Used batteries with thissymbol are reusable productsand have to be put into arecycling system. Usedbatteries must be disposed ofas special waste in accordancewith all standards.
1. Receiving the batteryThe cells are not to be stored in packaging,therefore, unpack the battery immediately afterarrival. Do not tilt the package or turn it upsidedown. The battery cells are equipped with a blueplastic transport plug. The lomain™ battery will bedelivered
• Filled and charged: The battery is ready forinstallation. Replace the transport plug by thered vent cap included in our accessories justbefore use. The battery must not be chargedwith the transport plug in the cells as this candamage the battery.
2. StorageThe rooms provided for storing the batteries mustbe clean, dry, cool (+10 °C to +30 °C) and wellventilated. Cells are not to be stored in thetransport packaging and must not be exposed todirect sunlight or UV-radiation.
If the cells are delivered in plywood boxes, openthe boxes before storage and remove the packingmaterial on the top of the cells. If the cells aredelivered on pallets, also remove the packingmaterial on the top of the cells.
Filled lomain™ cells can be stored up to 12months from the day of delivery.
Storage of filled cells at a temperature above+30 °C will result in a loss of capacity. This can beapproximately 5% per 10 degrees/year when thetemperature exceeds +30 °C. It is very importantthat the cells are sealed with the plastic transportplugs tightly in place. This is to be checked afterreceiving the goods. In case of electrolyte lossduring transport, refill the cell up to the “MAX”mark with genuine electrolyte before storage.
3. InstallationThe installation should be carried out inaccordance with the requirements of DIN EN50272, Part 2 “Safety Requirements for secondarybatteries and battery installations – Part 2:Stationary batteries” For non stationaryinstallations, specific standards are valid.
3.1 Location
Install the battery in a dry and clean room. Avoid inany case direct sunlight and heat. The battery willgive the optimal performance and maximumservice life if the ambient temperature rangesbetween + 10 °C and + 30 °C.
3.2 Ventilation
During the last phase of charging, the batterygases are released (a mixture of oxygen andhydrogen). Ventilation is necessary, even if thegeneration of gas is very low during float charging.
Compliance with local regulations as to ventilationmay be necessary for certain applications. If thereare no special regulations, standard DIN EN 50272,Part 2 must be met.
3.3 Setting up
Always follow assembly drawings, circuitdiagrams and other separate instructions.The transport plugs have to be replaced by the redvent caps included in the accessories.
Cell connectors and/or flexible cables should bechecked to ensure they are tightly seated. Terminalnuts, screws and connectors must be tightlyseated. If necessary, tighten with a torque wrench.
Connectors and terminals should be protected by athin layer coating of anti corrosion grease.
3.4 Electrolyte
The electrolyte for NiCd batteries consists of adiluted potassium hydroxide (KOH) solution(specific gravity 1.20 kg/litre ± 0.01 kg/litre) with alithium hydroxide component, in accordance withIEC 60993. The potassium hydroxide solution isprepared in accordance with factory regulations.The specific gravity of the electrolyte does notindicate the state-of-charge of the battery.It changes only insignificantly during charging anddischarging and is only minimally related to thetemperature.
When checking the electrolyte levels, a variation inlevel between cells is not abnormal and is due tothe different amounts of gas held in the separatorsof each cell. Before the battery is put into servicefor the first time, check that the electrolyte level isnot lower than 10 mm below the “MAX”mark.There is normally no need to adjust it. Do not openor remove the low pressure vents during normaloperation.
If the electrolyte level is lower than the upperedge of the plate block during service, the batteryshould not be disconnected from the charger for along time.
The GAZ® NiCd cells type lomain™ fulfil therequirements according IEC 62259, point 7.9 for gas recombination efficiency.
2
Warning!The gases emitted during charging are explosive. The electrolyte (potassium hydroxide, KOH) is highly corrosive. Exposed metal parts of thebattery always conduct a voltage and are electrically active parts. Precautions in accordance with DIN EN 50272, Part 2 must be observed.
