) are also classified
Eye Contact as non hazardous.
Immediately wash out the eyes with an eye wash
bottle or clean water for at least 10 minutes and
seek prompt medical attention.
15
2. ELECTRICAL ENERGY hospital. Remove any contaminated clothing. Do

not remove any clothing which is sticking.
Electrical energy can be supplied from batteries and
charging equipment. Electric Shock
Immediate action is essential in cases of severe
Nature of the Hazard electric shock as the nerves controlling
breathing and heart action may be affected. Do
Burns may occur from the heating effect on tools and not delay treatment by calling for a doctor; this
conductive objects in contact with live battery terminals should be done quickly if help is available or
or conductors. In addition sparks and molten metal may when the casualty recovers.
be ejected and combustible materials ignited. It is
possible to receive a severe electric shock from charging Make sure it is safe to approach. If the casualty
equipment and from a number of batteries connected in is not clear of a live conductor, break the
series, i.e. five or more 12 volt batteries - 60 volt contact. Switch off the current, remove the
nominal. plug, or wrench the cable free. If this is not
possible, stand on dry insulating material (wood,
Precautions rubber, brick, thickly folded newspaper, book)
1 Before using conductive tools on a battery and try push or pull the casualty clear of contact
remove metallic personal adornments from the using similar insulating material as a lever. Do
hands and wrists, e.g. watches and rings. NOT touch them with bare hands.
2 Switch off circuit before connecting or
disconnecting the battery otherwise a spark could If necessary give artificial respiration.
cause an explosion.
3 Always use insulated tools. 3. EMISSION OF GASES
4 Do not place tools or conductive objects on top of
batteries. WARNING - batteries, in particular wet flooded
5 Before using a battery charger consult batteries, can give off explosive gases. Adequate
manufacturer’s literature. ventilation MUST be provided.
6 Remember to switch the charger off before
connecting or disconnecting a battery. Hydrogen and oxygen are emitted during charging and
7 Do not wear coats or overalls made from pure can be emitted at other times, particularly if a battery is
synthetic fibre materials as these can hold static moved or shaken.
electric charge under certain circumstances.
8 Ensure connections are tight and circuit is safe Gas recombination cells under normal operating
before switching on battery. conditions release only very small quantities of
hydrogen and so any explosion risk is greatly reduced
See also Section 3. compared to flooded cells. Gas recombination cells
should not however be installed in containers or
Accident or Emergency Action/Treatment cubicles without adequate ventilation.
Burns
Cool the burned area with large amounts of
water. Do this for at least 10 minutes but do not
allow this process to delay the calling of an
ambulance or the removal of the patient to
16
Nature of the Hazard 6. DISPOSAL
An explosive atmosphere is created if the concentration Batteries, battery cases, battery acid, lead and lead
of hydrogen in air exceeds 4%. compounds must not be burned, but must be disposed
of in accordance with the appropriate national /
Precautions international legislation, and Local Waste Disposal
Always use eye protection (must comply with national/ Authority rules and regulations.
international standards) where there may be any
foreseeable risk. Charge in a well ventilated area. Avoid 7. FIRE
sources of ignition close to batteries.
Since batteries contain combustible materials the Local
In particular: Fire Authority should be consulted where a quantity of
No smoking - No naked flames batteries are stored together.
Always switch off current before making or
breaking electrical connection. The boxes and lids of batteries are made of various types
Avoid sparks caused by accidental short circuits. of plastic components which under normal usage, are
inert. In the case of fire the plastic components could
See also Section 2. decompose and may give off toxic vapours and
consequently suitable self-contained respiratory
Accident or Emergency Action/Treatment protection should be used during fire fighting.
Explosion 8. GENERAL
Seek any necessary medical attention and remember Familiarise yourself with the location of your health
that sulphuric acid may have been ejected. centre and how to contact your works nurse, first aider
or appointed person.
See also Section 1.
Remember to report any accident, involving personal
4. WEIGHT injury, in your official accident book.
Batteries are generally heavy, awkward units to handle Should any repair or other work on batteries be
and correct lifting techniques must therefore be used. required, the relevant national/international codes of
practice MUST be referred to.
5. DAMAGED BATTERIES
Any additional information, including battery labelling,
Battery plates consist of lead and its compounds, but that is provided to cover specific battery types and
can only be exposed if a battery is broken open. In the applications must be used in conjunction with this
unlikely event of this happening any spillage should be guide.
well damped, swept up and placed in a suitable acid
resistant, labelled container prior to disposal.
Normal personal hygiene precautions should be

observed.
See also Section 1 and Section 6.
17
INSTALLATION
INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

