Product Guide An Invensys company
Contents Page I/ The principle of the gas-recombination battery... 2 II/ Charge characteristics... 4 III/ Electrical performance tables... 5 IV/ Battery calculations Float applications... 12 Accidental deep discharge... 13 Effect of temperature on capacity... 13 V/ Installation of the battery Warning... 14 Unpacking the battery... 14 Setting up the battery stands... 14 Installing in a cabinet... 14 Connection of the cells... 14 Installation on standard metallic stand... 15 VI/ Battery storage Storage conditions... 16 Storage time... 16 Determining the state of charge of the battery... 16 Recharging stored batteries... 16 VII/ Commissioning... 16 VIII/ Maintenance... 16
POWERSAFE VE Range 1 TYPE voltage (Volts) Capacity (Ah) to 1.80V at 10 h rate at 20 C Capacity (Ah) to 1.75V at 20 h rate at 20 C Length in mm Width in mm Heigth over protection in mm 12 VE 38(3) 12 35 38 166 156 203 14.3 M5 6+/-10% 12 VE 38(3) 8 mm wrench 12 VE 50 12 46 50 218 164 220 18.9 M6 9+/-10% 12 VE 50 10 mm wrench 12 VE 60 12 56 62 271 164 220 22.9 M6 9+/-10% 12 VE 60 10 mm wrench 12 VE 75 12 68 74 314 164 220 26.7 M6 9+/-10% 12 VE 75 10 mm wrench 12 VE 90(3) 12 79 86 360 164 227 31.3 M6 9+/-10% 12 VE 90(3) 10 mm wrench 6 VE 110(3) 6 102 110 191 206 236 21.4 M8 16+/-10% 6 VE 110(3) 6 VE 140(3) 6 132 140 243 206 234 27.9 M8 16+/-10% 6 VE 140(3) 2 VE 170 2 152 170 128 165 220 10.2 M6 9+/-10% 2 VE 170 10 mm wrench 6 VE 155(3) 6 157 174 278 178 258 32.2 M8 16+/-10% 6 VE 155(3) 6 VE 180(3) 6 173 180 296 204 234 34.1 M8 16+/-10% 6 VE 180(3) 2 VE 225 2 200 225 110 208 260 13.9 M8 16+/-10% 2 VE 225 2 VE 310 2 275 310 142 208 260 18.5 M8 16+/-10% 2 VE 310 2 VE 400 2 350 400 195 208 260 24.0 M8 16+/-10% 2 VE 400 2 VE 450 2 400 450 195 208 260 26.2 M8 16+/-10% 2 VE 450 2 VEO 450(1) 2 400 450 195 208 260 26.8 M8 16+/-10% 2 VEO 450(1) 2 VE 540(2)(3) 2 519 540 296 204 240 34.7 M8 16+/-10% 2 VE 540(2)(3) 2 VE 550 2 500 550 238 208 260 32.1 M8 16+/-10% 2 VE 550 Weigth in kg Connexion Screw Torque (Nm) TYPE (1) cells with 4 posts - (2) Cells with 6 posts - (3) with integral handles
I/ The principle of the gas-recombination battery In a gas-recombination battery, the quantity of active materials in the plates and the alloys used in the manufacture of the grids which support the active materials, are such that oxygen is first released from the positive plate. The internal design of the battery ensures that this oxygen diffuses toward the negative plates where it reacts chemically with the spongy lead of the negative active material to form lead oxide. The sulphuric acid contained in the electrolyte is composed then reacts with this lead oxide to form lead sulphate and water. The lead sulphate thus formed is transformed electrochemically into lead to return sulphuric acid. This state of equilibrium will remain for as long as the battery remains fully charged. Schematically, we then have the following reactions : At the end of the charge or if overcharging, oxygen is released at the positive plate in the form of a gas. H 2 O 2H + + 1/2O 2 + 2e - The oxygen diffuses across the separator to the negative plate The oxygen reacts chemically with the spongy lead of the negative plate to form lead oxide. Pb + 1/2O 2 PbO The sulphuric acid reacts with the lead oxide to give lead sulphate and water, and so part of the spongy lead is chemically discharged to the lead suplhate state and the water consumed at the positive plate is regenerated. PbO + H 2 SO 4 PbSO 4 + H 2 O The spongy lead which was chemically discharged at the negative plate is re-charged chemically. PbSO 4 + 2H + + 2e - Pb + H 2 SO 4 These reactions occur within each cell, and an equilibrium is thus achieved. Electrolyte Conventional cell Oxygen and hydrogen escape to the atmosphere Powersafe Oxygen evolved from positive plate transfers to negative and recombines to form water. Separator 2