No smoking! Do not allow naked flames,embers or sparks near the battery due to therisk of explosion or fire!
Electrolyte is highly corrosive!
When working on batteries wear safety glasses and protectiveclothing. All metallic personal objects, such as rings, watches,bracelets etc. shall be removed before starting work on thebattery! Only use insulated tools! Comply strictly with theaccident prevention regulations and your national Health andSafety standards as well as DIN EN 50272, Part 1.
Electrolyte is harmful to skin and eyes. Therefore, after anaccidental contact with the electrolyte flood the eyesimmediately with large quantities of clean water for anextended period of time of at least 15 minutes. In all cases,consult a doctor immediately!Clothing contaminated with electrolyte should be washed inwater immediately!
Cells are heavy!Make sure they are safely installed!Only use suitable transport equipment!
Observe the instructions for use and place them visiblyclose to the battery! Work only on batteries after receivinginstruction from qualified personnel!
Warning: Risk of fire, explosion, or burns!Avoid any short circuit!Metallic parts of the battery are always undervoltage on the battery, do not place tools oritems on top of the battery!
The Installation, Operation and Maintenance Instructionsmust be strictly observed.Non-compliance with the Installation, Operation andMaintenance Instructions, use of nongenuine spares andthe usage of other than by EnerSys/GAZ specified parts,use of additives to the electrolyte and unauthorisedtampering will invalidate any entitlement to warranty.
WARNING!
Never use sulphuric acid oracidic water.
Acid will damage the battery!
Ni-Cd
Cd
3
It A =
3.5 Commissioning
The following instructions are valid forcommissioning between 20 °C and 30 °C.For different conditions please contact GAZ®.Charging with constant current is the preferredmethod.
If a site test is requested, it has to be carried out inaccordance with IEC 62259.
According to IEC 62259, 0.1 C5 A is also expressedas 0.1 It A. The reference test current It isexpressed as:
Cn Ah1 h
Example:0.1 It A means: 10 A for a 100 Ah battery or50 A for a 500 Ah battery
3.5.1 Commissioning with constant current
lomain™ cells stored up to 6 months:A commissioning charge is normally not requiredand the cells are ready for service. If fullperformance is necessary immediately, acommissioning charge of 10 hours at 0.1 It A isrecommended.
This procedure is carried out without any redlow-pressure vents.
During the charge the temperature should bechecked (see point 5).
lomain™ cells stored more than 6 months and upto 1 year:A commissioning charge of 15 hours at 0.1 It A isnecessary.
This procedure is carried out without any redlow-pressure vents.During the charge the temperature should bechecked (see point 5).
3.5.2 Commissioning with constant voltage
If the charger´s maximum voltage setting is toolow to supply constant current charging, divide thebattery into two parts and charge themindividually.
lomain™ cells stored up to 6 months:A commissioning charge is normally not requiredand the cells are ready for service. If fullperformance is necessary immediately, acommissioning charge of 20 hours at 1.65 V/cellwith current limited to 0.1 It A is recommended.
This procedure is carried out without any redlow-pressure vents.
During the charge the temperature should bechecked (see point 5).
lomain™ cells stored more than 6 months and upto 1 year:
A commissioning charge of 30 hours at 1.65 V/cellwith current limited to 0.1 It A is necessary.
This procedure is carried out without any redlow-pressure vents.
During the charge the temperature should bechecked (see point 5). In case of variable charging conditions, pleaseconsult your GAZ® representative.
4. Charging in OperationDo not open or remove the low pressure vent capsduring operation. The charging current limit shouldbe 0.1 It A maximum in general.
In order to reduce the water consumption it isrecommended to compensate it at elevatedtemperature as for example from +35ºC on by useof the negative temperature coefficient of -3mV/K.
For operation at low temperatures, i.e. below 0ºC,there is a risk of poor charging and it isrecommended to adjust the charging voltage or tocompensate the charging with the temperature(-3 mV/K, starting from an ambient temperatureof +20ºC).
