Alpha alphacell gelcell series User manual

AlphaCell™GelCell Series
AlphaCellTM GelCell Battery Users Guide
Storage, Maintenance, and Deployment
Effective: April, 2013
Alpha Technologies

Power
Alpha Technologies
®

3
745-680-C0-002, Rev. B1
AlphaCellTM GelCell Battery Users Guide
Storage, Maintenance and Deployment
745-680-C0-002, Rev. B1
Effective Date: April 2013
Copyright© 2013
Alpha Technologies, Inc.
Contacting Alpha Technologies: www.alpha.com
or
For general USA sales information and customer service (7 AM to 5 PM, Pacic Time), call
1 800 863 3930
For complete technical support in the USA, call
7 AM to 5 PM, Pacic Time or 24/7 emergency support
1 800 863 3364
For Sales information and Technical Support in Canada, call
1 800 667 8743
Photographs contained in this manual are for illustrative purposes only. These photographs may not match
your installation.
Operator is cautioned to review the drawings and illustrations contained in this manual before proceeding. If
there are questions regarding the safe operation of this product, please contact Alpha Technologies or your
nearest Alpha representative.
Alpha shall not be held liable for any damage or injury involving its enclosures, power supplies, generators,
batteries, or other hardware if used or operated in any manner or subject to any condition not consistent with
its intended purpose, or is installed or operated in an unapproved manner, or improperly maintained.
member of The Group
TM
NOTE:
NOTE:
NOTE:
AlphaCellTM
GelCell Battery
Users Guide
Storage, Maintenance
and Deployment

745-680-C0-002, Rev.B1
4
Table of Contents
Safety Notes....................................................................................................................................................... 6
Battery Maintenance Guidelines......................................................................................................................... 7
Recycling and Disposal Instructions................................................................................................................... 7
Storage............................................................................................................................................................... 8
Electrical Safety.................................................................................................................................................. 8
Chemical and Mechanical Safety ....................................................................................................................... 9
1.0 Introduction.......................................................................................................................................... 10
1.1 Description..............................................................................................................................11
2.0 Preparing for Maintenance .................................................................................................................. 12
2.1 Required Tools and Equipment .............................................................................................. 12
3.0 Periodic Maintenance Tasks and Schedule......................................................................................... 13
3.1 Monthly Remote Status Monitoring ........................................................................................ 13
3.2 Quarterly Preventive Maintenance ......................................................................................... 14
3.3 AlphaCellTM Battery Maintenance Log .................................................................................... 16
3.4 Battery Evaluation Procedures ............................................................................................... 18
3.5 Battery Refurbishment Plan.................................................................................................... 19
4.0 Battery System Float Charging............................................................................................................ 20
4.1 Alpha Power Supply Charging Prole .................................................................................... 21
5.0 Battery Symptoms and Solutions ........................................................................................................ 22
6.0 Battery Parameters by Model Number ................................................................................................ 25
7.0 Warranty and Return Information ........................................................................................................ 27
7.1 AlphaCellTM Limited Warranty.................................................................................................. 27
7.2 Battery Maintenance Report for Return Authorizations .......................................................... 29

5
745-680-C0-002, Rev. B1
Figures and Tables
Fig. 1, Capacity vs Storage Time........................................................................................................... 8
Fig. 2, Series Connected String of Batteries ........................................................................................11
Fig. 3, Parallel String of Batteries .........................................................................................................11
Fig. 4, Flow Chart, Monthly Status Monitoring..................................................................................... 13
Fig. 5, Flow Chart, Quarterly Preventive Maintenance........................................................................ 14
Fig. 6 Flow Chart for Battery Refurbishment Plan ............................................................................... 19
Fig. 7, Charger Modes......................................................................................................................... 21
Table 1, Conductance values, new vs. suspect batteries .................................................................... 18
Table 2, Battery Symptoms and Solutions........................................................................................... 22
Table 3, Battery Parameters, Current Models (threaded insert terminals) .......................................... 25
Table 4, Battery Parameters, Legacy Models (threaded insert terminals)........................................... 26
Table 5, Battery Parameters, Legacy Models, (Lead ag insert terminals) ......................................... 26
Table 6, Warranty Periods for AlphaCellTM batteries ............................................................................ 28

