Tel.X Ni-Cd batteries for telecom networks Technical manual

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1 Tel.X Ni-Cd batteries for telecom networks Technical manual March 2013

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3 Contents 1 Introduction Electrochemical principles Tel.X construction Cells and modules Battery string Features and benefits Long life Reliability No watering maintenance Resistance to electrical abuse Cell voltages Capacity and baseline performance Discharging Internal resistance Maximum inrush charge current Charging Constant voltage charging Float operation Reconditioning charge Reconditioning charge procedure Effect of temperature on performance Gassing Ventilation practice Storage and shelf life Charge retention Service life Effect of temperature on calendar life Special operation Cycling Temperature shock Prolonged power outage and over discharging Abusive operation Short circuit Thermal runaway Mechanical abuse Corrosion and carbonates Paralleling with other battery string technologies Battery sizing Appendix A Parallel currents Glossary

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5 Introduction and Electrochemical principles 1 Introduction Saft Tel.X batteries are inherently safe to handle and operate. As long as Saft s information and instructions are followed, they will last longer and function more reliably than other storage batteries. To obtain optimum performance and operating life and to ensure safe handling and operation, Saft s information and instructions must be followed. Other documents not included in this manual are: BIS (Battery Information Sheet) Tel.X Installation and Operation Manual and sheets In addition, studying this Technical manual will give you a better understanding of Tel.X batteries. Tel.X batteries are designed for standby operation in telecom networks and are particularly suited for uncontrolled temperature environments. 2 Electrochemical principles The Tel.X battery uses nickel hydroxide (NiOH) as active material in the positive electrodes, and cadmium hydroxide (CdOH) as active material in the negative electrodes. An aqueous solution of potassium hydroxide (KOH) is used for the electrolyte. The nature of the Tel.X electrochemistry promotes stable performance over its life, it exhibits fail safe behaviour under abuse and inhibits life limiting reactions like electrode corrosion. The electrolyte in the Tel.X is not acidic as with lead-acid batteries. The electrolyte is an alkaline aqueous solution of about 24% KOH. Additionally, there are small added quantities of lithium hydroxide (LiOH) and sodium hydroxide (NaOH) to improve life and high temperature performance. The electrolyte is only used for ion transfer and is not chemically changed or degraded during the charge/discharge cycle. It is sometimes referred to as the liquid wire. Like other flooded nickelcadmium batteries, in the Tel.X the amount of electrolyte does not restrict the available capacity. In contrast, in the case of the leadacid battery, the positive and negative active materials chemically react with the sulfuric acid electrolyte during the charge/discharge process. This results in an unavoidable aging and dilutes the acid solution when the battery is discharged. This is most significant in lead-acid batteries that use a limited amount of electrolyte such as AGM (Absorbed Glass Mat) type VRLAs. The lack of acid at the end of the discharge may limit the battery s capacity. In a Tel.X cell, the support structure of both electrodes includes materials such as nickel plated steel or pure nickel metal. These materials are relatively unaffected by the surrounding electrochemistry. Because of that, it will retain good conductive and mechanical characteristics throughout its useful life. In the case of the lead-acid battery, the basic support structure of both plates is lead. Lead is susceptible to corrosion resulting in positive plate growth and a mechanical weakening of the structure which leads to a gradual loss of conductivity and available capacity. In extreme cases corrosion, in the lead-acid cell, can cause an open circuit and thus cause complete loss of battery string support. This cannot happen to a Tel.X battery since the support structure of both electrodes are relatively unaffected by the electrochemistry. The charge/discharge reaction of a nickel-cadmium battery is given as follows. 2 NiOOH + 2 H Cd Charged 2 Ni(OH)2 + Cd(OH) 2 Discharged During discharge, the positive electrode is the cathode. The nickel oxyhydroxide active material is reduced to nickel hydroxide. Simultaneously, on the negative electrode, or the anode, the cadmium metal is oxidized to cadmium hydroxide. As the oxidation and reduction reaction continues, the voltage decreases. When most of the active material is consumed, the voltage declines more rapidly. Eventually the cut-off voltage is reached and the discharge stops. During charge, the reverse reaction takes place. As the active material re-charges the voltage increases. It continues to increase as active material accepts charge current. Eventually, the cell voltage rises to a level where hydrogen is evolved at the negative electrode and oxygen is evolved at the positive electrode. When this occurs, it is referred to as overcharging. Water is consumed in the electrolyte when gas exhausts from the cell. The battery maintains its state of charge by continuous float charging at the recommended set point voltage. By limiting the set point charge voltage as prescribed by the installation and operation manual, the eventual float charging current decreases and is maintained at low level. As a result, the water losses can be kept at a minimum. In this way, the Tel.X maintains a high state of charge and eliminates water topping over its useful life. Referring to charge/discharge reaction above, note that the KOH, a component of the aqueous electrolyte, is not mentioned in the reaction formula. This is because it is neither consumed nor produced during charge or discharge. Its only function is ion transference. In other words, it is a liquid wire that continues to support the electrochemical reactions with the same level during the discharge or the charge process. This is one main reason why electrode corrosion in the Tel.X is eliminated. According to the reaction, water (H 2 O) is produced during charge and consumed during discharge. With the flooded design of the Tel.X, the volume of electrolyte is large enough so that the change in its concentration is relatively small. The specific gravity is not affected in any significant way. With a relatively stable electrolyte concentration, a low internal resistance can be maintained even at the end of discharge. This results in the enhanced feature of the Tel.X to be fully discharged and utilize its active material well. This is a main reason why the Tel.X has the enhanced feature of only a minimal derating of discharge performance at very low temperature since the risk of freezing electrolyte is decreased. Thus, through its electrochemistry, the Tel.X battery string has a very stable behavior, a long life, a high level of performance in a wide range of temperature and a much greater resistance to abuse conditions than lead-acid batteries. 5

