Lucent Technologies KS-20472 User manual

Round Cell Batteries
KS-20472
Product Manual
Select Code 157-629-700
Comcode 107852477
Issue 3
December 1999
© 1999 Lucent Technologies

Product Manual
Select Code 157-629-700
Comcode 107852477
Issue 3
December 1999
Lucent Technologies
Round Cell Batteries
KS-20472
Notice:
Every effort was made to ensure that the information in this
document was complete and accurate at the time of printing.
However, information is subject to change.
© 1999 Lucent Technologies
All Rights Reserved
Printed in U.S.A.

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 Table of Contents - 1
Table of Contents
1 Introduction
Round Cell Batteries 1 - 1
Product Summary 1 - 1
Illustration 1 - 2
Customer Assistance Contacts 1 - 3
Customer Training 1 - 3
Customer Service 1 - 3
Technical Support 1 - 3
Product Repair and Return 1 - 3
Warranty Service 1 - 4
On-Line Power Systems Product Manuals 1 - 4
2 Product Description
Overview 2 - 1
Specifications 2 - 1
Features 2 - 2
Benefits 2 - 2
Battery Stands 2 - 3
Design 2 - 3
Construction 2 - 3
Arrangements 2 - 3
3 Ordering Information
Batteries 3 - 1
Ordering Table 3 - 1
Battery Stands 3 - 2
Ordering Table 3 - 2
24-volt Battery Plants 3 - 3
48-volt Battery Plants 3 - 4
130/140-volt Battery Plants 3 - 5
10 P.S.I. Earthquake Bracing 3 - 6
Earthquake Bracing of KS-20760 Battery Stands 3 - 7
4 Safety
Introduction 4 - 1
Safety Symbols 4 - 2

Lucent Technologies Round Cell Batteries
2 - Table of Contents Issue 3 December 1999
Admonitions 4 - 2
Poison 4 - 3
Electrical Hazard 4 - 4
Shock Hazard 4 - 5
Battery Gases 4 - 6
Vent Funnel and Orange Shipping Plug 4 - 8
Warning Signs 4 - 9
Additional Information 4 - 10
First Aid 4 - 10
Transportation 4 - 10
Handling 4 - 10
Environmental 4 - 10
5 Battery Storage
Overview 5 - 1
State of New Battery 5 - 1
Storage Conditions 5 - 1
Storage Time 5 - 1
6 Installation
Introduction 6 - 1
In This Section 6 - 1
Installation Tools, Materials, and Test Equipment 6 - 1
Unpacking and Handling 6 - 2
Guidelines 6 - 2
Specific Unpacking Instructions 6 - 2
Cleaning Jars 6 - 4
Cleaning Posts 6 - 4
Lifting Clamp 6 - 5
Installation Guidelines 6 - 6
Location 6 - 6
Battery Stands 6 - 7
Bases and Cable Guards 6 - 8
Soft Site Installations 6 - 9
Orienting and Spacing Cells in Stands 6 - 10
Guidelines 6 - 10
Black and Orange Plugs 6 - 11
Temperature Reference Cell Selection 6 - 12
Intercell Connection 6 - 12
Vent Funnel Installation and Disposition of Vent Plugs 6 - 13
Hydrometers 6 - 14
Assembling the Hydrometer 6 - 14
Flexible Tube Length Determination 6 - 14
Specific Gravity Readings 6 - 15

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 Table of Contents - 3
Initial Charging 6 - 16
Overview 6 - 16
Maximum Time Allowable Until Initial Charge 6 - 18
Total Hours of Initial Charge 6 - 19
Initial Charge Rectifier 6 - 19
Before Stopping the Initial Charge 6 - 20
After End of Initial Charge 6 - 20
Lead-sulfate Crystals 6 - 21
From Initial Charge To Service 6 - 21
Electrolyte Levels 6 - 22
Adjustments 6 - 22
Final Connection of Cell Groups 6 - 23
Installation Records 6 - 24
Storage Battery Report 6 - 24
Battery Maintenance Record 6 - 24
7 Operation and Maintenance
Overview 7 - 1
Maintenance 7 - 1
Replacement Procedures 7 - 1
Gassing Rate 7 - 1
Recommended Procedures and Intervals 7 - 2
Reference Tables 7 - 2
Safety 7 - 2
Check and Record Battery Float Voltage 7 - 3
Interval 7 - 3
Guidelines 7 - 3
Check and Record Individual Cells for Crystals 7 - 4
Interval 7 - 4
Guidelines 7 - 4
If Crystals Appear on All Cells in a String 7 - 5
If Crystals Appear on One or a Few Cells 7 - 5
Check and Record Reference Cell Temperature 7 - 6
Interval 7 - 6
Guidelines 7 - 6
Temperature Reference Cell 7 - 6
Procedure 7 - 6
Check Electrolyte Levels 7 - 7
Interval 7 - 7
Guidelines 7 - 7
Check Individual Cell Float Voltage 7 - 8
Interval 7 - 8
Guidelines 7 - 8
Determining Float Voltage 7 - 8
Taking Voltage Readings 7 - 8