Construction : These reactions can take place only by using : - plates composed of special alloy with several components which provide the plate grids with high mechanical strength and a high level of hydrogen overvoltage. - an appropriate ratio between positive and negative active materials. - fiberglass separators manufactured from borosilicate, giving them excellent resistance to high temperatures and to sulphuric acid.the high level of porosity of these separators is used to retain the quantity of electrolyte necessary for cell operation, but without any free electrolyte. - a pressure relief valve which allows gas to be released if necessary in the case of an accidental overcharge. ➀ Grey lid in ABS heat-welded to the container ➄ Terminals with threaded insert for maximum conductivity and ease of installation ➅ Gas-relief system ➆ Negative plate ➁ ABS container highly resistant to impact and vibration ➂ Positive plate ➃ Separator 3
II/ Charge characteristics The cells in the Powersafe VE product range must be charged at a constant voltage At an ambient temperature of 20 C, the batteries should be charged at 2.27-2.30 volts per cell. It is not necessary to limit the current as this will be governed by the maximum output available from the charger until the voltage limit is reached. Increased maintenance is recommended as the battery approaches end of useful life. The charging voltage of 2.27-2.30 volts should also be used for float charging. To achieve nominal performance characteristics, it is recommended to adjust this value to suit the ambient temperature, as indicated in the following table : Temperature 0 C 10 C 20 C 25 C 30 C 35 C (reference T ) Float charge voltage 2.36-2.39 V 2.31-2.34 V 2.27-2.30 V 2.25-2.28 V 2.23-2.26 V 2.21-2.24 V Under these conditions a full recharge will be completed in approximately 72 hours. Fast recharge : Recharge time can be reduced by increasing the charge voltage to 2.40 Volts per cell and it is possible, depending on the depth of discharge, to halve the recharge time. Under these conditions, however, the charge must be monitored and must be terminated when the charge current remains reasonably steady for 3 hours after the voltage limit has been reached.at the beginning of charge the current must be limited to 0.10C10 : 0.125C3(A). Ripple current : The ripple content of the charging current affects the life of the battery. It is recommended to limit the continuous ripple current to 0.05 C10 (in amperes) as recommended value (never exceed 0.10C10). Transient and other ripple type voltage excursions can be accommodated provided that, with the battery disconnected, the system peak to peak voltage including regulation limits falls within -+ 2.5 % of the recommended float voltage of the battery. 4
III/ Tables of performances Powersafe VE Discharge current in amperes End voltage : 1.60 V 12 VE 38 12 46.9 34.1 27.30 15.2 10.9 6.9 4.5 3.7 3.1 1.9 12 VE 50 12 61.9 45.0 35.9 20.0 14.3 9.0 5.9 4.8 4.1 2.5 12 VE 60 12 77.0 55.9 44.5 24.8 17.7 11.2 7.3 6.0 5.1 3.1 12 VE 75 12 92.9 67.4 53.4 29.8 21.2 13.4 8.8 7.2 6.1 3.7 12 VE 90 12 108.8 78.9 62.4 34.8 24.8 15.7 10.3 8.4 7.1 4.4 6 VE 110 6 120.4 86.4 68.6 40.4 29.1 19.0 12.5 10.4 8.7 5.4 6 VE 140 6 156.5 114.0 89.2 52.5 37.9 24.7 16.3 13.5 11.3 7.1 2 VE 170 2 194.9 142.0 110.0 62.0 44.0 28.8 19.4 16.2 13.6 8.5 6 VE 155 6 187 136 109 62.4 44.9 29.2 19.6 16.1 13.8 8.8 6 VE 180 6 187.0 136.0 110.0 65.0 47.0 31.1 20.9 17.3 14.6 9.1 2 VE 225 2 230.6 169.6 131.0 74.0 52.0 34.9 23.6 20.0 16.9 10.8 2 VE 310 2 311.5 233.6 180.0 102.0 72.0 48.1 32.5 27.5 23.3 14.8 2 VE 400 2 401.9 301.5 233.0 132.0 93.0 62.1 41.9 35.0 30.0 19.1 2 VE 450 2 452.2 339.1 262.0 148.0 105.0 69.8 47.1 40.0 34.2 21.8 2 VEO 450 2 461.2 339.1 262.0 148.0 105.0 69.8 47.1 40.0 34.2 21.8 2 VE 540 2 561.0 408.0 330.0 195.0 141.0 93.3 62.7 51.9 43.7 27.3 2 VE 550 2 531.0 391.0 319.0 185.0 131.0 87.3 58.9 50.0 42.8 27.3 Discharge current in amperes End voltage : 1.65 V 12 VE 38 12 46.2 33.6 27.3 15.2 10.9 6.9 4.5 3.7 3.1 1.9 12 VE 50 12 61.3 44.5 35.9 20.0 14.3 9.0 5.9 4.8 4.1 2.5 12 VE 60 12 76.4 55.5 44.5 24.8 17.7 11.2 7.3 6.0 5.1 3.1 12 VE 75 12 92.6 67.2 53.4 29.8 21.2 13.4 8.8 7.2 6.1 3.7 12 VE 90 12 108.8 78.9 62.4 34.8 24.8 15.7 10.3 8.4 7.1 4.4 6 VE 110 6 119.4 86.4 68.6 40.4 29.1 19.0 12.5 10.4 8.7 5.4 6 VE 140 6 155.2 114.0 89.2 52.5 37.9 24.7 16.3 13.5 11.3 7.1 2 VE 170 2 193.0 142.0 110.0 61.8 43.9 28.8 19.4 16.2 13.5 8.4 6 VE 155 6 186 136 108 62.3 44.8 29.2 19.5 16.1 13.7 8.8 6 VE 180 6 186.0 136.0 110.0 65.0 47.0 31.1 20.9 17.3 14.6 9.0 2 VE 225 2 230.6 169.6 131.0 74.2 52.4 34.9 23.6 20.0 16.9 10.8 2 VE 310 2 311.5 233.6 180.4 102.2 72.2 48.1 32.5 27.5 23.3 14.8 2 VE 400 2 401.9 301.5 232.8 131.9 93.1 62.1 41.9 35.0 30.0 19.1 2 VE 450 2 452.2 339.1 261.9 148.4 104.8 69.8 47.1 40.0 34.2 21.8 2 VEO 450 2 461.2 339.1 261.9 148.4 104.8 69.8 47.1 40.0 34.2 21.8 2 VE 540 2 558.0 408.0 330.0 195.0 141.0 93.3 62.7 51.9 43.7 27.1 2 VE 550 2 531.0 391.0 319.0 185.0 131.0 87.3 58.9 50.0 42.8 27.3 5