For typical VRLA Cells
This leaflet is intended as a guide only. For detailed instructions refer to the relevant installation, operating and
maintenance manual of the battery in question.
Safety Precautions
Handling Keep Flames Away Tools
Batteries are normally supplied In case of accidental overcharge a Use tools with insulated handles.
charged: they must be unpacked flammable gas can leak from the Do not place or drop metal objects
carefully. Avoid all short-circuits safety vent. on top of the battery. Remove
between opposite polarity poles Discharge any possible static rings, wristwatch and articles of
as the cell will produce very high electricity from clothes by clothing with metal parts that
short-circuit currents. touching an earth connected part. might come in contact with the
battery terminals.
Receiving the shipment Refreshing charge is advised Security

according to the relevant product All installation and ventilation
Unpack the batteries immediately
literature. must comply with the current
upon arrival. Inspect for possible
damage in shipment. Ensure that Failure to observe these conditions regional regulations and standards.
no accessories are discarded with may result in greatly reduced
the packing material. capacity and service life.
Mounting
Hawker battery racks or cabinets
Warning Installation are recommended for proper
The batteries contain immobilised The battery should be installed in a installation.
sulphuric acid. clean, dry area. VRLA cells with Assemble the rack according to
very low gas release in normal instructions supplied. Place the
Batteries with broken lids or
operation (recombination ratio≥ battery blocs or cells on the rack
containers may lose small amounts
95%) can be installed together with and arrange the positive and
of acid when deformed. Wear
other electrical equipment. negative terminals for connection
rubber gloves when handling
broken batteries. It is important that the battery is according the wiring diagram
installed on a stable floor (without supplied. Check that all contact
deformation). surfaces are clean and fit the bloc or
Storage cell connectors and the terminal
Store the battery in a dry, clean and bolts.
Temperature
preferably cool location. Tighten the bolts securely. Check
Avoid placing the battery in a
As the batteries are supplied the polarity to avoid short
warm place or against a window.
charged, storage time is limited. In circuiting of cell groups. Finally
The battery will give the best
order to easily charge the batteries connect the battery terminals to the
performance and service life when
after prolonged storage, it is charger.
working at a temperature between
advisable not to store it more than:
20°C (68°F) and 25°C (77°F).
6 months at 20°C (68°F)
Terminal Bolt Tightening
Ventilation The maximum torque load for
intercell connector bolts should be
A refreshing charge shall be Under normal conditions the gas
adhered to, and values are given in
performed after this time at 2.27V release is very low and natural
the relevant product literature.
per cell at 20˚C (68°F) for 96 hours ventilation is sufficient for cooling
purposes and inadvertent A loose connector can cause trouble
or until the charging current does
overcharge, enabling VRLA in adjusting the charger, erratic
not vary for a 3 hour period.
batteries to be used safely in offices battery performance, possible
The necessity of a refreshing charge damage to the battery and/or
and equipment.
can also be determined by personal injury.
measuring the open circuit voltage However care must be taken to
ensure ventilation when placed in Finally fit the connector covers.
of a stored battery.
closed cabinets. It is important that the battery is
mounted securely.
18
Cells in parallel strings For recommendations refer to the The effect of temperature
appropriate product literature.
VRLA cells of the same ampere on capacity
hour rating may be connected in Capacity is enhanced at
parallel to give higher current State of Charge temperatures >20°C (68°F).
capability. However precautions The state of charge of VRLA cells Capacity correction factors for
must be taken. can be determined approximately VRLA batteries can be found in the
equipotential wiring is by measuring the open circuit appropriate product literature.
required; that means connectors voltage after the battery has been at
on life
are designed such that the rest for a minimum of 24 hours, at
20°C (68°F). Operation of valve regulated
current is distributed equally
batteries at temperatures higher
between each string The actual values vary according to
than 20°C (68°F) will reduce life
to prevent any recharge the design of the VRLA battery and
expectancy.
problem, it is better to have a reference should be made to type
separate supply for each specific literature.
parallel string. Maintenance/Checks
Discharging VRLA batteries do not have to be
Charging topped up.
Discharged Cells
Float Voltage The containers and lids shall be
VRLA batteries must not be left in
kept dry and free from dust.
The float/charge voltage is 2.27V a discharged condition after
Cleaning must be carried out with
per cell at 20°C (68°F). supplying the load, but must be
a damp cotton cloth (no man-made
When the average ambient immediately returned to float
fibres).
temperature deviates more than recharge mode.
Every month check that the total
± 5°C (± 41°F) from the reference, it Failure to observe these conditions
voltage at battery terminals is (N x
is necessary to adjust the float may result in greatly reduced
2.27V) for a temperature of 20˚C
voltage. service life and unreliability.
(68°F). (N being the number of
The relevant values for adjustment cells in the battery). Once a year,
are given in the appropriate Accidental Deep Discharge take a reading of the individual cell
product literature. voltages constituting the battery.
When the VRLA battery is
Due to the phenomena of gas completely discharged the Keep a logbook in which the
recombination a difference of ± 4% consumption of sulphuric acid measured values can be noted as
for an individual cell voltage can be reduces the electrolyte strength to well as power cuts, discharge tests,
observed. nearly water. The sulphation of the etc.
plates is a maximum, increasing A full autonomy test can be carried
Charging Current considerably the cell’s internal out once a year.
resistance.
For maximum service life, VRLA
The battery must then be recharged
batteries should only be used with Special Applications
constant potential float chargers. at a constant voltage of 2.27V per
cell. As the internal resistance is Please contact your local sales office
high in the beginning, a minimum for advice when planning to use
Fast Recharge charge time of 96 hours may be VRLA batteries in special
necessary. applications such as repeated
Occasionally (4 or 5 times a year)
cycling or extreme ambient
the battery may be recharged at
conditions.
2.40V per cell.
Important notice:
Details are given in the appropriate
This type of deep discharge is
product literature.
abusive, and could affect the life
expectancy.
Ripple Current
Unacceptable levels of ripple
current from the charger of the load
can cause permanent damage and a
reduction in service life.
19

