Total Saft Tel.X-Plus Series User manual

1
Tel.X-Plus Ni-Cd Batteries
TLX+80, 100, 150, and 180 Range (48VDC, 40 cells string)
Installation and operating instructions
1Safety
• Never allow an exposed flame or spark near the
batteries, particularly while charging.
• Never smoke while performing any operation on
the battery.
• Wear appropriate personal protection
equipment (PPE), safety shoes, gloves, and eye
protection. Additional PPE (i.e. aprons, face
shield) may be required in case of accidental
ruptured module and exposed electrolyte.
• The electrolyte is harmful to skin and eyes. In the
event of contact with skin or eyes, wash
immediately with plenty of water. If eyes are
affected, flush with water for 15 minutes and
obtain immediate medical attention.
• Remove all rings, watches, and other electrically
conductive items before working on the battery.
• Use insulated tools.
• Avoid static electricity and take measures for
protection against electric shocks.
• Discharge any possible static electricity from
clothing and/or tools by touching an earth-
connected part "ground" before working on the
battery.
2Important notice
• Only Saft trained and certified personnel
should assemble and install Tel.X-Plus
battery strings (contact your Saft
representative).
• Local regulations related to battery
compartment ventilation (e.g. Telcordia GR-
487-CORE) should be carefully observed. Saft
will not be responsible for the non-
observance of these regulations.
• Refer to Saft's Installation and Operation
manual for complete instructions.
3Unpacking and inspection
Tel.X-Plus batteries are shipped filled with
electrolyte, a connection kit, and supportive
documentation.
• Make sure all items are received by checking
the material list included on each string
layout sheet.
• Check for damage or electrolyte spillage.
Report any abnormalities to the shipping
company as well as to Saft.
4Storage
Store the batteries in standard warehouse
conditions.
• Do not stack modules. Use original packaging
for storage. Do not stack boxes more than 3
high.
• Do not store in direct sunlight or expose to
excessive heat.
• Store the batteries in a temperature range of
-20°C (-4°F) to +35°C (+95°F).
• Tel.X-Plus batteries may be stored for up to
one year without special maintenance.
• If fully charged, the battery strings should
not be stored for more than 2 months (if long
storage is required, discharge the string to
10% state of charge).
5Preparation for transportation
• Make use of original packing cases if
possible. Otherwise, protect the batteries
from being damaged and short-circuited.
• Transport batteries upright and secured to
prevent tipping.
• For transportation over public roads, each
box or pallet must carry a "hazardous
material" label and any other indication
required by local transport authorities (DOT
classification; Batteries, Wet, Filled with
Alkali, Class 8, UN2795, PG III).
• Safety Data Sheet (SDS) is provided with each
shipment and is available online at
www.saftbatteries.com.
6Installation
6.1 General
Tel.X-Plus batteries are delivered filled with
electrolyte and at 10% State of Charge (SOC).
• Do not top up batteries with DI water before,
during, or after initial installation.
• Charge the battery (according to chapter 6.6).
6.2 Operating environment
• For tight spaces and to use a front accessible
connection, make sure to install all back
connections first, while blocks are staged
outside.
• Tel.X-Plus should never be installed in a
sealed space without ventilation. Refer to
Table A for ventilation guidelines.
• To prevent inadvertent short circuit, make
sure the connector
ends are insulated.
6.3 Recommended tools
The following tools will facilitate installation:
• Insulated torque wrench capable of 10±1N.m
(96 ± 9in.lbs).
• Insulated 10mm socket
• Digital Multi Meter (DMM), with an accuracy
of +/-10mVDC.
• Clamp-on current meter, with an accuracy of
±25mA.
6.4 String assembly
Battery configurations vary depending on the
application. A battery string layout is provided
with each string. The step by step procedures
may vary with application and layout.
• Measuring the cell Open Circuit Voltage (OCV)
is recommended to check for normal cell
condition (according to chapter 8). Before
installation, measure the OCV of each battery
cell and note the values (refer to Table B for
record keeping). The sum of the individual
cell voltages will be used to compare with the
assembled battery string voltage.
• Temporarily position the battery modules in
final position in accordance with the provided
layout diagram. Make sure to orient the
positive and negative terminals correctly
(when applicable, place barcode bearing
block on the (+) end of the battery string).
• Use only the parts provided.
• Use “labels numerical” provided to identify
each cell of the battery string. Starting with
battery string positive end as cell number one,
subsequently serialize the cells following the
electrical path resulting in numbering battery
string negative end cell as #40.
• Apply a light coat of No-Ox (provided) to all
terminal connections made before and after
applying torque.
• When making an electrical connection, torque
the terminal bolts to 10±1N.m (96±9in.lbs).
• Install all back connections first while blocks
are staged outside.
• After completing terminal connections, install
the battery top cover(s) (If applicable).
• To prevent inadvertent short circuit, make
sure the connectors’ exposed ends are
insulated.
• The modules can then be slid into place and
all front connections, back-to-front
connections can be made.
• At this stage, DO NOT connect the system’s
power cables.