6 Tel.X construction 3 Tel.X construction 3.1 Cells and modules A Tel.X module (or battery block) is constructed using single cells connected in series. The completed module assembly utilizes handles, covers and a stainless steel cradle. Handles provide two lifting points on each end of the module. Made of fabric, they can be positioned out of the way during installation. Module covers are held securely to the module providing complete protection from dirt, moisture and inadvertent short-circuiting. Intercell links complete the series connections of each cell in the module. They are nickel plated and NoOx is applied to each. Tabs carry the current from each plate (both positive and negative) to the terminals and are permanently welded to the terminals and the plates. H Cell vent allows the cell to vent gases, maintains 2 psi internal pressure and prevents spilling of electrolyte. Terminals provide a connection surface to carry the current from the cell. They are secured to the cell top with a clamp ring and sealed using o-rings. It uses an M6x1 bolt and is compatible with a standard ¼" (6.4 mm) ring terminal. Separator system keeps the plates isolated from each other and makes electrolyte available, in its highly porous structure, between the plates. Negative plate uses cadmium active mass to provide useful capacity. The width (W) and height (H) are fixed at 105 mm (4.125 ) and 254 mm (10.0 ), respectively, but the length (L) varies depending on how many cells are assembled in the module. See the Tel.X product data sheet for complete details. L W Positive plate uses nickel active mass to provide useful capacity. Cradle mechanically finishes the battery module assembly (or battery block). It s a welded construction of stainless steel. 6

7 3.2 Battery string Figure A typical 48 V nominal battery string is shown. It uses cable connections to allow front accessible connection points during field assembly. A Tel.X battery string is assembled using modules and various interconnection types. The assembly in Figure shows a typical 48 V nominal battery string. There are 4 modules interconnected. With a total of 38 cells connected in series (for a normal 48 V system), three of the modules are 10-cell and one is an 8-cell and in this case they are placed adjacent to each other. The cables use 6 AWG (13.3 mm 2 ) untinned copper with ¼" (6.4 mm) ring lugs that are nickel plated and crimped on each end. A heat shrink finishes each. The cables are normally routed from the back of one module to the front of another. This allows a front accessible connection point. In some cases, a back to back connection is used in order to finish the string with front connecting points for the power bus. 6 AWG (13.3 mm 2 ) cable, back to front connection 6 AWG (13.3 mm 2 ) cable, back to back connection (-) bus connection M6x1 bolt and washer (+) bus connection Another module connection method is shown in Figure When modules are placed in line with each other, a strap link is used. It s nickel plated metal and has an insulation sleeve. Any variation of module sizes can be used for a string. When a 24 V nominal assembly is made, 19 cells are used. Only use the same Tel.X type within a string assembly. However, connecting a Tel.X string on a power bus with other technologies and other size Tel.X can be considered. See the section Paralleling with other battery string technologies. Figure When inline modules are placed, a strap link is used to interconnect. 7

8 Features and benefits 4 Features and benefits The Tel.X design provides long and reliable life in standby applications without requiring regular maintenance. These are the main factors that make its total cost of ownership the lowest. 4.1 Long life Industrial nickel-cadmium batteries continue to demonstrate operating life in excess of 30 years on continuous float charge and in uncontrolled environments. For example, they have been used for nearly a century in outdoor rail signal applications where they have an excellent track record protecting life and valuable property. There are many examples of year old batteries capacity test results consistently higher than 90%. visual inspection, no other regular maintenance is required. 4.4 Resistance to electrical abuse Abusive conditions that will permanently damage lead-acid batteries will have little to no effect on Tel.X batteries. Occasional overcharging may result in more water usage but will have no effect on life. Undercharging or lack of charging during extended storage may lead to a temporary loss of capacity due to self discharge. This loss is reversible and full battery capacity will be restored after proper charging. The battery can be discharged completely and left with a load for days without damage. After inflicting the Tel.X with all the common abusive conditions it will re-charge, float charge and discharge normally. For more details, see sections Special operation and Abusive operation. 4.2 Reliability Nickel-cadmium batteries are the batteries of choice for the world s airlines and rail transit systems, and are generally used when reliable power is required to protect people s lives, valuable property or to avoid costly downtime. Tel.X batteries are reliable because of their stable chemistry. They do not suddenly fail and the most common lead acid ailments such as corrosion, plate growth and sulfating are not present in this battery system. Based on the long field history of nickelcadmium batteries and using standard calculation techniques, the MTBF results indicate more than 1,000,000 hours. 4.3 No watering maintenance When the Tel.X is operated as recommended (refer to Saft I/O manual) in a standby power application, no watering maintenance will be required. This is true for all environments of outside plant remote terminal applications. Several field test batteries and ongoing lab test results, operating at an average temperature of + 40 C (+ 104 F) were conducted. Results indicate that the battery could be left for over 20 years without a top up. Aside from normal power routines like checking bus voltage and 8