For typical tubular Gel-OPzV Cells
Safety Precautions
Handling Keep away fom flames Tools
Gel tubular batteries are supplied In case of accidental overcharge, Use tools with insulated handles.
charged: they must be unpacked flammable gas can leak from the Do not place or drop metal objects
carefully. Avoid all short-circuits safety vent. on top of the battery. Remove
between opposite polarity poles Discharge any possible static rings, wristwatch and articles of
as the cell will produce very high electricity from clothes by clothing with metal parts that
short-circuit currents. touching an earth connected part. might come into contact with the
battery terminals.
Receiving the shipment Installation Check that all contact surfaces are
clean and fit the bloc or cell
Unpack the batteries immediately The battery should be installed in a
connectors and the terminal bolts.
upon arrival. Inspect for possible clean, dry area. It does not give off
damage in shipment. Ensure no corrosive gas in normal operation Tighten the bolts securely. Check
accessories are concealed in the and therefore can be installed the polarity sequence to avoid short
packing materials before disposal. together with other electrical circuiting of cell groups. Finally
equipment. It is important that the connect the battery terminals to the
battery is mounted securely. charger.
Warning
The batteries contain immobilised
Temperature Terminal Bolt Tightening
sulphuric acid.
Avoid placing the battery in a The maximum torque load for
Batteries with broken lids or
warm place or against a sunny intercell connector bolts is 23Nm
containers may lose small amounts
window. The battery will give best (2.3 Mkg) to 25 Nm (2.5Mkg). A
of acid when deformed. Wear
performance and service life when loose connector can cause trouble
rubber gloves when handling
working at a temperature between during discharge or charge and
broken batteries.
20°C (68°F) and 25°C (77°F). voltage drop or heating, which can
cause damage to the battery or
Storage injury to persons.
Ventilation
Store the battery in a dry, clean and Finally fit on the connector covers
preferably cool location. Under normal conditions gas (insulation).
release is negligible and natural
As the batteries are supplied
ventilation is sufficient for cooling
charged, storage time is limited. In
purposes, even when inadvertently Cells in parallel strings
order to easily charge the batteries
overcharged, enabling batteries to Gel cells of the same ampere hour
after prolonged storage, it is
be used safely in offices and with rating may be connected in parallel
advisable not to store them more
other electrical equipment. to give higher current capability.
than:
Do not exceed 4 parallel strings.
6 months at 20°C (68°F) However equipotential wiring is
4 months at 30°C (86°F) Stands
required. Connectors must be
2 months at 40°C (104°F) Battery racks are recommended for designed so that the current is
proper installation. distributed equally between each
A refreshing charge should be Assemble the rack according to the string.
performed after this time at 2.23V instructions supplied. Place the
per cell at 20°C (68°F) for 96 hours battery blocs or cells on the rack
or until the charging current does and arrange the positive and the
not vary for a 3 hour period. negative terminals for connection
according to the wiring diagram.
Failure to observe these conditions
may result in greatly reduced
capacity and service life.
20
Charging State of Charge Important notice:
Float Voltage The battery state of charge can be This type of deep discharge is
determined approximately by abusive, and could affect the life