6.5 Connecting power
•Measure the battery string’s overall voltage
and compare this with the sum of individual
OCV’s previously measured in chapter 6.4. If
the compared value shows a discrepancy
greater than 1.0VDC, verify the polarity,
position, and connection of each module. Re-
assemble if required.
• If a battery needs to be connected to a live
system, it may be necessary to pre-charge
the battery prior to installation (to minimize
the inrush current).
•Ensure the output of the rectifier is adjusted
to 1.43VDC per cell; i.e., the DC bus voltage
should be set to -57.2VDC for a 40 cell Tel.X-
Plus string.

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• Disable rectifier Temperature
Compensation Voltage (TCV) control. Tel.X-
Plus complies with all Telcordia GR3020
requirements. The technology will not enter
thermal runaway, even under abusive
conditions (i.e. electrolyte dry out).
• Affix label “-57.2VDC & TCV disabled”
(provided) onto or near to Tel.X-Plus string
and rectifier to inform that the float voltage
has been set to -57.2VDC and the TCV has
been disabled.
• Using a DMM, verify the polarity of the power
cables before connecting them to the battery.
DO NOT color match.
• Make sure that the cables are properly
secured and supported.
• Apply a light coat of No-Ox (provided) to the
main power terminal connections before and
after applying torque.
• When making an electrical connection,
torque the terminal bolts to 10±1N.m
(96±9in.lbs).
6.6 Charging
• Constant voltage charging is recommended
and should be set to 1.43VDC (-57.2VDC per
40 cell string). Lower voltage setting will
result in undercharge level, higher voltage
setting to excessive electrolyte consumption.
• In order to fully re-charge in 24 hours, the
minimum current available for each battery
string should be C8/10 (Table A). Charging at
lower current than prescribed in Table A will
result in longer charging time.
• Disable rectifier TCV control (if equipped).
Table A
TLX+
Type
Nominal
capacity
C8
(Ah)
24hr
Recharge
current
C 8 / 10
( A )
Max Float
Charging
Current
(mA)
Force
Ventilation
at 25
o
C /
77
o
F
80
75
7.5
380
0.1 m
3
/hr
or
4 (ft
3
/hr)
100
97
9.7
490
150
140
14.0
700
180
172
17.2
870
7Maintenance and Inspection
7.1 Watering
Watering is not required over the operational
life of the Tel.X-Plus.
7.2 Cleaning
It is good practice to visually inspect the string
during periodic site visits. Vacuuming or dusting
with a soft brush is adequate if the string is dirty.
A wet rag may be used, but do not use any
detergent, chemicals, or cleaning aids. Do not
use metal brushes.
7.3 Routine inspection
• Confirm rectifier output voltage and make
sure it is adjusted correctly (see chapter 6.6).
• Re-torqueing the terminal bolts is not
required(the hardware is constructed from
nickel-plated steel, nickel-plated copper, and
stainless steel, which are hard metals that
remain stable over time and require no re-
torqueing maintenance).
• Check the float charging current:
-Using a clamp-on current meter, measure
the float current at either power cable.
-The battery requires action only if the float
current is higher than 5mA per Ah while
float charging at 1.43VDC per cell (see
Table A).
-To confirm the battery was not recharging
following a power outage and to prevent a
false reading, repeat the float current
measurement after a week of float
charge.
-If the float current remains at 5mA per Ah
or higher, schedule the battery
replacement within the next 3 months.
8Commissioning and troubleshooting
Measure the cell OCV (use Table B for record
keeping).
• Gain access to the cell terminals by removing
the battery top cover(s).
• Using a DMM, measure each cell. Cell voltage
should be greater than or equal to 1.10VDC.
• If a cell is below 1.10VDC, set the battery
module aside and call Saft for further
instructions.
Float charge voltage (Vf) measurement (use
Table B for record keeping).
• Safely gain access to the cell terminals by
removing the battery top cover(s). Take
precaution not to short circuit the battery
terminals to conductive parts of the cabinet.
• While on float charge, measure each cell Vf
using a DMM.
• Cells Vfshould be between Vf -0.10VDC and
Vf +0.05VDC of each other. Contact Saft for
further instructions if Vfare beyond these
specifications.
• Battery block Ohmic value measurement is
not required.
9Removal and recycling
• Make sure appropriate packing materials are
available.
• Make sure each cell cap is installed to
prevent spillage.
• All local laws and regulations must be
respected when removing, transporting and
storing used batteries.
• Contact your local Saft representative for
instructions on recycling.
Table B
Date
/ /
/ /
/ /
Cell #
OCV
(X.XX VDC)
Float
voltage
(X.XX VDC)
Float
voltage
(X.XX VDC)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
String
Min
___ (1.10) ___ (Vf
-
0.10) ___ (Vf
-
0.10)
Max
- ___ (Vf
+
0.05) ___ (Vf
+
0.05)
Saft
ISD
26 quai Charles Pasqua
92300 Levallois-Perret-France
Tel.: [phone]
www.saftbatteries.com
Doc No: 22008-1219-2
Edition: December 2019
Data in this document is subject to
change without notice and becomes
contractual only after written
confirmation.
Saft America Inc.
ISD
711 Gil Harbin Ind. Blvd.
Valdosta GA 31601
Tel.: [phone]
www.saftbatteries.com