9 Cell voltages 5 Cell voltages Figure 5.1. Typical voltage spectrum of the Tel.X. Cell Voltage The nominal voltage for the nickel cadmium couple is 1.20 V per cell. This value was originated by the normal mid-discharge level of voltage during a nominal discharge rate. It is characterized over a wide range of cell designs and over a wide range of applications. In this way, it is a generic value. It is mostly used where nominal estimations about some characteristic metrics are made like Wh or Wh/l. End of Discharge Voltage Nominal Voltage Average Discharge Voltage Open Circuit Voltage In a more practical look, the actual cell voltage values can vary depending on the mode of operation. Figure 5.1 shows the typical voltage spectrum range of the Tel.X based on a few modes of operation giving cell values and string values scaled for a 48 V nominal system. Float Voltage Reconditioning Charging V String Voltage (38 cells) The average discharge voltage is in the range of 1.23 to 1.26 V per cell (46.7 V to 47.9 V) for discharge rates equal to 3 to 12 hours of runtime and after 24 hours of re-charge time. See Figure 7.1 in the section Discharging for typical discharge voltage curves. There are two ranges for charging the Tel.X. The typical in service charging method uses a single set point voltage between 1.43 to 1.45 V per cell (54.6 V to 55.1 V). At this single set point, the string is re-charged following a discharge event as well as float charged during standby operation. However, in a special procedure of high voltage overcharging (for details see Reconditioning charge section), the cell voltage will be in the range of 1.65 V per cell when completing the charge. 9

10 Capacity and baseline performance 6 Capacity and baseline performance For telecommunication batteries like the Tel.X, capacity is commonly measured in ampere-hours (expressed using Ah). This corresponds to the quantity of electricity that can be supplied under specified conditions. On discharge, it is the amount of stored chemical energy delivered to a load. For a constant discharge current, it is equal to the value of current multiplied by the total time of discharge. The symbol C is used for capacity. Under specific conditions of test, the value of C varies since the available capacity from a battery is dependent on the charging method used, the temperature of the battery and the rates of charge and discharge. For the Tel.X, two baseline values of C are defined based on different industry standards. Table 6.1 summarizes the test conditions that establish the baseline performance values for two industry references. The industry reference of GR-3020 includes the generic requirements for nickel-cadmium batteries used in the outside plant telecom applications. The capacity evaluated in accordance with GR-3020 establishes a baseline level of performance. This value of capacity is indicative of the level of performance when used in telecom applications while using ideal test conditions. The symbol C 8 is used to represent this value since the test conditions evaluate the level of capacity to provide 8 hours of runtime. The baseline performance is most useful for comparisons across product lines in order to contrast their relative performance differences. It is also used to establish standard discharge curves. The actual performance can deviate from this baseline value depending on the rate of discharge, conditions of charging (available current, voltage set-point and duration) and battery temperature. In practical use, the C 8 capacity is used as a baseline value. It is adjusted since the actual capacity varies due to the departure from standard conditions of test. For example, telecom applications are normally operating the battery in standby mode that includes long periods of charging (or float charging). This deviation from 24 hours of charging slightly reduces the available capacity due to the prolonged charging effect. As a result, published values of capacity are nominally lower than the baseline value. This value is referred to as the nominal capacity and uses the same symbol, C 8. The nominal capacity is referenced as the 100% performance level of the Tel.X. The industry reference of IEC is an industrial specification and includes the requirements for flooded nickelcadmium batteries. This method of test establishes the C 5 capacity. It represents the best available capacity of the Tel.X due to a constant current charging method with no upper voltage limit combined with a lower end of discharge voltage. The C 5 capacity is referred to as the rated capacity. It is rarely used as a baseline performance reference with regards to telecom applications. Table 6.1. Definition of baseline performance of the Tel.X at 25 C (77 F). Charge Discharge Industry Reference Associated Symbol Type Temp. Time Current (A) Voltage limit* Current (A) EODV** GR-3020 C 8 Telecom IEC C 5 General * Volts per cell ** End of discharge voltage per cell C (77 F) 20 C (68 F) 24 h 0.15 C C h 0.20 C 5 none 0.20 C