The recommended float/charge
measuring the open circuit voltage expectancy.
voltage is 2.23 V per cell at 20°C
after the battery has been at rest for
(68°F).
a minimum of 24 hours.
When the average ambient The effect of temperature
temperature deviates more than State of charge Voltage on capacity
± 5˚C (± 41°F) from the reference, it 100% 2.13 Vpc Correction factor for capacity,
is recommended to adjust the float 70% 2.09 Vpc according to temperature, the
voltage as follows: 50% 2.06 Vpc reference temperature being 20°C
20% 2.02 Vpc (68°F):
2.35Vpc at 0°C (32°F)
2.28Vpc at 10°C (50°F) Discharge End Temperature
2.23Vpc at 20°C (68°F) (standard)
Discharging time voltage 14°F 32°F 50°F 68°F 86°F
2.20Vpc at 30°C (86°F) End of Discharge Voltage (hour) (Volt) -10°C 0°C 10°C 20°C 30°C
2.17Vpc at 35°C (95°F) according to the discharge time 1 1.67 0.39 0.59 0.80 1 1.05
The end of discharge voltage must 3 1.75 0.55 0.70 0.85 1 1.05
Due to the phenomena of gas
be limited to the values listed 5 1.77 0.60 0.74 0.87 1 1.04
recombination a difference of ±
below.
2.5% for an individual cell voltage 10 1.80 0.60 0.74 0.87 1 1.04
may be observed. Discharge time (t) End voltage (Volts)
1h < t < 5h 1.70V
Charging Current
5h < t < 8h 1.75V
Maintenance/Checks
8h < t < 24h 1.80V
Gel cells are maintenance free,
For maximum service life, gel
A low voltage disconnect or timer sealed, lead acid batteries and do
tubular batteries should only be
is recommended to prevent deep not have to be topped up.
used with current limited constant
discharge. The containers and lids should be
potential float chargers, current
limited to 10% of 10 hour capacity. Special attention should be given kept dry and free from dust.
In practice the charging current to small loads that are not Cleaning must be undertaken with
must not exceed 0.3C10. However if automatically disconnected at the a damp cotton cloth without man-
the application guarantees a depth end of discharge. made fibres.
of discharge (DOD) less than 40% Every month, check that the total
of the rated capacity, then the Discharged Cells voltage at battery terminals is
charging current limits itself and (N x 2.23V) at a temperature of
Gel batteries must not be left in a
current limitation may be omitted. 20°C (68°F). (N being the number
discharged condition after
of cells in the battery). Once a year,
supplying the load, but must be
take readings of individual cell
Fast Recharge immediately returned to float
voltages.
The battery may be recharged at recharge mode.
Keep a logbook in which the
2.35V per cell with current limited Failure to observe these conditions
measured values can be noted as
to 10% of the 10 hour capacity. Fast may result in greatly reduced
well as power cuts, discharge tests,
charging should be discontinued service life and unreliability.
etc.
after approximately 10 or 15 hours.
A discharge test for full automony
Accidental Deep Discharge can be carried out once a year.
Quality of the charging current The battery must then be recharged
under floating voltage at a constant voltage of 2.23V per
The nature of the charging current cell, with a current limited to
Special Applications
has an influence on the life 0.1C10 capacity in order to prevent Whenever gel tubular cells are to
expectancy of the batteries. The rms excessive heating. As the internal be used for special applications
value of the alternating component resistance is high at first, a such as repeated cycling or under
(fundamental and harmonic) must minimum charge time of 96 hours extreme ambient conditions, please
not exceed 0.1C10. on continuous may be necessary. contact your local sales office.
charge.
21