745-680-C0-002, Rev.B1
6
Safety Notes
Review the drawings and illustrations contained in this manual before proceeding. If there are any questions
regarding the safe installation or operation of the system, contact Alpha Technologies or the nearest Alpha
representative. Save this document for future reference.
To reduce the risk of injury or death, and to ensure the continued safe operation of this product, the following
symbols have been placed throughout this manual. Where these symbols appear, use extra care and
attention.
A WARNING presents safety information to PREVENT INJURY OR DEATH to the
technician or user.
WARNING!
The use of CAUTION indicates safety information intended to PREVENT DAMAGE to material or
equipment.
CAUTION!
A NOTE provides additional information to help complete a specic task or procedure.
NOTE:
The use of ATTENTION indicates specic regulatory/code requirements that may affect the placement of
equipment and installation procedures.
ATTENTION:

7
745-680-C0-002, Rev. B1
Lead-acid batteries contain dangerous voltages, currents, and corrosive material. Battery
installation, maintenance, service, and replacement must only be performed by authorized
personnel.
WARNING!
Battery Maintenance Guidelines
• For optimal performance, inspect batteries every 3 months for:
Signs of battery cracking, leaking or swelling. The battery should be replaced immediately
by authorized personnel using a battery of the identical type and rating (match conductance,
voltages, and date codes as specied in this document).
Signs of battery cable damage. Battery cable should be replaced immediately by
authorized personnel using replacement parts specied by vendor.
Loose battery connection hardware. Refer to documentation for the correct torque and
connection hardware for the application.
• Do not attempt to remove the vents (valves) from the AlphaCell GelCell battery or add water. This is a
safety hazard and voids the warranty.
• Apply NO-OX grease on all exposed connections.
• When necessary, clean up any spilled electrolyte in accordance with all federal, state, and local
regulations or codes.
• Follow approved storage instructions.
• Always replace batteries with those of an identical type and rating. Never install untested batteries.
• Do not charge batteries in a sealed container. Each individual battery should have at least 1/2 inch of
space between it and all surrounding surfaces to allow for convection cooling.
• All battery compartments must have adequate ventilation to prevent an accumulation of potentially
dangerous gas. Never place batteries in a sealed enclosure. Extreme caution should be used when
maintaining and collecting data on the battery system.
Recycling and Disposal Instructions
• Spent or damaged batteries are considered environmentally unsafe as they contain lead and dilute
sulfuric acid. They should not be "thrown away" with common refuse.
• Always recycle used batteries in accordance with federal, state, provincial, and local regulations. The
Alpha Group provides recycling services. Call 800 863 3930 or contact your local Alpha representative.

745-680-C0-002, Rev.B1
8
32ºF (0ºC)
50ºF (10ºC)
68
ºF
(2
0
º
C
)
8
6ºF (
3
0ºC
)
1
0
4ºF
(
40
º
C)
Storage Time (Months)
Residual Capacity (%)
Fig. 1, Capacity vs. Storage Time
During storage please note:
• The self-discharge rate is related to ambient temperature. The lower the temperature, the less
the discharge. Batteries should be stored in a clean, ventilated, and dry location with an ambient
temperature of 32ºF to 68ºF (0ºC to 20ºC).
• It is important to track open circuit voltage which is related to the density of the electrolyte. If
the open circuit voltage is lower than 12.6V or the batteries have been stored beyond the limits
shown in Figure 1, the batteries should be charged to avoid damage caused by self-discharge.
• All batteries should be fully charged before storage. Record the storage date and next
supplemental charge date in a maintenance record and on the battery.
• Upon battery deployment, verify all batteries within each string measure in the range of
+/- 0.3Vdc of the string average.
Electrical Safety
• Lethal voltages are present within the power supply and electrical enclosures. Never assume that
an electrical connection or conductor is not energized. Check circuits with a volt meter prior to any
installation or removal procedure.
• Observe circuit polarities.
• Always use the buddy system when working under hazardous conditions.
• Ensure no liquids or wet clothes contact internal components.
• Hazardous electrically live parts inside this unit are energized from batteries even when the AC input
power is disconnected.
• Use an insulated blanket to cover exposed portions of the battery system when performing extended
maintenance that could result in personal or equipment contact with the energized conductors.
• Certain types of rectier circuits used in charging the battery may not include a line isolating transformer.
In these cases extreme caution should be used when maintaining and collecting data on the battery
system.
The product warranty is void if the batteries are not stored and recharged in accordance with these guidelines.
NOTE:
Important Storage Practices
All lead acid batteries experience self-discharge while in open circuit storage. This causes circuit
voltage and capacity to decrease (see Fig.1). This is especially true if the batteries are stored for
long periods of time at higher temperatures. Storage of the batteries in the shaded area of Figure
1 is not recommended, as higher temperatures combined with longer periods of storage will result
in diminished residual capacity — hence a shorter battery lifespan.