Discharge current in amperes End voltage : 1.70 V 12 VE 38 12 44.8 32.9 26.3 14.9 10.6 6.7 4.4 3.6 3.1 1.9 12 VE 50 12 58.9 43.2 34.5 19.6 14.0 8.8 5.8 4.7 4.0 2.5 12 VE 60 12 73.0 53.6 42.8 24.2 17.3 10.9 7.2 5.9 5.0 3.1 12 VE 75 12 87.7 64.4 51.4 29.1 20.8 13,2 8.6 7.1 6.0 3.7 12 VE 90 12 102.4 75.2 60.0 34.0 24,3 15.4 10.1 8.2 7.0 4.3 6 VE 110 6 115.5 84.5 67.6 40.4 29.1 19.0 12.5 10.4 8.7 5.4 6 VE 140 6 150.2 109.8 87.9 52.5 37.9 24.7 16.3 13.5 11.3 7.1 2 VE 170 2 187.0 140.0 109.0 61.8 43.9 28.8 19.4 16.2 13.7 8.6 6 VE 155 6 184 135 108 61.9 44.6 29.1 19.5 16.1 13.7 8.7 6 VE 180 6 185.4 135.7 109.9 65.0 47.0 31.1 20.9 17.3 14.6 9.0 2 VE 225 2 219.3 165.0 128.8 74.2 52.4 34.9 23.6 20.0 16.9 10.8 2 VE 310 2 299.0 227.4 177.4 102.2 72.2 48.1 32.5 27.5 23,3 14.8 2 VE 400 2 385.9 293.4 228.9 131.9 93.1 62.1 41.9 35.0 30,0 19.1 2 VE 450 2 434.1 330.1 257.5 148.54 104.8 69.8 47.1 40,0 34.2 21.8 2 VEO 450 2 438.6 330.1 257.5 148.4 104.8 69.8 47.1 40.0 34.2 21.8 2 VE 540 2 556.2 407.1 329.7 195.0 141.0 93.3 62.7 51.9 43.7 27.0 2 VE 550 2 509.0 380.0 311.0 185.0 131.0 87.3 58.9 50,0 42.8 27.3 Discharge current in amperes End voltage : 1.75 V 12 VE 38 12 43.4 31.7 26.3 14.5 10.4 6.7 4.4 3.6 3.0 1.9 12 VE 50 12 57.0 41.7 34,5 19.1 13.7 8.7 5.8 4.7 4.0 2.5 12 VE 60 12 70.7 51.7 42.8 23.7 17.0 10.8 7.1 5.8 4.9 3.0 12 VE 75 12 84.9 62.1 51.4 28.4 20.4 13.0 8.6 7.0 5.9 3.7 12 VE 90 12 99.2 72.5 60.0 33.2 23.9 15.2 10.0 8.2 6.9 4.3 6 VE 110 6 110.7 80.6 65.7 39.6 28.5 18.5 12.5 10.4 8.7 5.4 6 VE 140 6 143.9 104.8 85.4 51.5 37.1 24.1 16.3 13.5 11.3 7.1 2 VE 170 2 176.0 129.0 105.5 60.1 43.4 28,7 19.4 16.2 13.6 8.5 6 VE 155 6 178 132 105 61.1 44.1 28.8 19.3 15.9 13.6 8.7 6 VE 180 6 180.0 133.0 109.0 65.0 47.0 31.1 20.9 17.3 14.6 8.9 2 VE 225 2 210.3 158.3 124.4 69.8 50.2 33.8 23.6 20.0 16.9 10.8 2 VE 310 2 280.4 218.1 171.4 96.2 69.2 46.6 32.5 27.5 23,3 14.8 2 VE 400 2 361.7 281.4 221.2 124.2 89.2 60.1 41.9 35.0 30.0 19.1 2 VE 450 2 407.0 316.5 248.8 139.7 100.4 67.7 47.1 40,0 34,2 21.8 2 VEO 450 2 420.5 316.5 248.8 139.7 100.4 67.7 47.1 40.0 34.2 21.8 2 VE 540 2 540.0 399.0 327.0 195.0 141.0 93.3 62.7 51.9 43.8 26.8 2 VE 550 2 481.0 369.0 305.0 175.0 125.0 84.6 58.9 50.0 42.8 27.3 6
Discharge current in amperes End voltage : 1.80 V 12 VE 38 12 40.6 30.3 24.9 14.0 10.0 6.4 4.2 3.5 2.9 1.8 12 VE 50 12 53.4 39.9 32.7 18.4 13.2 8.4 5.6 4.6 3.9 2.4 12 VE 60 12 66.1 49.4 40.5 22.8 16.3 10.4 6.9 5.6 4.8 3.0 12 VE 75 12 79.5 59.4 48.6 27.4 19.6 12.5 8.3 6.8 5.8 3.6 12 VE 90 12 92.8 69.3 56.8 32.0 22.9 14.6 9.7 7.9 6.7 4.2 6 VE 110 6 102.9 76.7 62.7 37.7 27.6 18.3 12.3 10.2 8.7 5.4 6 VE 140 6 133.8 99.7 81.6 49.1 35.9 23.8 16.0 13.2 11.3 7.0 2 VE 170 2 160.8 122.6 95.6 56.8 41.2 27.4 18.5 15.2 13.0 8.0 6 VE 155 6 169 126 102 59.6 43.3 28.3 19 15.7 13.4 8.6 6 VE 180 6 171.0 130.0 107.0 63.7 46.3 31.1 20.9 17.3 14.6 8.9 2 VE 225 2 189.9 144.7 117.0 68.6 49.5 33.8 23.6 20.0 17.2 10.7 2 VE 310 2 249.2 199.4 161.2 94.6 68.2 46.5 32.6 27.5 23.4 14.7 2 VE 400 2 321.6 257.2 208.0 122.0 88.0 60.0 42.0 35.0 30.1 18.9 2 VE 450 2 361.7 289.4 234.0 137.3 99.0 67.5 47.3 40.0 33.9 21.3 2 VEO 450 2 379.8 289.4 234.0 137.3 99.0 67.5 47.3 40.0 33.9 21.3 2 VE 540 2 513.0 390.0 321.0 191.1 138.9 93.3 62.7 51.9 43.7 26.7 2 VE 550 2 440.0 344.0 289.0 171.0 124.0 84.4 59.0 50.0 42.4 26.7 Discharge current in amperes End voltage : 1.85 V 12 VE 38 12 36.4 28.0 22.8 13.3 9.3 5.9 3.9 3.2 2.7 1.7 12 VE 50 12 47.8 36.8 29.9 17.5 12.2 7.8 5.2 4.2 3.6 2.2 12 VE 60 12 59.3 45.6 37.1 21.7 15.1 9.6 6.4 5.2 4.5 2.8 12 VE 75 12 71.2 54.8 44.5 26.0 18.2 11.6 7.7 6.3 5.4 3.3 12 VE 90 12 83.2 64.0 52.0 30.4 21.2 13.5 9.0 7.4 6.3 3.9 6 VE 110 6 92.2 69.9 57.8 35.6 26.1 17.3 11.7 9.6 8.2 5.1 6 VE 140 6 119.9 90.9 75.2 46.3 33.9 22.4 15.2 12.5 10.7 6.7 2 VE 170 2 141.7 110.5 87.4 52.8 38.4 25.4 17.2 14.2 12.1 7.5 6 VE 155 6 169 126 102 59.6 43.3 28.3 19 15.7 13.4 8.6 6 VE 180 6 159.0 123.0 100.0 60.7 44.7 29.4 19.6 16.2 13.6 8.3 2 VE 225 2 167.3 131.1 103.5 63.0 46.1 31.5 21.8 18.2 15.8 10.0 2 VE 310 2 224.3 180.7 142.6 86.8 63.6 43.4 30.1 25.1 21.7 13.7 2 VE 400 2 289.4 233.1 184.0 112.0 82.0 56.0 38.8 32.4 28.0 17.7 2 VE 450 2 325.6 262.3 207.0 126.0 92.3 63.0 43.7 36.5 31.5 19.9 2 VEO 450 2 334.6 262.3 207.0 126.0 92.3 63.0 43.7 36.5 31.5 19.9 2 VE 540 2 477.0 369.0 300.0 182.1 134.1 88.2 58.8 48.6 40.9 25.0 2 VE 550 2 393.0 311.0 246.0 158.0 115.0 78.8 54.5 45.6 39.4 25.0 7