Lucent Technologies Round Cell Batteries
4 - Table of Contents Issue 3 December 1999
Check Battery Cycle Monitor 7 - 9
Interval 7 - 9
Guidelines 7 - 9
Inspect Battery Jars and Stands 7 - 10
Interval 7 - 10
Cleaning Cell Jars and Covers 7 - 10
Cleaning Battery Stands, Cabinets, and Miscellaneous
Equipment 7 - 11
Inspect, Clean, or Replace Safety Vent Funnel 7 - 12
Interval 7 - 12
Guidelines 7 - 12
Procedure 7 - 12
Check Battery Connections 7 - 13
Interval 7 - 13
Guidelines 7 - 13
Safety 7 - 13
Corrosion 7 - 14
Opening Battery Connections 7 - 14
Cleaning Battery Connections 7 - 15
Perform Discharge Capacity Test 7 - 16
Interval 7 - 16
Guidelines 7 - 16
Procedure 7 - 16
Measure Specific Gravity 7 - 18
Guidelines 7 - 18
Replace a Cell in an Existing String 7 - 19
Introduction 7 - 19
String Disconnected from Load/Charger 7 - 20
String Connected to Load/Charger 7 - 21
Replace or Add a String to an Existing Plant 7 - 23
Guidelines 7 - 23
Gassing Rate 7 - 24
8 Discharge and Power Data
Overview 8 - 1
In This Section 8 - 1
Battery Discharge Capacity Tables 8 - 1
9 Installation and Maintenance Records
Overview 9 - 1
Introduction 9 - 1
Storage Battery Report 9 - 1
Battery Maintenance Record 9 - 1

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 Table of Contents - 5
10 Material Safety Data Sheet
11 Product Warranty

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 List of Figures - 1
List of Figures
Figure 1-1: KS-20472 Round Cell (cutaway view) 1 - 2
Figure 2-1: Dimensions of Battery Stands Equipped
with KS-20472 Round Cells 2 - 4
Figure 6-1: Lifting Clamp 6 - 5
Figure 6-2: KS-20472 Round Cell Installation 6 - 6
Figure 6-3: Polyester Battery Stand Bases, Backs,
and Dovetail Keys 6 - 7
Figure 6-4: Typical Method of Supporting Cable Guard
and Equipment on Top of a Round Cell Battery Stand 6 - 8
Figure 6-5: Battery Stands Showing Earthquake
Bracing and Cable Routing 6 - 9
Figure 6-6: Round Cell Orientation 6 - 11
Figure 7-1: Correcting Capacity for Temperature 7 - 17
Figure 7-2: Replacing a Defective Cell With a New Cell 7 - 22