For typical Vented, Pasted and Tubular Positive Plate Cells
Safety Rules during installation, test or work on batteries

1 Before installing a battery, 3 To avoid electostatic charges When working on the battery, first
make sure that first-aid and explosion risks ’discharge’ yourself of static
material is available, ie: Whether cells are dry or filled, electricity by touching an earthed
Water charged or discharged, they metallic part (door, water pipe,
Water filled eye wash may contain explosive gases etc). Repeat this action
occasionally until the work is
(hydrogen and oxygen) which
complete.
In case of electrolyte spillage, can, in the presence of a spark
rinse affected parts of the body or flame, cause an explosion. It
with a lot of cold water. If is therefore forbidden:- 4 Take care not to create
electrolyte gets into the eyes, rinse to smoke in a battery room accidental short-circuits by
dropping metallic objects onto
thoroughly with eye-wash. In all to create electric sparks
intercell connectors.
cases, seek medical advice to use soldering equipment
urgently.
to use portable machines
plugged into an electric plug
NOTE: For remote installations
to wear clothes likely to
provide a first aid kit on site.
acquire an electrostatic charge
(nylon)
2 Always wear protective
to use unprotected tools
glasses, gloves and preferably
protective clothing when the to store metallic objects near
the battery
battery is to be filled with
electrolyte.
Electrolyte is a corrosive
sulphuric acid solution
Unpacking To recharge the battery more easily The charging current should, if
and rapidly, the following storage possible, be restricted to 0.3°C10. If
Unpack the batteries as soon as they
times are recommended: the electrolyte temperature reaches
are delivered.
45°C (113°F), charging must be
Verify that the equipment has been Temperature Time stopped and resumed when it has
delivered in good condition, if it 20°C (68°F) 3 months fallen to 35°C (95°F).
has not, notify the forwarding agent 30°C(86°F) 2 months
and/or sales office. The battery is charged when every
40°C(104°F) 1 month
cell without exception reaches the
nominal specific gravity value at
Battery storage Recharge of stored batteries 20°C (68°F) with the electrolyte
Store the battery in a dry, cool and 2 types of charging are possible: level midway between the
clean place. maximum and minimum line.
Constant Current Charge

Storage times
Storage times for stationary Must be carried out under
batteries depend on temperature. surveillance.
22
Installation Bolt Torque Limits Recharge after discharge
Battery Room 10-25 Nm (dependent on type) - see Every battery must be recharged,
individual product manual. immediately after use; do not store a
The layout and contents of a battery battery discharged.
room must comply with all
A charging voltage of 2.23V to
standards in force in the country. Ventilation 2.30V per cell is generally used to
The layout of the battery room must The battery installation must allow recharge a battery.
allow for easy access to the natural or artificial ventilation both A voltage of 2.30V to 2.40V can be
batteries. at the top and bottom of the battery applied to recharge the battery more
to eliminate any explosive gas rapidly.
mixture.
Battery Installation Equalizing charge
Stand Installation When must equalizing charges be
Calculation of ventilation
Assemble stand according to the applied?
The quality of air required in litres
instructions supplied When electrolyte levels have
per hour is calculated as follows:
been adjusted
Fit insulators (compulsory for Q = 55 x i x n
high voltage batteries) When all specific gravities
Q in litres/hour
recorded at a temperature of
Fit braces and cross beams n = number of cells
20°C (68°F) are less than 0.010
i = max. current of charge
units compared to nominal
Check that the stand is level * example only - national standards specific gravity.
vary
Use appropriate wedges when When individual cells show a
packing under insulators voltage difference of +/-0.02
Note Volts with the average cell
Make sure that all insulators are voltage
in contact with the stand For installation and commissioning
of dry charged batteries, please
The battery can then be installed follow instructions given in the Duration
appropriate product literature Depends on the voltage applied,
Installation of Cells on cell temperature and room
temperature, but is normally 24-
Battery cells should be installed Operating instructions 36 hours
in series
Continue charging until the cells
Float Voltage
Assemble battery on stand specific gravities have reached
making sure that the positive A float voltage of 2.23Vpc to nominal values. Begin the charge
terminal of one cell is connected 2.30Vpc is normal. Consult in the morning, ensure that after
technical literature for 1 to 2 hours of charging the
to the negative terminal of the
adjustments according to current value is below 0.2C10
adjacent cell and continue in the
temperature and other variations Check electrolyte temperature on 3
same fashion
or 4 cells during charge. If the
Check cell alignment temperature remains below 30°C
Charging current
(86°F) cells may be left under
Fit connectors and bolts (check Should be restricted to 0.3C10 equalizing charge voltage for 24
tightness and cleanliness) hours.
Charging current quality affects
Use the insulators provided battery life. Charging current The end of charge signal is when
must be filtered so that the value nominal specific gravity is obtained.
Make sure that all vent caps are of the alternating component is
closed minimised
Note: In all cases charging must be
suspended if the electrolyte
temperature reaches 45°C (113°F).
23
Technical data Maintenance/Tests The time interval between topping up