Discharge current in amperes End voltage : 1.90 V 12 VE 38 12 32.2 25.2 20.3 11.9 8.5 5.4 3.6 2.9 2.5 1.6 12 VE 50 12 42.3 33.1 26.7 15.6 11.1 7.1 4.7 3.9 3.3 2.0 12 VE 60 12 52.4 41.0 33.1 19.4 13.8 8.8 5.8 4.8 4.1 2.5 12 VE 75 12 63.0 49.3 39.7 23.3 16.6 10.5 7.0 5.8 4.9 3.0 12 VE 90 12 73.6 57.6 46.4 27.2 19.3 12.3 8.2 6.7 5.7 3.5 6 VE 110 6 74.8 58.3 49.0 30.4 22.3 14.7 9.9 8.1 7.0 4.3 6 VE 140 6 97.2 75.7 63.7 39.5 28.9 19.1 12.9 10.6 9.0 5.6 2 VE 170 2 117.6 92.4 76.4 45.9 34.0 22.4 15.1 12.6 10.7 6.7 6 VE 155 6 135 104 85 51.4 37.8 24.9 16.9 14 12 7.68 6 VE 180 6 121.1 94.4 79.0 49.0 36.0 23.8 16.0 13.2 11.3 7.0 2 VE 225 2 135.7 108.5 88.9 55.1 40.5 27.0 18.6 15.5 13.3 8.6 2 VE 310 2 186.9 149.5 122.5 76.0 55.8 37.2 25.6 21.4 18.3 11.8 2 VE 400 2 241.2 192.9 158.0 98.0 72.0 48.0 33.0 27.6 23.6 15.2 2 VE 450 2 271.3 217.0 177.8 110.3 81.0 54.0 37.1 31.1 26.6 17.2 2 VEO 450 2 271.3 217.0 177.8 110.3 81.0 54.0 37.1 31.1 26.6 17.2 2 VE 540 2 363.3 283.1 237.0 147.0 108.0 71.5 48.1 39.5 33.8 21.0 2 VE 550 2 330.0 264.0 221.0 138.0 101.0 67.5 46.4 38.8 33.8 21.6 Tables of available power Power per cell in watts End voltage : 1.60 V 12 VE 38 12 86.5 64.3 51.1 29.0 20.6 13.5 8.7 7.2 6.1 3.8 12 VE 50 12 118.6 84.5 67.1 38.2 27.0 17.7 11.4 9.4 8.0 4.9 12 VE 60 12 148.2 104.7 83.2 48.3 34.2 22.1 14.3 11.8 9.9 6.1 12 VE 75 12 174.8 126.7 100.7 58.5 41.4 26.8 17.3 14.2 12.0 7.4 12 VE 90 12 201.4 146.9 116.7 67.8 48.0 31.1 20.1 16.5 13.9 8.6 6 VE 110 6 222.2 160.3 127.6 77.4 56.1 36.9 24.4 20.2 17.0 10.6 6 VE 140 6 288.9 211.5 165.9 100.6 72.9 48.0 31.7 26.2 22.1 13.8 2 VE 170 2 358.7 263.4 204.6 118.0 85.0 56.0 37.7 31.5 26.3 15.8 6 VE 155 6 340 251 202 117 85.1 56 37.7 31.2 26.7 17.1 6 VE 180 6 370.0 265.0 214.0 125.0 92.6 62.0 42.0 34.3 28.9 18.0 2 VE 225 2 419.4 312.0 244.0 141.0 100.0 67.0 45.5 38.6 32.8 20.9 2 VE 310 2 566.9 429.9 336.0 194.0 138.0 92.0 62.7 53.1 45.1 28.8 2 VE 400 2 731.5 554.7 433.0 251.0 178.0 119.0 80.9 67.5 58.1 37.0 2 VE 450 2 823.0 624.0 487.0 282.0 200.0 134.0 91.0 77.2 66.4 42.3 2 VEO 450 2 838.8 624.0 487.0 282.0 200.0 134.0 91.0 77.2 66.4 42.3 2 VE 540 2 1110.0 795.0 642.0 375.0 277.8 186.0 126.0 102.9 86.7 54.1 2 VE 550 2 957.0 709.0 591.0 353.0 250.0 168.0 113.6 96.5 82.9 52.9 8
Power per cell in watts End voltage : 1.65 V 12 VE 38 12 86.5 64.3 51.1 29.0 20.6 13.5 8.7 7.2 6.1 3.8 12 VE 50 12 115.5 84.5 67.1 38.2 27.0 17.7 11.4 9.4 8.0 4.9 12 VE 60 12 144.4 104.7 83.2 48.3 34.2 22.1 14.3 11.8 9.9 6.1 12 VE 75 12 172.0 126.7 100.7 58.5 41.4 26.8 17.3 14.2 12.0 7.4 12 VE 90 12 199.5 146.9 116.7 67.8 48.0 31.1 20.1 16.5 13.9 8.6 6 VE 110 6 221.3 161.0 128.6 77.4 56.1 36.9 24.5 20.2 17.0 10.6 6 VE 140 6 287.7 212.4 167.2 100.6 72.9 48.0 31.9 26.2 22.1 13.8 2 VE 170 2 355.1 263.4 204.6 118.3 84.6 55.9 37.7 31.5 26.4 16.5 6 VE 155 6 340 251 202 117 85.1 56 37.7 31.2 26.7 17.1 6 VE 180 6 369.0 265.0 214.0 125.0 92.3 61.6 41.6 34.3 28.9 17.9 2 VE 225 2 419.4 312.0 243.6 141.0 100.1 67.0 45.5 38.6 32.8 20.9 2 VE 310 2 566.9 429.9 335.6 194.3 137.9 92.3 62.7 53.1 45.1 28.8 2 VE 400 2 731.5 554.7 433.0 250.6 177.9 119.1 80.9 67.5 58.1 37.0 2 VE 450 2 823.0 624.0 487.1 282.0 200.1 134.0 91.0 77.2 66.4 42.3 2 VEO 450 2 838.8 624.0 487.1 282.0 200.1 134.0 91.0 77.2 66.4 42.3 2 VE 540 2 1107.0 795.0 642.0 375.0 276.9 184.8 124.8 102.9 86.7 53.8 2 VE 550 2 957.0 709.0 591.0 353.0 250.0 168.0 113.6 96.5 82.9 52.9 Power per cell in watts End voltage : 1.70 V 12 VE 38 12 85.5 62.6 49.8 28.7 20.3 13.1 8.6 7.1 6.0 3.7 12 VE 50 12 114.0 82.3 65.4 37.7 26.7 17.2 11.3 9.3 7.9 4.9 12 VE 60 12 142.5 101.9 81.1 46.7 33.1 21.3 14.0 11.6 9.8 6.1 12 VE 75 12 171.0 123.4 98.2 57.2 40.5 26.0 17.1 14.0 11.9 7.4 12 VE 90 12 199.5 144.0 113.8 67.1 47.5 30.5 20.0 16.3 13.8 8.5 6 VE 110 6 215.0 158.6 127.5 77.4 56.1 36.9 24.4 20.2 17.0 10.6 6 VE 140 6 279.5 206.2 165.8 100.6 72.9 48.0 31.7 26.2 22.1 13.8 2 VE 170 2 