9
745-680-C0-002, Rev. B1
Chemical Hazards
Any gelled or liquid emissions from a valve-regulated lead-acid (VRLA) battery contains dilute sulfuric acid,
which is harmful to the skin and eyes. Emissions are electrolytic and are electrically conductive and corrosive.
To avoid injury:
• Servicing and connection of batteries shall be performed by, or under the direct supervision of, personnel
knowledgeable of batteries and the required safety precautions.
• Always wear eye protection, rubber gloves, and a protective vest when working near batteries. To avoid
battery contact, remove all metallic objects, (such as rings or watches), from your person.
• Batteries produce explosive gases. Keep all open ames and sparks away from batteries.
• Use tools with insulated handles, do not rest any tools on top of batteries.
• Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects
or other reproductive harm. Battery post terminals and related accessories contain lead and lead
compounds. Wash hands after handling (California Proposition 65).
• If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your
company’s approved chemical exposure procedures.
• Neutralize any spilled battery emission with the special solution contained in an approved spill kit or with
a solution of one pound (454g) bicarbonate of soda to one gallon (3.8l) of water. Report a chemical spill
using your company’s spill reporting structure and seek medical attention if necessary.
• Always replace batteries with those of an identical type and rating (match conductance, voltages, and
date codes as specied in this document).
• Never install old or untested batteries.
• Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have
developed on your body.
• Use special caution when connecting or adjusting battery cabling. An improperly or unconnected battery
cable can make contact with an unintended surface that can result in arcing, re, or a possible explosion.
• A battery showing signs of cracking, leaking, or swelling should be replaced immediately by authorized
personnel using a battery of identical type and rating.
Mechanical Safety
• Keep hands and tools clear of fans.
• Fans are thermostatically controlled and will turn on automatically.
• Power supplies can reach extreme temperatures under load.
• Use caution around sheet metal components, especially sharp edges.
• Depending on the model, batteries can weigh anywhere from 25 to 100 pounds (11kg to 45kg). Exercise
care when handling and moving batteries. Use proper handling equipment.
WARNING!

745-680-C0-002, Rev.B1
10
The purpose of this guide is to provide the user with the necessary information to maintain batteries in storage
and deploy batteries in Alpha Powering systems, as well as perform battery testing, install replacements and
recycling.
This manual guides you through periodic maintenance checks and troubleshooting of the AlphaCell GelCell
batteries of 50 through 107 ampere hours capacity.
Adherence to the procedures and practices detailed in this guide will not only insure the battery operates per
specications, but also provides the proper backup for the Alpha Powering system in which it is installed.
To achieve these goals, this guide will address the following topics:
• The storage and maintenance of new battery inventory.
• Deployment of AlphaCell batteries into Alpha Power systems.
• Proper preventiative maintenance practices for AlphaCell batteries.
• Replacement and recycling of AlphaCell batteries.
• Warehousing, testing, and redeployment of reuseable AlphaCell assets.
• How to keep proper maintenance records for troubleshooting and/or Warranty claims.
1.0 Introduction