11 Discharging 7 Discharging The ability to utilize the charged capacity while discharging is a function of a few main factors when operating at + 25 C (+ 77 F). Level of current; the higher the current the lower the available capacity. Level of cutoff voltage; the higher the cutoff voltage the lower the available capacity. Based on standard conditions of test that establish the baseline performance, Figure 7.1 shows the typical discharge voltage characteristics at different rates of discharge. The Tel.X is designed and suited for long runtimes. This is apparent when comparing the 0.25 C 8 A curve with the 1 C 8 A curve, where in this range the Tel.X utilizes more than 95% of its stored capacity. Additionally, it utilizes more than 80% of its nominal capacity at the 0.5 C 8 A rate to an end voltage of 1.10 V per cell (42 V per string). That is equivalent to about 1.6 hours of runtime. When the current is increased to the 1 C 8 A rate, the available capacity decreases to approximately 20% to the same end voltage. That s equivalent to approximately 12 minutes of runtime. The available capacity is a function of discharge rate and end voltage. This is shown in Figure 7.2. It illustrates the available capacity (% of C 8 ). It is shown that the charge capacity is utilized above 80% at 2 hour runtimes and higher for 1.10 V per cell. Rate tables are used to summarize performance and provide useful values for sizing. Values of constant current and constant power are included. Refer to the Tel.X product data sheet for the published performance. The available capacity is also a function of the battery temperature. As the temperature decreases below + 25 C (+ 77 F), the ability to utilize the charged capacity decreases. This is due to an increase in the cell s internal resistance. Figure 7.3 shows several discharge curves at the 8-hour rate (0.125 C 8 A or C 8 /8A). The rate of decrease of available capacity increases faster as the temperature decreases below 0 C (32 F). For further details about temperature and performance, see section Effect of temperature on performance. Figure 7.1. The voltage characteristics of the Tel.X are shown with typical discharge curves at 25 C (77 F) Average Cell Voltage C 8A (C 8/12) C 8A (C 8/8) 0.25 C 8A (C 8/4) 0.50 C 8A (C 8/2) 1 C 8A (C 8/1) % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% Capacity (% of C) 8 ) Figure 7.2. The available capacity of the Tel.X as a function of discharge rate and end of discharge voltage is shown at 25 C (77 F). 110% Available Capacity (% C8) 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 1.14 V per cell 1.10 V per cell 1.05 V per cell 1.00 V per cell 0% Hours of Runtime Figure 7.3. The voltage characteristics of the Tel.X at the C 8 A (8-hour rate) at different temperatures V String Voltage % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% Capacity (% of C 8 ) 25 C (77 F) 0 C (32 F) - 20 C (- 4 F) V String Voltage Average Cell Voltage 11

12 7.1 Internal resistance The internal resistance defines how much voltage change will occur when a load is applied or a change of load is applied. The calculated product of the applied current, in amps, and value of internal resistance shown in Figure estimates the cell voltage drop, in mv per cell, immediately after the application of the load. The value of internal resistance depends on the type of Tel.X cell. As the capacity increases, the internal resistance decreases. The internal resistance also varies with the state of charge and is non-linear when under a continuous load. It varies by approximately ±8 % in the useful capacity range of the Tel.X depending on the state of charge reached during the continuous mode of operation (discharge or charge). Figure gives the average internal resistance including the inter-cell connections of each Tel.X cell type. It indicates a ±8 % window of values. For an example, to estimate the internal resistance of a 48 V nominal battery string, the average value of internal resistance multiplied by 38 cells is suitable. Figure The average internal resistance of the cell is labeled for each Tel.X type at 25 C (77 F) with inter-cell connections included. The maximum variation of ±8 % is indicated by the limit bars and includes the state of charge and mode of operation factors. milli-ohms per cell TLX 80 TLX 100 TLX 150 TLX Maximum inrush charge current In the case where the rectifier current capacity or control does not limit the re-charge current, the Tel.X will accept charge current limited by its internal resistance. When powered on, the inrush charge current will have a maximum value over a few seconds and will decrease rapidly over a few minutes as charge continues. The value of this inrush charge current depends on the open circuit voltage of the battery string. The open circuit voltage varies depending on the state of charge of the battery string, i.e., delivered with standard discharged state or delivered with fully charged state. The state of charge will also depend on the period of time the string was in storage and at what temperature it was stored at. See Table for a summary of maximum inrush charge currents at 20 to 25 C (68 to 77 F). The inrush values are given for the normal operation parameters of 1.43 Vpc charge set point (54.4 V on a 38-cell string) and maximum storage times (see Tel.X Installation and Operation Manual for more details). 12 Table The maximum inrush currents for the Tel.X. Type Delivered standard (10% SOC) Delivered charged (full SOC) Less than 1 week storage (Amps) 1 year of storage (Amps) Less than 1 week storage (Amps) Values are ±9% depending on normal variation of cell internal resistance. 2 months of storage (Amps) TLX TLX TLX TLX