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 List of Tables - 1
List of Tables
Table 2-A: Round Cell Battery Specifications
(Specific Gravity 1.215 Acid Models) 2 - 1
Table 3-A: Round Cell Batteries Ordering Information 3 - 1
Table 3-B: Round Cell Battery Stand Ordering Information 3 - 2
Table 3-C: Lists of J-Code Drawings for Battery Stand
Arrangements of 24-volt Power Battery Plants 3 - 3
Table 3-D: Lists of J-Code Drawings for Battery Stand
Arrangements of 48-volt Power Battery Plants 3 - 4
Table 3-E: Lists of J-Code Drawings for Battery Stand
Arrangements of 130/140-volt Power Battery Plants 3 - 5
Table 3-F: List of J-Code Drawings for 10 P.S.I. Earthquake
Bracing Battery Stand Arrangements 3 - 6
Table 3-G: Guidelines for Earthquake Bracing
of KS-20760 Battery Stands 3 - 7
Table 6-A: Total Hours of Initial Charge
at 2.5 to 2.55 Volts Per Cell 6 - 19
Table 7-A: Monthly Maintenance Procedures 7 - 2
Table 7-B: Quarterly Maintenance Procedures 7 - 2
Table 7-C: Annual Maintenance Procedures 7 - 2
Table 7-D: At 5-year Intervals Maintenance Procedures 7 - 2
Table 8-A: Ratings Table for List 1S Round Cell Batteries
(Discharge Currents are in Amperes) 8 - 2
Table 8-B: Battery Discharge Amperes Model KS-20472,
List 2S Cells 8 - 3
Table 8-C: Battery Discharge Amperes Model KS-20472,
List 3S Cells 8 - 4
Table 8-D: Battery Discharge Amperes Model KS-20472,
List 4S Cells 8 - 5

Lucent Technologies Round Cell Batteries
2 - List of Tables Issue 3 December 1999
Table 8-E: Battery Discharge Amperes High Rate, UPS Rate
Model KS-20472, List 1S Cells 8 - 6
Table 8-F: Battery Discharge Amperes High Rate, UPS Rate
Model KS-20472, List 2S Cells 8 - 6
Table 8-G: Battery Discharge Amperes High Rate, UPS Rate
Model KS-20472, List 3S Cells 8 - 7
Table 8-H: Battery Discharge Amperes High Rate, UPS Rate
Model KS-20472, List 4S Cells 8 - 7
Table 8-I: Estimated 1 and 5 Minute Rate in Amperes
to 1.75 Volts Per Cell 8 - 8
Table 11-A: New Battery Warranty Periods and Conditions 11 - 1

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 Introduction 1 - 1
1 Introduction
Round Cell Batteries
Product Summary This product manual (Select Code 157-629-700) provides information
on Lucent Technologies’ Round Cell Batteries. A Round Cell battery is
a stationary, lead-acid, flooded cell that was designed by Bell
Laboratories, the acknowledged leader in technology, research, and
design of power systems.
Lucent Technologies power products have proved their reliability by
serving the telephone industry for decades. All of the components in the
Round Cell battery meet Lucent Technologies’ strict specifications and
quality standards. Nearly one million Round Cells are in service
today–an unparalleled record of experience and trustworthiness.
Designed to provide long reliable service life and reduced lifetime
maintenancecosts,theRoundCellisappropriate for bothhighdischarge
rate uninterruptible power supply (UPS) applications and low discharge
rate (standby reserve) applications. Applications include telephone
central offices, microwave stations, rapid rail systems, power utility
sub-stations, and generating plants.

Lucent Technologies Round Cell Batteries
1 - 2 Introduction Issue 3 December 1999
Round Cell Batteries, continued
Illustration Figure 1-1 shows a cut-away view of the Round Cell Battery.
Figure 1-1: KS-20472 Round Cell (cutaway view)

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 Introduction 1 - 3
Customer Assistance Contacts
Customer Training Lucent Technologies offers customer training on many Power Systems
products. For information call 1-972-284-2163. This number is
answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6),
Monday through Friday.
Customer Service For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-THE-1PWR (1-800-843-1797). Services
provided through this contact include initiating the spare parts
procurement process for out of service emergencies, ordering Lucent
Technologies documents, and providing other product and service
information.
For other customers worldwide, call 001-972-840-0382. This number is
answered from 8:00 a.m. until 4:30 p.m., Central Time Zone (Zone 6),
Monday through Friday.
Technical Support Technical support for Lucent Technologies customers is available
around the world during the normal product warranty period and also
while specific contractual agreements extend this service.
For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-CAL-RTAC (1-800-225-7822) to contact a
product specialist to answer your technical questions and assist in
troubleshooting problems.
For other customers worldwide, contact your local field support center
or your sales representative to discuss your specific needs.
ProductRepairand
Return Repair and return service is provided for Lucent Technologies
customers around the world.
For customers in the United States, Canada, Puerto Rico, and the US
Virgin Islands, call 1-800-255-1402 for information on returning of
products for repair.
For other customers worldwide, contact your sales representative to
discuss your particular circumstances.