Recommended charging voltages for ambienttemperatures from + 20 °C to + 35 °C are:
4.1. Two step chargeFloat charge: 1.40 - 1.42 V/cellBoost charge: 1.45 - 1.46 V/cellCurrent limitation: 0.1 It A
4.2. Single step charge1.42 - 1.44 V/cell
Current limitation: 0.1 It A
5. Periodic MaintenanceGAZ® lomain™ are extreme low maintenancebatteries and require a minimum of maintenance.The following is recommended:
• The battery must be kept clean using onlywater. Do not use a wire brush or solvents ofany kind.
• Visually check the electrolyte level. Refilling isrecommended when the filling level reaches the“MIN“mark. However it must never drop belowthe “WARNING LEVEL”mark. Use only distilledor deionized water to top-up the cells inaccordance with IEC 60993. Experience will tellthe time interval between topping-ups.
NOTE: Once the battery has been filled with thecorrect electrolyte at the factory, there is no needto regulary check the electrolyte density.Interpretation of density measurements is difficultand could lead to misunderstandings.
• Check regularly (approximately every 24months) that all connectors, nuts and screwsare correctly torqued. All metal parts of thebattery should be corrosion-protected by a thinlayer coating of anti-corrosion grease. Do notcoat any plastic part of the battery, for examplecell cases!
• Check the charging voltage every 12 months.If a battery is parallel connected, it is importantthat the recommended charging voltageremains unchanged. If a single-cell voltage ofbelow 1.35 V is detected during float charging,it is recommend to charge the cell(s) separatelypursuant to section 3.5.1 Commissioning withconstant current.
• The charging current in the strings should alsobe checked to ensure equality. These checkshave to be carried out every 12 months.
• High water consumption of the battery isusually caused by improper voltage setting ofthe charger.
• Check the electrolyte temperature from time to
time. The temperature of the electrolyte shouldnever exceed 45 °C, as higher temperatureshave a detrimental effect on the performanceand lifetime of the cells. During charging, anelectrolyte temperature of ≤ 35 °C should beaimed for. On exceeding 45 °C the chargingshould be temporarily interrupted until theelectrolyte temperature drops to 35 °C.The temperature measurements are to be madeat one cell in the middle of the battery. Lowambient or electrolyte temperatures down to–25 °C do not have any detrimental effect on thebattery, they just cause a temporary reductionof capacity.
6. Additional warning notesNiCd batteries must not be operated or stored inthe same room as lead acid batteries. In additionto this, the charging gases from lead acid batteriesmust be kept away from NiCd batteries by suitableprecautions such as ventilation or hermeticisolation of the rooms. Tools for lead acid batteriesmust not be used for NiCd batteries.
Risk of short circuit and fire:Do not place electrically conductive objects such astools etc. on top of the battery!
Risk of injury:No rings or metal bracelets should be worn duringthe assembly of the battery.
Risk of explosion:Open the doors of the battery cabinet duringcharging so that the charging gases can escape.The charging gases from batteries are explosive.Do not allow naked flames, sparks or other sourcesof ignition in the vicinity of the battery!
Caution – potassium hydroxide solution iscorrosive!A potassium hydroxide solution is used aselectrolyte. It is a highly corrosive liquid which cancause severe damage to health if it comes intocontact with eyes or skin (risk of blinding).Even swallowing of small quantities may causeinternal injuries.
When working with the electrolyte and on thecells or batteries, rubber gloves, safety glasseswith side guards and protective clothing mustalways be worn!
Contact with the eyes: Flood eyes immediately with large quantities ofwater for 10 – 15 minutes. Consult a doctor immediately.
Contact with the skin: Remove contaminated clothing immediately andwash the affected skin areas with large quantitiesof water. In case of discomfort seek medicaladvice.
Swallowing:Rinse the mouth immediately with large quantitiesof water and keep drinking large amounts of water.Do not provoke vomiting.Call an emergency doctor immediately.
In the event of injuries: Rinse thoroughly for a long time under runningwater. Consult a doctor immediately.
Publication No. EN-GAZ-IOM-003 February 2013 - Subject to revisions without prior notice. E.&O.E.