13 Charging 8 Charging Tel.X battery strings can be charged with constant voltage or constant current. In telecom applications, constant voltage is the common method used. Single set point rectifiers are normally installed. In this case, the rectifiers share the DC output current by providing charge current to the battery strings and discharge power to the telecom load. Constant voltage charging methods are most appropriate when operating the Tel.X in a standby application where emergency power is provided infrequently. Constant current is not commonly used with telecom applications. Considered as an optional way of charging, constant current is the best way to get the Tel.X battery string fully charged and in the shortest period of time. This method may require off-line charging or implementation of an auxiliary charging device while installed in the telecom application. Constant current charging methods are most adequate where frequent and deep discharge cycling may be encountered or a reconditioning charge is required. See Chapter 10 concerning Gassing and Table Constant voltage charging For constant voltage charging, several rectifiers connected in parallel may be wired or plugged in to the main DC bus. Similarly, several battery strings may be connected to the same bus sharing the available re-charge current. This method employs a single set point voltage level and typically does not include current control. Understanding that there is an operating tradeoff between water consumption and set point voltage is important. Maintaining the voltage as low as possible minimizes the amount of overcharge and as a result water consumption will be at a minimum. But, at low voltage set point, after a discharge it will take longer to bring the batteries back to full capacity. In this case, the batteries may, for some period, operate below 100% state of charge. If frequent discharge cycling is encountered, the available capacity may operate at below 100% state of charge for a longer period of time. This will not reduce battery life, but full battery capacity may not always be available. The charging voltage should therefore be set according to the Figure Constant voltage re-charge characteristics of the Tel.X at 25 C (77 F). 48 V String Voltage Rate Factor %C 8 Available Capacity % 120% 100% 100% 80% 80% 60% 60% 40% 40% 20% 20% 0.20 C 8 current limit current limit 0.20 C 8 current limit 0.10 C 8 current limit current limit 0.10 C 8 current limit A = (Rate Factor) x (C (C 8 8 )) 0% 0% Hours recommended set point. This will obtain a high level of recharge in the shortest amount of time and keep the water consumption at a normal level. The Tel.X is designed to not require water additions over its useful life if operated within recommended limits. Table Single set point voltage for the Tel.X. Cell 24 V nominal V nominal Number of Cells in series Recommended set point Maximum set point Minimum available charging current for each battery string Minimum re-charge time with minimum available current Operating limits of the Tel.X are given in Table Operating within the maximum and minimum limits allows the Tel.X to perform with little deviation from published performance while maintaining maintenance free operation. Figure shows the re-charge 0.10 C 8 A 24 h Cell Voltage 13

14 characteristics for constant voltage set point of 1.45 V per cell and at 25 C (77 F). As the charge continues the state of charge increases and eventually the current will decrease. Temperature Compensated Voltage control (TCV) Temperature compensated voltage control is not recommended. The Tel.X should have its set point voltage at one level no matter what the operating temperature. With the voltage set at one value, the current will vary as the battery temperature changes. This is normal and it is also beneficial since the changing current compensates appropriately to keep the battery string at a high state of charge. If temperature compensated voltage control is active, it will not be detrimental to the Tel.X however the battery string may operate at less than 100% state of charge. This is because when temperature compensation is active, it reduces the set point voltage automatically when the temperature increases. When this happens, the current going into the battery string, during float charge, decreases. Since the Tel.X actually needs higher current at higher temperature during float charge, with a relatively lower current, the state of charge will eventually stabilize lower. As a result, at the same level of discharge power, the runtime will decrease. 8.2 Float operation For standby operation in telecom applications, battery strings normally float charge over 99% of their useful life. The Tel.X was designed for this type of operation. When operated at the recommended set point voltage, it is optimized to have the best tradeoff between re-charge time, state of charge and water consumption. The purpose of float charging is to maintain a high state of charge during standby operation. During float charging, the float current stabilizes to offset the selfdischarge. Any excess float current is overcharging and consuming water. After a discharge event and following re-charge, the float current is, for all practical purposes, stabilized after 1 week. A measurement of the float current is a good way to determine the Tel.X state of health. As it ages, the self discharge increases which, in turn, increases the float current. If the value exceeds the normal sanction, then further investigation is necessary. If the string is determined to have a poor state of health, the eventual replacement of the Tel.X battery string can be handled on a routine basis over a few months time as there is no risk of unsafe operation even when the string is unhealthy. If temperature compensated voltage is operated on the Tel.X, the reduced state of charge is reversible and can be recovered. A reconditioning charge method can be implemented to recover the capacity most efficiently. Parallel connected strings and re-charging Make sure to take care about parallel connected battery strings and the distribution of current, particularly when installing and powering battery strings with a low state of charge. See Appendix A Parallel currents for more details. Never connect and power battery strings in parallel with unknown or different states of charge. In this case, if connected, the strings will pass a high level of current until the voltages equilibrate. Table Typical float current values for the Tel.X. Typical float current at 40 C (104 F) is normally less than Battery requires action if the float current is persistently measured to exceed at any temperature TLX 80 TLX 100 TLX 150 TLX ma 73 ma 106 ma 130 ma 380 ma 490 ma 700 ma 860 ma 14