346.0 260.4 206.0 118.3 84.6 55.9 37.7 31.5 26.4 16.8 6 VE 155 6 339 251 202 117 85.1 56 37.7 31.2 26.7 17.1 6 VE 180 6 366.5 263.0 213.6 123.1 91.4 61.0 41.1 33.6 28.3 17.4 2 VE 225 2 403.6 306.4 240.7 141.0 100.1 67.0 45.5 38.6 32.8 20.9 2 VE 310 2 549.8 422.1 331.7 194.3 137.9 92.3 62.7 53.1 45.1 28.8 2 VE 400 2 709.4 544.6 428.0 250.6 177.9 119.1 80.9 67.5 58.1 37.0 2 VE 450 2 798.1 612.7 481.5 282.0 200.1 134.0 91.0 77.2 66.4 42.3 2 VEO 450 2 807.1 612.7 481.5 282.0 200.1 134.0 91.0 77.2 66.4 42.3 2 VE 540 2 1099.5 789.0 640.8 369.2 274.2 182.9 123.2 100.8 84.9 52.3 2 VE 550 2 923.0 703.0 577.0 353.0 250.0 168.0 113.6 96.4 82.9 52.9 9
Power per cell in watts End voltage : 1.75 V 12 VE 38 12 82.7 60.4 48.1 28.2 20.0 12.9 8.5 7.0 5.9 3.7 12 VE 50 12 110.2 79.3 64.6 37.7 26.7 17.2 11.3 9.2 7.8 4.9 12 VE 60 12 137.8 98.3 81.0 47.3 33.5 21.5 14.0 11.5 9.7 6.0 12 VE 75 12 164.8 119.0 96.2 56.6 40.2 25.9 16.9 13.8 11.6 7.2 12 VE 90 12 191.9 138.0 111.5 65.9 47.0 30.3 19.8 16.1 13.6 8.5 6 VE 110 6 206.4 151.9 124.8 76.2 55.2 35.9 24.4 20.2 17.0 10.6 6 VE 140 6 268.3 197.5 162.2 99.1 71.8 46.7 31.7 26.2 22.1 13.9 2 VE 170 2 327.1 241.4 201.1 115.8 83.9 55.7 37.7 31.5 26.6 16.8 6 VE 155 6 333 249 200 117 85.1 56 37.7 31.2 26.7 17.1 6 VE 180 6 344.0 245.0 210.0 122.0 90.6 60.0 40.6 33.3 28.0 17.3 2 VE 225 2 388.9 293.9 232.7 133.4 96.4 64.9 45.5 38.6 32.8 20.9 2 VE 310 2 518.7 405.0 320.5 183.7 132.8 89.5 62.7 53.1 45.1 28.8 2 VE 400 2 669.2 522.5 413.6 237.1 171.3 115.4 80.9 67.5 58.1 37.0 2 VE 450 2 752.9 587.8 465.3 266.7 192.7 129.9 91.0 77.2 66.4 42.3 2 VEO 450 2 777.8 587.8 465.3 266.7 192.7 129.9 91.0 77.2 66.4 42.3 2 VE 540 2 1032.0 735.0 630.0 366.0 271.8 180.0 121.8 99.9 84.1 51.9 2 VE 550 2 879.0 685.0 569.0 334.0 241.0 163.0 113.6 96.4 82.9 52.9 Power per cell in watts End voltage : 1.80 V 12 VE 38 12 77.9 57.0 46.2 27.0 19,2 12.0 8.1 6,7 5.7 3.5 12 VE 50 12 104.9 74.3 61,3 35,7 25.4 16.0 10.6 8.7 7.4 4.6 12 VE 60 12 131.1 92.1 76.4 44.5 31.6 19.9 13.2 10.8 9.1 5.7 12 VE 75 12 154.9 111.5 91.4 54.0 38.2 24.2 15,9 13.0 11.0 6.8 12 VE 90 12 178.6 129.3 106.4 63.5 44.9 28.5 18.7 15.2 12.8 8.0 6 VE 110 6 193.5 145.7 120.3 73.1 53.7 35.6 24.0 19.9 17.0 10.6 6 VE 140 6 251.5 189.4 156.4 95.0 69.8 46.3 31,2 25.8 22.1 13.8 2 VE 170 2 301.5 230.1 183.1 110.0 79.9 53.1 36.1 29.7 25.6 15.7 6 VE 155 6 320 241 195 115 84.4 55.5 37.4 31 26.5 17.0 6 VE 180 6 327.0 253.0 210.0 120.0 89.6 59,4 40.3 32.8 27.6 16.9 2 VE 225 2 355.0 271.3 219.9 131.7 95.5 65.5 45.8 38.8 33.4 20.8 2 VE 310 2 465.7 373.8 303.0 181.5 131.6 90.2 63.1 53.3 45.3 28.5 2 VE 400 2 600.9 482.3 391.0 234.2 169.8 116.4 81.5 67.9 58.4 36.8 2 VE 450 2 676.0 542.6 439.9 263.5 191.0 131.0 91.7 77.6 65.7 41.4 2 VEO 450 2 109.9 542.6 439.9 263.5 191.0 131.0 91.7 77.6 65.7 41.4 2 VE 540 2 981.0 759.0 630.0 360.0 268.8 178.3 120.9 98.4 82.8 50.7 2 VE 550 2 810.0 644.0 541.0 330.0 239.0 163.0 114.5 96.4 82.1 51.7 10
Power per cell in watts End voltage : 1.85 V 12 VE 38 12 75.1 51.2 41.8 24.6 17.6 11.3 7.5 6.1 5.2 3.3 12 VE 50 12 95.0 67.3 55.0 31.2 23.1 14.9 10.0 8.2 6.9 4.4 12 VE 60 12 118.8 79.2 68.1 37.9 28.6 18.6 12.5 10.2 8.7 5.4 12 VE 75 12 140.1 96.7 81.8 47.0 34.4 22.3 14.9 12.2 10.3 6.5 12 VE 90 12 161.5 112.1 95.6 56.1 40.2 26.1 17.3 14.2 12.0 7.6 6 VE 110 6 175.2 134.6 111.9 69.2 50.9 33.7 22.8 19.0 16.2 10.1 6 VE 140 6 227.8 174.9 145.5 90.0 66.1 43.9 29.6 24.6 21.0 13.1 2 VE 170 2 267.8 210.0 167.8 102.6 74.9 49.7 33.7 27.9 23.7 14.8 6 VE 155 6 297 226 184 111 81.4 53.8 36.4 30.1 25.8 16.6 6 VE 180 6 309.0 234.0 189.0 119.0 89.0 58.6 39.7 32.4 27.3 16.7 2 VE 225 2 316.5 247.6 195.8 122.2 89.9 61.4 42.6 35.5 30.7 19.4 2 VE 310 2 423.6 341.1 269.7 168.3 123.8 84.6 58.6 49.0 42.3 26.8 2 VE 400 2 546.6 440.1 348.0 217.2 159.8 109.2 75.7 63.2 54.6 34.6 2 VE 450 2 615.0 495.1 391.5 244.4 179.4 122.9 85.1 71.1 61.4 38.9 2 VEO 450 2 633.1 495.1 391.5 244.4 179.8 122.9 85.1 71.1 61.4 38.9 2 VE 540 2 927.0 702.0 567.0 357.0 267.0 175.8 119.1 97.2 81.8 50.1 2 VE 550 2 728.0 586.0 466.0 305.0 225.0 154.0 106.4 88.9 76.8 48.6 Power per cell in watts End voltage : 1.90 V 12 VE 38 12 61.2 47.9 38.6 22.6 16.1 10.2 7.2 5.9 5.0 3.1 12 VE 50 12 80.4 62.9 50.7 29.7 21.1 13.5 9.4 7.7 6.6 4.1 12 VE 60 12 99.6 78.0 62.8 36.8 26.2 16.7 11.7 9.6 8.2 5.1 12 VE 75 12 119.7 93.7 75.5 44.3 