11
745-680-C0-002, Rev. B1
1.1 Description
The AlphaCell GelCell battery is a lead acid battery that facilitates an oxygen recombination
cycle. The net result, under normal conditions, is minimal gas emission and water loss from
the electrolyte. The electrolyte is immobilized in either a gel form or is absorbed within an
absorbent separator between the plates. Consequently, there is no requirement to add water
to the cells or to measure the electrolyte specic gravity.
You can connect multiple strings of batteries in parallel. This provides a system whose
capacity equals the sum capacity of all the strings. For example, in Fig. 3, two 36V 90Ah
capacity strings are connected in parallel to provide a nominal 36V at 180Ah.
A 12V battery is made up of six 2V cells internally connected to provide 12 volts.
The battery system is a group of 12V batteries connected in a series string to provide a
higher voltage system. In Fig. 2, three of the nominal 12V batteries are connected in series to
provide an 18 cell system with a nominal voltage of 36V.
Fig. 3, Parallel String of Batteries
Fig. 2, Series String of Batteries
(For illustration purposes, a 36Volt string is shown. 48Volt strings are also available)
Alpha highly recommends fusing in single and parallel string congurations.
WARNING!
to power supply: red (+), black (-)
inline fuse
inline fuse
to power supply: red (+), black (-)
1B
3A
2B3B
1A2A
upper tray
lower tray
3A 1A2A
inline fuse
[Front]

745-680-C0-002, Rev.B1
12
2.0 Preparing for Maintenance
The battery system should be remotely monitored monthly and physically inspected quarterly. If the
battery system has an automatic monitoring system to gather the electrical and environmental data,
the monthly checks should consist of evaluating the recorded data and visiting any site that does not
meet the specications listed in the detailed procedures below. At a minimum each site needs to be
physically inspected every three months.
You do not have to measure the electrolyte specic gravity or add water to the cells.
All batteries in the string should be numbered to facilitate recording and analysis of data unique to
each unit.
Notify anyone affected by the intended maintenance or troubleshooting activity. This should include
but not be limited to anyone responsible for the status monitoring equipment at the head-end or NOC.
2.1 Required Tools and Equipment
Prior to beginning maintenance, ensure that all required tools and equipment, including safety
equipment, is available and functional.
The following is a list of the minimum equipment required to maintain and troubleshoot the
AlphaCell GelCell battery:
• Digital voltmeter
• Socket wrenches, insulated
• Box end wrenches, insulated
• Torque wrench calibrated in inch/lbs
• Rubber gloves
• Full face shield
• Safety Glasses
• Plastic apron
• Portable eyewash
• Spill kit, including sodium bicarbonate solution
• Fire extinguisher
• Optional equipment, depending on the type of maintenance being performed,
includes:
• True RMS Volt Meter with DC Amp Clamp
• Midtronics Conductance Meter
• 100 amp momentary load test set
• System load bank (DC if to be performed at the battery and AC if to be performed
by loading a power supply output— contact your Alpha Sales Representative for
purchasing information).
• NO-OX Corrosion Inhibitor
• Paper Towels and/or rags

13
745-680-C0-002, Rev. B1
3.0 Periodic Maintenance Tasks and Schedule
The following tasks are to be performed on a monthly and quarterly schedule.
The following maintenance procedure requires a fully functional status monitoring system capable of
remotely measuring and recording the following data on a periodic basis:
• Battery Temperature
• Individual Battery Voltage
• Total Battery String Voltage
Please note: If status monitoring is not available these checks need to be made during the quarterly
onsite visit and any batteries not meeting the minimum requirement must be addressed at such time.
Procedure
1. If any individual battery voltage varies more than 0.5V above or below the average for the
string then a site visit is required.
Example V1 = 13V, V2 = 13V, V3=14V
Average voltage = 13.3V
If V3 greater than average by 0.5V, then a site visit is required
2. If the RTS temperature is greater than 10 degrees C above the current regional ambient
temperature then a site visit is required.
3. Prioritize site visits based on highest RTS temperatures and battery voltages
4. Visit the site within 30 days and remedy the problem by replacing the bad battery or
batteries and reset quarterly maintenance.
Review Status
Monitoring Data
RTS
Temperature >10C
above Ambient
Battery Voltage
>0.5V Above/Below
String Average
Monitor as per PM
Program
No No
Yes Yes
Perform
Quarterly PM
Fig. 4, Flow Chart for Monthly Remote Status Monitoring
3.1 Monthly Remote Status Monitoring