varies from 1 to 8 years depending on:
Effect of temperature on capacity Equipment
type of alloy
If the battery operating temperature is Hydrometer cell type
different from 20°C (68°F) a correcting Thermometer room temperature
factor will have to be applied to Filler battery age
capacity value taking into account
Voltmeter After having checked electrolyte
discharge time.
levels, apply an equalizing charge
1 Pasted positive plate Maintenance until normal electrolyte specific
gravity is restored
Recharge 32°F 41°F 50°F 59°F 68°F 77°F 86°F 95°F 104°F
time 0°C 5°C 10°C 15°C 20°C 25°C 30°C 35°C 40°C Keep containers, lids and battery
5 - 58 rooms clean
minutes 0.68 0.77 0.85 0.94 1 1.03 1.06 -.09 1.11 Log book
1 - 24
Wipe out salt and acid stains on
hours 0.74 0.61 0.88 0.95 1 1.02 1.05 1.07 1.06 terminals, connections and lids We recommend that a log book is kept
with a wet sponge in which the following information is
Example: A battery with a 200Ah
Never clean containers and lids recorded:
capacity at 20°C (68°F) for a 5 hour
autonomy will have a capacity of with solvents, detergents, oils or periodical measurements
similar products capacity tests
176Ah when discharged at 10°C
(200 x 0.88) Every 3 months storage times and conditions
1 Check total voltage at battery topping up dates
terminals. It must equal: discharges due to power-cuts, etc
2 Tubular positive plate
NxU
Recharge 32°F 41°F 50°F 59°F 68°F 77°F 86°F 95°F 104°F
time 0°C 5°C 10°C 15°C 20°C 25°C 30°C 35°C 40°C N = number of battery cells
Advice for greater reliability and
5 - 58 U = floating voltage per cell to be
minutes 0.58 0.68 0.79 0.91 1 1.05 1.09 1.12 1.14 longer life of batteries
applied according to cell type and
1 - 24 annual average room temperature.
hours 0.81 0.86 0.91 0.96 1 1.03 1.05 1.06 1.07 A battery is generally the last
2 Measure voltage, specific gravity protective barrier against power cuts;
Example: A battery with a 1000Ah
and temperature of a few reference battery maintenance is therefore very
capacity at 20°C (68°F) for a 10 hour cells. important in prolonging cell life.
autonomy will have a capacity of
3 Check electolyte levels Correctly adjust the float voltage
850Ah when discharged at 5°C (41°F)
(1000 x 0.86) 4 Measure room temperature Top-up with distilled or de-ionized
water at periodic intervals
Correction of specific gravity (dependent on cell technology)
Every 6 months
according to temperature Never add sulphuric acid
1 Measure total voltage of battery Keep the battery clean and dry
Electrolyte specific gravity varies with
and ambient temperature
temperature; if temperature is above Keep connectors clean
2 Measure all cells voltages
or below 20°C (68°F) specific gravity Apply an equalizing charge
readings must be corrected using the 3 Measure specific gravity of a few periodically (essential to maintain
table below: cells with varying voltages as well a proper state of charge and
as electrolyte level and temperature homogeneous electrolyte)
Specific gravity 4 Apply equalizing charge
59°F 68°F 77°F 86°F 95°F 104°F
15°C 20°C 25°C 30°C 35°C 40°C
An autonomy test can be applied
1.147 1.144 1.142 1.140 1.138 1.134 one or twice a year
1.167 1.164 1.162 1.159 1.157 1.153
1.186 1.183 1.180 1.197 1.176 1.172
Water topping
1.206 1.203 1.200 1.197 1.194 1.190
1.217 1.213 1.210 1.207 1.204 1.200 Top up with distilled or de-ionized
water on a charged battery, before
1.222 1.218 1.215 1.212 1.209 1.205
the electrolyte reaches minimum
1.227 1.223 1.220 1.217 1.214 1.210
level
1.237 1.233 1.230 1.227 1.224 1.220
When adding water, never exceed
1.248 1.244 1.241 1.238 1.234 1.230 maximum level
1.259 1.255 1.252 1.249 1.245 1.240
1.269 1.265 1.262 1.259 1.255 1.250
24
Hawker Group
PO Box 227
Avon House
The Westinghouse Site
Chippenham
Wiltshire SN15 1SJ
Tel: +44 1249 442 551
Fax: +44 1249 442 550
www.hawker-batteries.com
An Invensys company
Hawker/Gen/1/July99