31.5 20.0 14.0 11.5 9.8 6.1 12 VE 90 12 139.8 109.4 88.2 51.7 36.7 23.4 16.4 13.4 11.5 7.1 6 VE 110 6 144.7 113.9 96.1 59.7 43.7 29.0 19.6 16.1 13.8 8.6 6 VE 140 6 188.1 148.0 124.9 77.6 56.9 37.7 25.4 20.9 17.9 11.2 2 VE 170 2 223.4 176.6 146.7 90.2 66.8 44.1 29.8 24.9 21.2 13.2 6 VE 155 6 263 203 167 102 75.1 49.8 33.9 28.1 24.2 15.6 6 VE 180 6 234.3 184.5 154.8 96.3 70.7 46.9 31.7 26.1 22.3 13.9 2 VE 225 2 257.7 205.7 168.8 108.6 79.8 53.2 36.6 30.6 26.1 16.9 2 VE 310 2 355.1 283.5 232.5 149.6 109.9 73.3 50.4 42.1 36.0 23.3 2 VE 400 2 458.2 365.8 300.0 193.0 141.8 94.6 65.0 54.4 46.5 30.0 2 VE 450 2 515.5 411.5 337.5 217.1 159.5 106.4 73.1 61.2 52.3 33.8 2 VEO 450 2 515.5 411.5 337.5 217.1 159.5 106.4 73.1 61.2 52.3 33.8 2 VE 540 2 703.0 553.5 466.9 290.2 212.5 140.8 95.0 78.3 67.0 41.7 2 VE 550 2 627.0 511.0 420.0 271.0 200.0 133.0 91.4 76.4 65.3 42.3 11
IV/ Battery calculations a. Floating applications A battery application is characterised by : - a voltage which must be held within certain limits, - a power level which must be delivered - a set capacity to maintain the load in terms of time. By the use of these three parameters, calculations can be effected as follows : - A situation requires : a maximum voltage of 484 volts a minimum voltage of 383 volts - The ambient temperature is 20 C - The float voltage is to be 2.27 volts per cell. Preliminary calculation : The maximum number of cells : 484 V / 2.27 V = 213 cells The minimum voltage per cell at the end of discharge : 383 V / 213 = 1.80 volts. Case 1 : discharge with a surge at the start of discharge - The surge power is to be 154.3 kw for 10 minutes, followed by 25.7 kw for 4 hours. Discharge current : During the surge : 154300 W/383 V = 403 amps And then :25700 W/383 V = 67 amps Determining the cell required for the current required Current flow during surge : ( 403 A x 10 mins)/60 mins= 67 Ah Current flow for 4 hours : 67 A x 4 h = 268 Ah Total capacity drawn : 67 Ah + 268 Ah = 335 Ah. Equivalent discharge time at 67 amps to supply 335 Ah : 335/67 = 5 hours From the table of performance characteristics, expressed in terms of the discharge current in amps for 1.80 V end voltage, the cell to give a current of 67 amps for 5 hours is the 2VE 450. Conclusion : In this example; it is the total number of Ah required which determines the battery to be used, i.e. 213 cells of type 2 VE 450. Case 2 : discharge with a surge at the end of discharge (here again, it is the surge which dictates the battery to be used) The continuous power is to be 25.7 kw for one hour, followed by a surge of 138 kw for 20 minutes. P P 154,3 KW 138 KW 25,7 KW 25,7 KW 10 4h10 T 1h20 T 12
Discharge current : - During the surge : 138000 W/383 V=360 amps - Before the surge : 25700 W/383 V= 67 amps Capacity drawn in 1 hour : 67 A x 1 h = 67 Ah Capacity drawn during surge (20 mins) (360 amps x 20 mins)/60 mins=120 Ah Total capacity drawn : 187 Ah Equivalent discharge time at 360 amps to supply 187 Ah (187/360)x 60 min=31 min From the table of performance characteristics, expressed in terms of the discharge current in amps for 1.80 V end voltage, the cell to give a current of 360 amps for 31 minutes is the 2 VE 450. The battery to be used will consist of 213 cells of type 2 VE 450. b) Accidental deep discharge This may involve discharge of the battery into indicator lamps, a lower load on the battery than that initially planned, a failure of the charging system, a discharged battery not recharged immediately, etc On a full battery discharge : All of the sulphuric acid has been consumed, and the electrolyte is now entirely water. Sulphation of the plates is at a maximum, thus increasing greatly the internal resistance of the accumulator. The aqueous solution in which the battery now finds itself can give rise to the development of metal flakes on the separator during recharging, and this may cause the cell to short-circuit internally. Important note : This type of deep discharge will still result in the premature deterioration of the battery, and a significant effect on its life expectancy. c) Effect of temperature on capacity The following table gives the correction factor according to temperature, where the reference temperature is 20 C. Discharge time 5 minutes to 59 minutes 1 hour to 24 hours 0 C 5 C 10 C 15 C 20 C 25 C 30 C 35 C 40 C 0.81 0.87 0.91 0.96 1 1.03 1.06 1.08 1.10 0.87 0.91 0.93 0.97 1 1.02 1.03 1.04 1.05 13