745-680-C0-002, Rev.B1
14
3.2 Quarterly Preventive Maintenance
Required Equipment
• True RMS Volt Meter with DC Amp Clamp
• Midtronics Conductance Battery Tester
Fig. 5, Flow Chart for Quarterly Preventive Maintenance
Yes
No
Yes
Yes
No
Replace the individual failed battery with
a battery that is within +/- .3 Volts of the string average.
Battery String
Float Current
>0.5A
Log each battery’s
conductance and
voltage
Disconnect
Batteries
Record Information
on Site Visit Record
Monitor as per PM
Program
Site Visit
Battery
Refurbishment
Plan
Return battery to
warehouse
Remote Status
Monitoring
Procedure
Ensure Power
Supply is in Float
Mode
Battery
> 0.5V
from the average
string voltage
No
Does the individual battery pass
the Evaluation Procedure #1
outlined in Section 3.4?
(see page 18)
Replace the string

15
745-680-C0-002, Rev. B1
3.2 Quarterly Preventive Maintenance, continued
Procedure
1. Verify the power supply is in Float mode.
2. Use the DC Amp clamp to measure and record each individual battery string’s oat current.
3. If the individual string oat current is greater than 0.5 amps, replace the battery string. Measure
and record the individual battery conductance and voltage on the Site Visit Record.
4. If the string oat current is less than 0.5 amps,
4.1 Disconnect the batteries from the system
4.2 Measure the battery conductance. If any reading is below the suspect level, refer to Table 1,
page 18, for mhos values for battery models.
4.3 Measure the battery voltage. If any reading is less than 12.6V then replace all those batteries
in the string.
4.4 If any individual battery voltage varies more than 0.5V above or below the average for the
string then replace the string.
Example: V1 = 13V, V2 = 13V, V3=14V
Average voltage = 13.3V
If V3 is greater than average by 0.5V, then the batteries should be replaced.
Batteries removed from the site should then be tested per Section 3.5,
"Battery Refurbishment Plan".
4.5 Log the site location, battery location, model, manufacturer date codes, voltage and
conductance readings for all batteries.
5. Record data on Battery Maintenance log.
6. Verify the spacing between the batteries from front to back is at least 1/2" or 13mm, and adjacent
batteries do not touch one another.
7. Ensure the enclosure is clean and free of debris.
8. Measure and record the top center battery's temperature. This is typically the warmest battery in
the string.
9.Visually inspect the batteries for:
Cleanliness
Terminal damage or evidence of heating or overheating
Container or cover damage
10. Check terminal posts for signs of corrosion. If corrosion is present, neutralize with a solution of
1 lb (454g) sodium bicarbonate (baking soda) to 1 gallon (3.8l) of water. Rinse and dry.
11. Verify terminal posts are coated with NO-OX grease or a spray-on protectant. Reapply as
needed.
12. Retorque all the interunit connecting hardware to the values noted in Table 3 on page 25.

745-680-C0-002, Rev.B1
16
3.3 AlphaCellTM Battery Maintenance Log
Follow this sample when lling out the maintenance log (following page).
Evaluation Procedure
#1
Evaluation Procedure
#2
Evaluation Procedure
#3
Vdc
Float
No
Load
Conductance
mhos @
77°F
Vdc 24
Hour
OCV
Conductance
mhos @
77°F/25°C
Vdc @
100A after
10 seconds
Vdc 24
Hour
OCV
A 1 195GXL 4/08 3/08 .2 70° 13.4 1100
A 2 195GXL 4/08 3/08 .2 70° 13.5 1080
A 3 195GXL 4/08 3/08 .2 70° 13.4 1120
B 1 195GXL 4/08 3/08 .1 70° 13.4 1090
B 2 195GXL 4/08 3/08 .1 70° 13.4 1105
B 3 195GXL 4/08 3/08 .1 70° 13.6 1060
A 1 195GXL 4/08 3/08 7/8 .1 85° 13.3 1120
A 2 195GXL 3/08 7/8 .1 85° 13.3 1100
A 3 195GXL 3/08 7/8 .1 85° 13.4 1105
B 1 195GXL 3/08 7/8 .1 85° 13.2. 1070
B 2 195GXL 3/08 7/8 .1 85° 13.2 1100
B 3 195GXL 3/08 7/8 .1 85° 13.2 1080
String
Battery Type
Battery
Initial Install Date
Mfr. Date Code
PM Date
Float Current
Battery Temp
Node / Location
Power Supply Type
Load (kW)