15 8.3 Reconditioning charge A high voltage charging method is required to conduct a reconditioning charge. See section 8.4 concerning the procedure. A reconditioning charge may be necessary for batteries that have been subjected to various forms of electrical abuse or irregular operating conditions such as: long storage periods (more than 1 year) frequent deep discharges with limited constant voltage recharge cycling at high temperatures with insufficient recharge Table Charging current TLX 80 TLX 100 TLX 150 TLX 180 Capacity C 5 (Ah) Current C 5 (A) Figure High voltage charge As Tel.X batteries represent a relatively high initial investment, batteries that appear to have low capacity should not be discarded. A reconditioning charge may completely restore the battery to full capacity. If facilities for such work are not available within your company, call your Saft representative for advice V C-rate %C 8.4 Reconditioning charge procedure In case we need to check the IEC capacity (IEC 60623) the following procedure must be applied: 1. Make sure that the string is discharged fully to 1.00 V/cell with C/5A and each cell is at the same SOC. 2. Charge at constant voltage with a maximum voltage set point of 1.65 V per cell and current limit of C 5 /5A as mentioned in the Table Continue charging for a minimum of 30 hours (a maximum of 1 week). See Figure Maximum 30 minute pause is allowed. 5. Apply the load mentioned in the Table and discharge to a cutoff of 1.0 V per cell (measured at the string terminals) and verify that the 5 hr of runtime are delivered. 15

16 Effect of temperature on performance 9 Effect of temperature on performance As the temperature deviates from 25 C (77 F) the Tel.X s ability to charge and discharge is affected. The impact of temperature on the performance is summarized in Table 9.1. The overall result of the summarized factors is a deviation from the baseline performance. To estimate expected performance in an uncontrolled environment, a temperature derating factor should be used when sizing the capacity. Figure 9.1 gives the derating factors for the Tel.X in the range of - 20 C (- 4 F) to 40 C (104 F). The derating factors given in Figure 9.1 are estimated using Telcordia GR and IEEE test methods and are compiled in order to provide practical approach to estimating the Tel.X performance. Table 9.1. The main factors that impact the performance of the Tel.X with a change in temperature are summarized. Less than 20 C (68 F) 20 C to 25 C (68 F to 77 F) Higher than 25 C (77 F) Charging factors Float charging factors Charge efficiency increases resulting in higher state of charge with the same level of current Charge acceptance decreases, due to an impedance increase, resulting in lower charge current at the same voltage Discharging factors Voltage decreases, due to an impedance increase, resulting in less utilized charged capacity to the same end voltage Baseline performance according to published values Charge efficiency decreases resulting in lower state of charge with the same level of current Charge acceptance increases, due to an impedance decrease, resulting in higher charge current at the same voltage Voltage slightly increases, due to an impedance decrease, resulting in slightly better utilized charged capacity to the same end voltage Figure 9.1. The temperature derating factors for the Tel.X are shown. They can be applied for published discharge rates of 4 hours to 24 hours. Temperature (ºF) % % of Published Performance 90% 80% 70% 60% 50% 40% 30% Temperature (ºC) 16

17 Gassing 10 Gassing During normal operation, hydrogen gas, oxygen gas and water vapor are exhausted through the cell vent. When exhausted, the water is incrementally consumed from the electrolyte. Water vapor is a result of evaporation. Hydrogen and oxygen gas results from electrolysis during periods of overcharging. It should be noted that gassing from electrolysis only occurs during overcharging and float charging. It will not occur during battery storage, normal discharging and normal re-charging Ventilation practice A Tel.X battery should never be installed in a sealed space without any ventilation. Industry specifications associated to ventilation practice can be found in GR 487 and EN Additionally, the gas recombination level of the Tel.X was tested in accordance with NFC It has a recombination level higher that 95 %. For GR 487, the maximum hydrogen gassing rates are given in Table 10. For EN , the ventilation equation is given in Table and the I gas parameters are given in Table The following tables provide information needed by the ventilation standards most commonly used in different areas of the world. The Tel.X uses a low pressure valve in the cell vent. This valve maintains approximately 1 to 2 psig (0.07 to 0.14 bars gauge) of internal cell pressure. The valve regulates the exhaust and reduces water consumption by increasing the oxygen recombination. The slightly higher cell pressure also reduces the rate of water evaporation. The primary mechanism of water consumption is gassing through electrolysis. During overcharging, electrolysis occurs with a fixed stoichiometry. That is, for every 3 Ah of overcharge, 1 cm 3 of water is consumed and dissociated into gas. And for every 1 cm 3 of water electrolyzed and exhausted, approximately 690 cm 3 of oxygen and 1380 cm 3 of hydrogen are generated on the positive and negative plates, respectively. Not all the gas generated on the plates is exhausted. A part of the oxygen and hydrogen gas is recombined back into water. When this occurs, the net reaction replenishes some of the water that was initially consumed. The gasses that do not recombine will eventually exhaust from the cell. During float charging the current is very low, the recombination rate is in excess of 95 % and the proportion of the current that generates oxygen gas and recombines back to water is quite large. The Tel.X operates as a standby battery and is float charging or overcharging at a low rate over most of its life. See Table 10 for maximum hydrogen gassing rates. The reported values were measured in accordance with GR Table 10. Tel.X measured maximum gassing rates. Operation type Floating Reconditioning Volts/ cell T (ºC / ºF) 25 / / / / 113 Table Forced ventilation for EN Cell type H 2 per cell (l/h) H 2 per 38 cell string (l/h) TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX TLX Equation (1) Q = (0.05) x (n) x (I gas ) x (C n ) x (10-3 )[m 3 / hour] n = Number of cells operating either in parallel and/or series I gas = See Table C n = Tel.X Nominal Telecom Ah Table Tel.X parameters for EN ventilation calculation. Operation type Voltage (V per cell) I gas (ma/c 8 Ah at 25ºC / 77ºF) Floating Reconditioning