V/ Installation of the battery Warning : - The cells of the Powersafe VE Series batteries are already charged when delivered, and are fitted with a protective cap on each terminal.they should be unpacked with care. - Avoid short-circuiting terminals of opposite polarity, because these units are capable of discharging at a very high current especially if the lid or the container is damaged. Unpacking the battery - Each shipment of Powersafe VE Series batteries is accompagnied by a packing list. - The packing list should be checked, and the Sales Department Telecoms/IT should be told immediately of any missing items. Setting up the battery stands - The structure should be assembled in accordance with instructions supplied with the equipment. Wooden stands - Ensure that the stretchers and cross-members are correctly interlinked. - Take up any irregularity in floor surface using shims Metal stands - Ensure that all frame members are correctly interlinked - Use the adjustable feet to take up irregularities in the floor surface - Recommend stands over 3 tiers high are wall mounted - Metal stands should always be connected to the building earth in accordance with current regulations. Place the duckboarding around the battery stand as shown in the figure on p.15. Mounting in a cabinet Ensure that the cabinet : - is sufficiently strong to cope with the weight of the battery - is covered with a layer of insulation - is naturally ventilated. Connection of cells All connections should be insulated In series : The number of cells in series will determine the total float of voltage : U = v x N Total float Float voltage Number of cells Voltage for one cell In parallel : VE cells of the same Ah rating may be connected in parallel to give higher current capability. This connection in parallel will be preferably carried out through an equipotential wiring for an equal current distribution in each string. There is no technical reason for limiting the number of strings but for practical installation reasons, it is recommended not to exceed 4 strings in parallel especially if the battery is used in high discharge rates (Standby time lower than 1 hour). General recommendations - Do not wear clothing of synthetic material, to avoid the generation of static potentials. - Use insulated tools. - Place the cells beginning with the least accessible rows, spacing the cells as shown on the drawing. - Consult the drawing for the correct position of the cell poles ( positive=red washer, negative = blue washer). - Before attaching the inter-cell flexible cables, check that all terminals are in the correct position. - The battery cells are connected in series, that is with a positive pole connected to a negative pole. - Use only a damp cotton cloth for cleaning purposes - THE TIGHTENING TORQUE FOR CONNECTION SCREWS VARIES ACCORDING TO THE IR DIAMETER : M5 screws : torque from 5.5 Nm to 6.5 Nm maximum M6 screws :torque from 8Nm to 10 Nm maximum M8 screws : torque from 15 Nm to 17 Nm maximum (see table on p.1 of the brochure) Safety : All installations must comply with the current regulations and norms. 14
Length Installation on standard metallic stand - in vertical position Width of stand 410 510 610 of cells 2 levels 3 levels 4 levels 2 levels 3 levels 4 levels 2 levels 3 levels 4 levels 12 VE 38 Max. No of cells 24 36 48 36 54 72 36 54 72 Total height (mm) 894 1319 1744 894 1319 1744 894 1319 1744 12 VE 50 Max. No of cells 16 24 32 24 36 48 24 36 48 Total height (mm) 911 1336 1761 911 1336 1761 911 1336 1761 12 VE 60 Max. No of cells 12 18 24 18 27 36 24 36 48 Total height (mm) 911 1336 1761 911 1336 1761 911 1336 1761 12 VE 75 Max. No of cells 12 18 24 18 27 36 18 27 36 Total height (mm) 911 1336 1761 911 1336 1761 911 1336 1761 12 VE 90 Max. No of cells 10 15 20 12 18 24 12 18 24 Total height (mm) 918 1343 1768 918 1343 1768 918 1343 1768 6 VE 110 Max. No of cells 16 24 32 20 30 40 24 36 48 Total height (mm) 927 1352 1777 927 1352 1777 927 1352 1777 6 VE 140 Max. No of cells 8 12 16 16 24 32 16 24 32 Total height (mm) 925 1350 1775 925 1350 1775 925 1350 1775 2 VE 170 Max. No of cells 30 45 60 42 63 84 48 72 96 Total height (mm) 911 