17
745-680-C0-002, Rev. B1
3.3 AlphaCellTM Battery Maintenance Log
Node / Location
Power Supply Type
Load (kW)
Evaluation Proce-
dure #1
Evaluation Procedure
#2
Evaluation Procedure
#3
Vdc
Float
No
Load
Conductance
mhos @
77°F
Vdc 24
Hour
OCV
Conductance
mhos @
77°F/25°C
Vdc @
100A after
10 seconds
Vdc
24
Hour
OCV
String
Battery Type
Battery
Initial Install Date
Mfr. Date Code
PM Date
Float Current
Battery Temp

745-680-C0-002, Rev.B1
18
To help identify batteries approaching end of life in an operating power system, test #1 should be performed at each
maintenance interval. For batteries not installed in an operating power system, test #2 or #3 may be performed. For
accuracy, tests must be performed on fully charged batteries.
A battery failing any of the following combined tests is dened as a faulty battery. The battery will be replaced under the
terms of the warranty if within the dened warranty period.
Evaluation Procedure 1
Conductance/Impedance Test – Measure the conductance of each battery. Any battery that possesses a conductance
that is 50% less than the initial reading taken at the point of install can be considered suspect of being below 70%
capacity and should be evaluated further. The battery temperature must be approximately the same each time this reading
is taken (see Table 1 below). Use temperature compensation feature when using Midtronics meter.
AND
Float Voltage Test – Measure the oat voltage of each battery in the string that is on oat charge. Any battery in the string
measured at 13.2 volts or less is a suspect battery and should be further evaluated with the steps below. Any battery
below 12.6 volts should be replaced. The 13.2 & 12.6 voltage values are based on a 77˚F (25˚C) temperature. Adjust the
voltage for higher or lower temperatures by 0.0168 Volts per battery per degree Fahrenheit. The higher the temperature
above 77˚ F (25˚C) the lower the voltage will have to be adjusted and vice-versa for temperature below 77˚F (25˚C). (i.e.:
at a temp of 89˚F (32˚C) would have a corresponding oat voltage of 13.0 volts).
Evaluation Procedure 2
Conductance/Impedance Test – Measure the conductance of each battery. Any battery that possesses a conductance
that is 50% less than the initial reading taken at the point of install can be considered suspect of being below 70%
capacity and should be evaluated further. The battery temperature must be approximately the same each time this reading
is taken. Consult table 1 below for guidance. Use temperature compensation feature when using Midtronics meter.
AND
24 Hour Open Circuit Test – Measure the open circuit voltage of the suspected battery 24 hours after the battery has
come off of oat charge. Care must be taken to ensure that the battery is at full state of charge when it is disconnected
from the power supply. The battery should exhibit a voltage about 12.60V. A battery below this voltage should be replaced.
A fully charged battery below 12.6 volts is below 70% capacity, but a battery above 12.6 volts is not necessarily above
70% in capacity. Batteries that have been sitting for extended periods should be recharged after 6 months or when they
reach 12.48 volts (75% capacity), which ever comes rst depending on the storage temperature.
Evaluation Procedure 3
24 Hour Open Circuit Test – Measure the open circuit voltage of the suspected battery 24 hours after the battery has
come off of oat charge. Care must be taken to ensure that the battery is at full state of charge when it is disconnected
from the power supply. The battery should exhibit a voltage about 12.60 volts. A battery below this voltage should be
replaced. A fully charged battery below 12.6 volts is below 70% capacity, but a battery above 12.6 volts is not necessarily
above 80% in capacity. Batteries that have been sitting for extended periods should be recharged after 6 months or when
they reach 12.48 volts (75% capacity), which ever comes rst depending on the storage temperature.
AND
100A Load Test – Measure the voltage of each battery at the end of a 10 second 100-amp load test. Again, the
temperature must be equivalent to that of the original test performed at the point of installation. A signicant drop in
voltage versus the previous test will indicate deterioration of the battery. A 12-volt battery that falls below 10.80 volts
should be considered faulty and should be replaced.
To maintain consistent test results, ensure the same Midtronics conductance tester is used for each test cycle.
NOTE:
3.4 Battery Evaluation procedures for AlphaCell™ GXL,
GXL-HP and Gold-HP batteries
Midtronics Conductance
Models 3200/micro CELLTRON
170XLT 85 GXL-HP 135 GXL 160 AGM 165 GXL 195 GXL 195 GXL 220 GXL 195 GOLD-HP 220 GOLD-HP
Approximate Conductance Values (mhos)
Healthy Battery @ 77°F (25°C)
1040-1560 480-720 900-1350 1040-1560 800-1200 880-1320 800-1200 960-1400 880-1320 960-1400
Suspect Battery @ 77°F (25°C) in mhos <520 <240 <450 <520 <400 <440 <400 <480 <440 <480
Table 1, Conductance values, healthy vs. suspect batteries