18 Storage and shelf life 11 Storage and shelf life Tel.X batteries are shipped at 10% state of charge. The state of charge is set by what s commonly called a re-polarization charge. This low state of charge allows the Tel.X batteries to be stored for extended periods of time without maintenance. When stored at that level, the self discharge is very low. The maximum storage period, without maintenance, is 1 year if stored at - 20 C to 35 C (- 4 F to 95 F). While being stored, the Tel.X cell self discharges. As the cell self discharges its voltage will decrease. Figure 11.1 represents the average open circuit voltage (OCV) evolution of a cell over a period of 1 year. Day zero represents the same day the re-polarization charge set the state of charge at 10%. The self discharge rate will increase with higher temperature and decrease with lower temperature. As a result the measured OCV will vary compared to the values given in Figure Figure The measured evolution of the open circuit voltage (OCV), of the Tel.X, during a 1 year stand at 25 C (77 F) is shown. Open Circuit Voltage (V/cell) Days since 10% repolarization charge It is not recommended to store the Tel.X in a fully charged state. The main problem with storing at a high state of charge is the positive electrode self discharges at a different rate than the negative electrode. If this is allowed to continue for too long, the difference in the electrodes state of charge will grow. These effects are bigger with higher temperature. As a consequence, the available capacity, after charging with a constant voltage set point, may result in a lower available capacity. In order to recover this difference in electrode state of charge and return to normal expected capacity, a reconditioning charge may be necessary. See section Charge retention for more information about the impact of long storage in the fully charged state Charge retention Self discharge tests were conducted on the Tel.X in accordance with GR The performance level after storage was also evaluated and the Tel.X met the minimum required sanctions. Self-discharge is mostly due to electrochemical side reactions in the cell and the rate of self discharge depends on the storage temperature. Table Summary of charge retention results for Tel.X after 6 months of storage. C ( F) Retained Capacity (% of C 8 ) Actual Capacity (% of C 8 ) 23 (73) 81% 101% 45 (113) 31% 89% 18

19 With higher temperature, the self discharge rate increases. Before storage, the battery was fully charged. After 6 months in storage and without re-charge, the battery was discharged at the 8-hour rate to a cut-off voltage of 1.10 V/cell. This was the retained capacity. After, the battery was re-charged at 1.45 V/cell for 24 hours and immediately discharged at the 8-hour rate to 1.10 V/cell. This was the actual capacity. Table summarizes the results after storage at two temperatures for a new and unused battery. At 23 C (73 F) storage temperature, the retained capacity was 81%. That means that approximately 19% was lost due to self-discharge. The actual capacity, after storage, was found to be 101% of nominal capacity. At 45 C (113 F), the retained capacity was 31% or approximately 69% was lost due to self-discharge. In this case, the rate of chemical side reactions were increased with temperature, as expected. After a re-charge and discharge, the actual capacity was 89% of nominal capacity. This lower than nominal result suggests that storage, in the fully charged state, at high temperature should be avoided. Even so, the capacity is not irreversibly lost and can be recovered by performing a reconditioning charge. Figures and show the discharge characteristics of the retained capacity and after re-charging for the actual capacity. The results of this test demonstrated compliance to GR-3020: Charge retention after 6 months was 81% and well within the specified minimum of 50%. For the 45 C (113 F) test, reconditioning charge cycles were done in order to demonstrate the ability to recover capacity. After reconditioning, the actual capacity was recovered from 89% to 100% of nominal capacity. Figure After a 6 month storage in the full charged state, the discharge voltage as a function of %C 8 is shown at 23 C (73 F) and 45 C (113 F). These discharges determined the retained capacity after storage ºC (73ºF) 23 C 45ºC (113ºF) 45 C Voltage (V/cell) Figure The first discharge cycle after the 6 month storage is shown. These discharges determined the actual capacity after storage ºC (73ºF) 23 C 45ºC (113ºF) 45 C 1.35 Voltage (V/cell) Test /01/2008 Cycle Capacity (%C 8 ) Test /01/2008 Cycle Capacity (%C 8 ) 19