1336 1761 911 1336 1761 911 1336 1761 6 VE 180 Max. No of cells 12 18 24 12 18 24 16 24 32 Total height (mm) 925 1350 1775 925 1350 1775 925 1350 1775 2 VE 225 Max. No of cells 24 36 48 36 54 72 40 60 80 Total height (mm) 951 1376 1801 951 1376 1801 951 1376 1801 2 VE 310 Max. No of cells 16 24 32 28 42 56 32 48 64 Total height (mm) 951 1376 1801 951 1376 1801 951 1376 1801 2 VE 400-450 Max. No of cells 16 24 32 20 30 40 24 36 48 Total height (mm) 951 1376 1801 951 1376 1801 951 1376 1801 2 VEO 450 Max. No of cells 16 24 32 20 30 40 24 36 48 Total height (mm) 951 1376 1801 951 1376 1801 951 1376 1801 2 VE 540 Max. No of cells 12 18 24 12 18 24 16 24 32 Total height (mm) 931 1356 1781 931 1356 1781 931 1356 1781 2 VE 550 Max. No of cells 8 12 16 16 24 32 16 24 32 Total height (mm) 951 1376 1801 951 1376 1801 951 1376 1801 6 VE 155 is design primarily in a cabinet. If stand details are required, please consult the sales departement. Ferrule Stand drawing. Constructional details and dimensions Schelf 425 Total height 10 - in horizontal position (please contact our sales departement) 15 1010 Width 410,510 or 610
VI/ Battery storage Storage conditions : The battery should be stored away from any moisture or source of heat. Storage times : The self-discharge of Powersafe VE Series batteries as a function of temperature is as follows : 3 % per month at 20 C 6 % per month at 30 C 10 % per month at 40 C In order to ensure that the battery can be charged easily after a long period of storage, it is recommended that batteries should not be stored for more than the following periods without recharging : 6 months at 20 C 4 months at 30 C 2 months at 40 C Failure to comply with these recommendations may compromise the life expectancy of the battery. Determining the state of charge of the battery The state of charge of the battery can be determined by measuring the off-load voltage after the battery has been allowed to rest for 24 hours. % of Voltage per cell at differents temperatures capacity at 20 C 0 C 10 C 20 C 30 C 40 C 100% 2,16 2,15 2,14 2,13 2,13 80% 2,09 2,09 2,09 2,09 2,09 60% 2,06 2,06 2,06 2,06 2,06 40% 2,02 2,02 2,02 2,02 2,02 20% 1,97 1,97 1,97 1,97 1,97 Recharging stored batteries The batteries should be recharged at the float charge voltage to suit the temperature 2.27 2.30 volts at 20 C per cell for example) for a minimum period of 96 hours. The battery will be charged when the charging current has remained constant for a period of 3 hours. VI/ Commissioning - Ensure that batteries are kept at all times in clean and dry conditions. - Before commissioning, the batteries must be charged at a constant regulated voltage to match the prevalling temperature for a minimum period of 48 hours. VII/Maintenance - Check the tightening of connections. - Every month, it is recommended that the total voltage at the battery terminals be measured. It should be Nx2.27-2.30 at a temperature of 20 C, where N is the number of cells in the battery. - Once each year, it is recommended that the voltage of each cell in the battery should be read off. - A difference of plus or minus 2.0% between these individual voltages and the average voltage may be observed. This is due to the gas- recombination process. - A check on capacity (independent operation on load) can be performed once or twice per year. Safety : When carrying out any work on the battery, the applicable safety standards should be followed. 16 Note : it is recommended that a battery log be maintained, and that records should be kept of the total voltage measurements, any mains failures, major battery discharges (current and time) etc. The main factors causing reduction in the life expectancy of Powersafe VE Series cells : - deep discharges - poor regulation on the float voltage - cycling or micro-cycling - poor quality ( smoothing) of the charging current - high ambient temperature.
Hawker S.A. Rue Alexander Fleming ZI EST BP 962 62033 Arras Cedex France Tel: + 33 3 21 60 25 25 Fax: + 33 3 21 73 16 51 www.hawker.invensys.com e-mail : hawker.france@hawker.invensys.com Ref. DCE0009G/02-02 - Hawker reserves the right to change or revise without notice any specification or other details given in this publication. Please refer to the website address for details of your nearest Hawker office