Lucent Technologies Round Cell Batteries
1 - 4 Introduction Issue 3 December 1999
Customer Assistance Contacts, continued
Warranty Service For domestic warranty service, contact your Warranty Service Manager
(WSM). For international warranty service, contact your sales
representative.
On-Line Power
Systems Product
Manuals
For Lucent Technologies users logging in from inside the corporate
firewall, the address of the “Power Systems On-Line Product Manuals”
page is http://www.cic.lucent.com/lineage.html.
For customers logging in from outside the firewall, the address is
http://www.lucent8.com/lineage.html. The annual subscription fee for
access to this site is $25. To obtain a password, follow the instructions
on-line or call 1-888-Lucent8 (1-888-582-3688). When prompted for an
order number, enter or say “167-790-010.”

Lucent Technologies Round Cell Batteries
Issue 3 December 1999 Product Description 2 - 1
2 Product Description
Overview
Specifications The Lucent Technologies Round Cell Battery is available in four
models. All four models have a common post size that allows for
common intercell connectors.
The specifications for these models are provided in Table 2-A.
Table 2-A: Round Cell Battery Specifications
(Specific Gravity 1.215 Acid Models)
KS-20472
List 1S KS-20472 List 2S KS-20472 List 3S KS-20472 List 4S
Ampere Hours
(8 hour rate
@ 25°C/77°F) 1600 Ah 864 Ah 488 Ah 296 Ah
Weight 346 lbs
156.9 kg 198 lbs 89.8 kg 133 lbs 60.3 kg 100 lbs 45.4 kg
Height 26-3/4"
(67.94 cm) 18-7/8" (47.94 cm) 15-3/8" (39.05 cm) 13-5/8" (34.60 cm)
Diameter 13-3/4"
(34.92 cm) 13-3/4" (34.92 cm) 13-3/4" (34.92 cm) 13-3/4" (34.92 cm)
Total Weight
(Volume)
of Electrolyte
85 lbs (8.4 gal)
38.6kg (31.7 L) 50 lbs (4.9 gal) 22.7kg (18.7 L) 34 lbs (3.4 gal) 15.4kg (12.7 L) 26 lbs (2.6 gal) 11.8kg (9.7 L)
Total Weight
(Volume)
of Sulfuric
Acid
24.7 lbs (1.6 gal)
11.2 kg (6.1 L) 14.5 lbs (0.95 gal) 6.6 kg (3.6 L) 9.9 lbs (0.65 gal) 4.5 kg (2.4 L) 7.5 lbs (0.50 gal) 3.4 kg (1.9 L)

Lucent Technologies Round Cell Batteries
2 - 2 Product Description Issue 3 December 1999
Overview, continued
Features • Slow-growth, pure lead grid
• Patented, life-increasing grid geometry
• Water-impermeable, PVC jar
• Unique, high-strength jar-to-cover seal
(bond strength >1000 lbs per linear inch of seal)
• Patented, leak-preventing post seal incorporates epoxy sleeve, rubber
boot, and patented tin-alloy
• Unique, transparent circular jar
• Nonconductive, acid-resistant, polyester-glass stand
Benefits • Extended life:
– Unique grid design results in a cell capacity that actually
increases with age during float service. After 15 years of
service, Round Cells have a capacity greater than when
originally installed.
– Cell lifetime exceeds any other battery available today.
– No derating is required (20% derating typically required for
most other batteries).
• Minimal maintenance:
– 10- or 15-year intervals between water supplements
– Leak-free history of nearly a million installations over 25 years
– Cursory inspections recommended for cleanliness and corrosion
– Transparency enables visual inspection for crystal growth
– Time-consuming specific-gravity checks are eliminated
• Safety/standards compliance:
– Designed to minimize the hazards of fire and electrolyte
leakage
– Flammability rating: UL94V-0, ASTM D 2863, 33% LOI
– Seismic rating with specific Round Cell battery stand
• Easy installation:
– Space-saving, lightweight polyester-glass stand snaps together
• High reliability:
– Plate capacity increases over time. Jar size allows for 3% grid
growth before contact, resulting in a battery life that extends
well beyond 40 years when maintained properly.