20 Service life 12 Service life A battery s useful life can be characterized by the amount of cycles it can perform, when mostly in cycling mode or the amount of time it can operate, when mostly in standby mode. Telecom applications can involve either mode, but in most cases, it s normally more indicative of a standby mode. The expected calendar life normally limits the useful life of a Tel.X in telecom applications. The end of life (EOL) is typically defined by a 20% loss of capacity. This irreversible capacity leaves only 80% of it s beginning of life performance. For the Tel.X, as the aging and loss of capacity continues, it experiences linear degradation. This means that the Tel.X will continue to provide useful power in a predictable way over its useful life and beyond. For comparison, when VRLA s have lost 20% of capacity, the available power may decrease very rapidly after. It can be unpredictable and the risk of a sudden death event may be eminent. Figure 12.1 compares the general trend of capacity loss over their useful life Effect of temperature on calendar life Tel.X batteries are designed to last 20 to 30 years at 25 C (77 F). At higher operating temperatures, the battery s life will be reduced. However, the temperature effect on life is much lower for the Tel.X than it is for a leadacid battery. At lower temperature, the battery life is expected to be as long as the 25 C (77 F). According to various independent organizations such as Eurobat, IEEE and Telcordia (Formerly Bellcore), for approximately every 10 C (18 F) increase in battery temperature above room temperature, the reduction in life for a lead-acid battery is 50%. The corresponding life reduction for the Tel.X battery is only 20%. This reduction in lifetime for a Ni-Cd battery and, for comparison, VRLA battery is illustrated graphically in Figure Figure shows the lifetime of Tel.X and of a VRLA battery at different temperatures, as typically used in remote telecom applications. 20 Figure The comparison of end of life characteristics of the Tel.X and VRLA. Available Capacity 80% End of Life VRLA with sudden death Time in standby mode Tel.X experiences linear degradation Figure The comparison of minimum calendar life as a percentage of 25 C (77 F) life at elevated temperature. Temperature (ºF) % of 25 C (77 F) Life % 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Temperature ( C) (ºC) Tel.X VRLA Figure Years of lifetime comparison of a 10 year design VRLA with Tel.X. Years of Life Years of Life Temperature (ºF) VRLA Tel.X Temperature (ºC) ( C)

21 Special operation 13 Special operation 13.1 Cycling Batteries in telecom applications are generally on float charge and normally see very few deep discharges. The effect of cycling on the life of a Tel.X battery in a typical telecom application is therefore negligible. The Tel.X is optimized for continuous float charging conditions. If it is operated in a frequent cycling application, it will be necessary to apply a higher charging voltage to maintain the battery at a high state of charge (the same applies to lead acid batteries). The required charging voltage and frequency to apply the higher charge voltage will depend on depth of discharge and frequency of discharge. The level of charge voltage required will often be higher than the normal voltage available in telecom applications. Offline charging or auxiliary charging devices may be necessary in this case. Frequent deep cycling of batteries on float charge at 1.43 V per cell (54.4 V for a 38 cell battery) will gradually decrease their capacity. The decreased capacity is temporarily faded and is reversible. Full capacity can be restored with a reconditioning charge. Likewise, repeated cycle testing (deep discharges) in the field of the same battery string with only float voltage recharge should be avoided. Each recharge will gradually return less capacity to the battery, particularly at high temperatures. If more than one deep discharge has been performed in succession, a reconditioning charge may be needed to bring the battery back to full capacity. Repeated cycle testing does not represent normal telecom operating conditions and should only be conducted in a lab or a workshop with appropriate reconditioning chargers Temperature shock The Tel.X can withstand temperature extremes without compromising its performance. Two tests were conducted using Telcordia GR-63 as a guideline. Figure compares the discharge voltage curves after temperature shock at + 70 C (+ 158 F) and - 40 C (- 40 F) with the baseline performance before the shock. In both cases, the performance compared almost identically with the baseline. The actual capacity and mid-discharge voltage, in both cases, were the same as the baseline; 100% of C 8 and 1.25 V/cell, respectively. In another extreme test example, it was shown that the Tel.X could start operating after being dormant or cold soaked at - 40 C (- 40 F) for an extended period of time. The rationale behind this test is to demonstrate that the Tel.X is compatible in a few extreme operational scenarios. The scenarios include (a) initial installation in the winter after a cold storage and (b) restarting a system (or restoring A/C power) after a power outage or disruption of service during the winter. In both cases, the equipment could begin charging the battery at a very cold temperature. With the test conducted in accordance with GR-3108 Class 3 Equipment, the results showed that the battery can operate without a safety event, without sustaining damage and without any deterioration of functional performance. Figure shows the behavior of the battery at startup. As charging continued, the environment temperature was allowed to increase to 20 C (68 F) over a period of 7 days. Approximately 126% of its nominal capacity was accepted in this period. Figure The cell voltage as a function of discharge capacity is compared with its baseline performance after a temperature shock at both - 40 C (- 40 F) and 70 C (158 F). The performance difference is not noticeable. Cell Voltage Figure The first 6 hours after applying power to the TLX- 150 at - 40 C (- 40 F) are shown. It accepted a significant level of current at the cold temperature. Current (A) Baseline Baseline After 70ºC After (158ºF) 70 C Shock After -40 C - 40ºC Shock (- 40ºF) Shock % 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% Temperature %C 8 Test /02/2008 Cycle Time (h) Current Confidential - SAFT PROPRIETARY 7/3/10 / Excel Graphs BW-2 SD.xls / Figure Temperature ( C) 21

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