HAWKER Battery Handbook

Uploaded by

Copyright:

Available Formats

HAWKER Battery Handbook

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HAWKER Battery Handbook

Uploaded by

Copyright:

Available Formats

Generic 29/7/99 3:25 pm Page 1

STANDBY BATTERIES TECHNICAL MANUAL

The Hawker Group is the largest manufacturer of industrial batteries in the

Batteries from Hawker Group companies provide primary and reserve

As the world’s leading supplier of industrial batteries, we operate on all

Computer controlled equipment and quality control techniques have been

RESEARCH & DEVELOPMENT

Current development is focused on the pure lead and lead-calcium-tin/AGM

TYPES OF BATTERIES AND THEIR USES

Flooded Lead Acid Batteries

Valve Regulated Lead Acid Batteries

VALVE REGULATED LEAD ACID BATTERIES....

When a charge current flows through a fully charged

However, evolution of oxygen gas and hydrogen gas S

2e - + 2H+ + 1/2 O2 H2O

and the final product is water. Conventional Cell

If the process were 100% efficient, no water would be

ABSORPTIVE GLASS MAT (AGM)

GELLED ELECTROLYTE (GEL)

Because a conventional microporous separator is T O 02 T

The Planté plate is only used as a positive electrode and

The tubular plate is also only used as a positive

The pasted plate electrode can be used both as a positive

Rod plate electrodes can be either positive or negative.

VALVE REGULATED LEAD ACID PRODUCT ILLUSTRATIONS

TUBULAR GEL (OPzV) PRODUCT

1 Pressure Relief Valve

4 Flat Pasted Plate - Negative

5 Positive Grid Coating

8 Diecast Positive Grid Spines 9

FLOODED LEAD ACID PRODUCT ILLUSTRATION

3 Cell Pillars and Connectors

All the Hawker product literature Method Conclusion: Use 24 - P cells

watts per cell required 60,500 watts

HEALTH AND SAFETY GUIDELINES

HEALTH AND SAFETY GUIDELINES

ALWAYS refer to safety recommendations required Note operating instructions

ALWAYS ensure that only authorised personnel Shield eyes

Warning - Electric energy / high voltages

HANDLING BATTERIES Ingestion

Precautions Suitable acid resistant, labelled containers should be

2. ELECTRICAL ENERGY hospital. Remove any contaminated clothing. Do

Nature of the Hazard 6. DISPOSAL

Normal personal hygiene precautions should be

See also Section 1 and Section 6.

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Receiving the shipment Refreshing charge is advised Security

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Charging State of Charge Important notice:

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS

Safety Rules during installation, test or work on batteries

Constant Current Charge

Installation Bolt Torque Limits Recharge after discharge

Technical data Maintenance/Tests The time interval between topping up

You might also like