19
745-680-C0-002, Rev. B1
3.5 Battery Refurbishment Plan
Does battery meet
the minimum
conductance values
per Table 1?
Yes
Group 1 – Voltage 12.6 to 12.9 and conductance 600 to 900 mhos.
Group 2 – Voltage 12.6 to 12.9 and conductance 900 to 1200 mhos.
Group 3 – Voltage 12.9 to 13.2+ and conductance 600 to 900 mhos.
Group 4 – Voltage 12.9 to 13.2+ and conductance 900 to 1200 mhos.
Manufacture date codes should be within
18 months for batteries in string
Measure
Conductance
Measure
Battery
Voltage
Sort Batteries per
Conductance &
Voltage
Batteries Returned
from Site. Measure
and document 24
hour Open Circuit
Voltage (OCV).
(Must occur within 24
hours of removal from
charger)
Properly recycle
batteries per EPA
requirements
Battery
Refurbishment
Plan
Group re-deployable
batteries as indicated for
future deployment as
strings
No Yes
Does battery meet
the minimum of
12.6 Volts for the 24
hour OCV?
Measure
Battery
Voltage
Batteries stored in
warehouses for
extended periods of
time refer to “Important
Storage Practices” on
page 8.
No
Fig. 6, Flow Chart for Battery Refurbishment Plan

745-680-C0-002, Rev.B1
20
4.0 Battery System Float Charging
Battery System Float Charging Voltage
Encountering temperature extremes
When you encounter temperature extremes, temperature compensate the oat
charging voltage. The temperature compensation coefcient is -0.0028 V/C per °F
(-0.005 V/C per °C).
For example if the normal battery temperature is 90°F (13° above 77°F) you should
reduce the average oat charging voltage range by 0.036 V/C (13° x -0.0028 V/C per
°F) to between 2.21 and 2.26 V/C. For an 18 cell battery this is 39.78 to 40.86 VDC.
This helps reduce the potential for thermal runaway at elevated temperatures.
If the battery operates at cold temperatures, (60°F, 17° below 77°F, for example), you
can increase the charging voltage to improve recharging time.
For example, increase the charging voltage range by -17° x -0.0028 V/C per degree
or 0.048 V/C. For the 180 cell string this is 41.36 to 42.26 Vdc.
Under or overcharging
If the battery is undercharged for a period of time during which there are multiple
discharges, the battery does not fully recharge after each discharge and provides
progressively lower capacity.
Excessive overcharging causes premature aging of the battery and loss of capacity,
noted by excessive oat current, corrosion of the plate grids, and gassing and drying
of the limited amount of electrolyte.
Severe overcharging over extended periods of time can induce a thermal runaway
condition. This requires replacing the battery system.
NOTE:
The following set points are recommended for AlphaCell Batteries when used with the XM
Series 2 or GMX Power Supply.
AlphaCellTM GelCell Batteries
Bulk / Float 2.27 V/C
Accept 2.40 V/C
Temp Comp -5mV/C/C
AlphaCellTM 195GXL FT
Bulk / Float 2.26 V/C
Accept 2.35 V/C
Temp Comp -4mV/C/C
AlphaCellTM IGL Series
Bulk / Float 2.25 V/C
Accept 2.32 V/C
Temp Comp -3mV/C/C