VTX 3.

3
June 2013

Vantex
New Generation
Ni-Cd battery
Technical manual
For cells delivered before May 2012, use the Technical manual VTX3.1 – September 2010
Contents
1. Introduction 4 8. Special operating factors 10
8.1 Electrical abuse 10
2. Applications 4 8.2 Mechanical abuse 10

3. Construction features 4 9. Battery sizing principles

3.1 Plate assembly 4 in stationary applications 11
3.2 Separator 5 9.1 The voltage window 11
3.3 Electrolyte 5 9.2 Discharge profile 11
3.4 Terminal pillars 5 9.3 Temperature 11
3.5 Venting system 5 9.4 State of charge or
3.6 Cell container 5 recharge time 11
9.5 Ageing 11
4. Principles of the oxygen 9.6 Floating effect 11
recombination cycle 5
10. Installation and
5. Battery features 6 operating instructions 12
10.1 Receiving the shipment 12
6. Operating characteristics 7 10.2 Storage 12
6.1 Capacity 7 10.3 Installation 12
6.2 Cell voltage 7 10.4 Commissioning 12
6.3 Internal resistance 7 10.5 Charging in service 13
6.4 Effect of temperature on 10.6 Periodic maintenance 13
performance 7
6.5 Short-circuit values 8 11. Maintenance 13
6.6 Open circuit loss 8
6.7 Cycling 8 12. Disposal and recycling 14
6.8 Water consumption 8
6.9 Gas evolution 8

7. Battery charging 9
7.1 In service -
charging methods 9
7.2 Temperature compensation 9
7.3 Charge acceptance 10
7.4 Charge efficiency 10

3
1. Introduction
The nickel-cadmium battery is the most publication means that no addition of regular maintenance checks are still
reliable battery system available in water is necessary during the lifetime of necessary (see section 10 Installation and
the market today. Its unique features the product when operated under Alcad’s operating instructions). In addition to all
enable it to be used in applications recommended conditions. the well-proven advantages of the
and environments untenable for other nickel-cadmium pocket plate battery,
widely available battery systems. To This publication details the design and Vantex offers exceptional electrical
offer a highly reliable battery of zero operating characteristics of the Alcad performance enabling customers to
or ultra-low maintenance Alcad has Vantex battery. When operated in benefit from a smaller battery capacity
developed the Vantex New Generation recommended conditions, Vantex New to suit their specific applications. Alcad
maintenance-free pocket plate battery. Generation will not require any topping- Vantex is certified compliant to
The term “maintenance-free” in this up during its entire service life. Other IEC 60623 / IEC 62259 battery standards.

2. Applications
Vantex batteries are designed to supply for the oil and gas, utility and electricity
• UPS the ideal maintenance-free power backup industries where availability and reliability
• Process control solution for installations that demand of backup power is essential.
• Emergency systems maximum reliability and optimum TCO
• Security systems (Total Cost of Ownership) while operating
• Offshore oil and gas for long periods at high ambient
• Switchgear temperatures. Vantex is especially suited

3. Construction features
Construction of the Alcad Vantex
Vantex New Generation battery cell is based upon Alcad pocket plate
technology and a new high-tech concept
Flame-arresting low pressure vent
designed to achieve maintenance-
Terminal pillars beneath terminal covers. free operation in terms of topping-up,
In line with EN 50272-2 / IEC 62485-2
(safety) with IP2 level improved performance and chargeability.
Plate group bus bar

Plate tab 3.1 Plate assembly

The nickel-cadmium cell consists of two
groups of plates, one containing nickel
hydroxide (the positive plate) and the
Polypropylene fibrous separator other containing cadmium hydroxide (the
negative plate).

Pocket plate
The active materials of the Alcad Vantex
Polypropylene cell container
pocket plate are retained in pockets
formed from nickel-plated steel strips
double-perforated by a patented process.
These pockets are mechanically linked
together, cut to the size corresponding
Cells are welded together to form rugged blocks up to 10 depending on cell size and type. to the plate width and compressed to
the final plate dimension. This process

4
leads to a component which is not only 3.3 Electrolyte The pillar to lid seal uses a compressed
mechanically robust but also retains its The electrolyte used in Vantex, which is visco-elastic sealing method. The pillars
active material within a steel boundary a solution of potassium hydroxide and are held in place by compression lock
which promotes conductivity and lithium hydroxide, is optimized to give the washers. This assembly is designed to
minimizes electrode swelling. best combination of performance, life and provide satisfactory sealing throughout
energy efficiency over a wide operational the life of the product.
These plates are then welded to a current temperature range.
carrying bus bar which further ensures the 3.5 Venting system
mechanical and electrical stability of the With the Vantex, as with all nickel cadmium, Vantex is fitted with a flame-arresting
product. the electrolyte concentration does not
low-pressure vent for each cell of the
change significantly between a full
battery. This vent operates as a one way
The alkaline electrolyte does not react charged state and a full discharged state.
valve (as defined in IEC 60050-482) which
with steel, which means that the It retains its ability to transfer ions between
will allow the release of small quantities
supporting structure of the Vantex battery the cell plates irrespective of the charge
of hydrogen and non-recombined oxygen.
stays intact and unchanged for the life of level. In most applications the electrolyte
the battery. There is no corrosion and no It allows venting if the internal pressure
will retain its effectiveness for the life of
risk of “sudden death”. the battery and will never need replacing. exceeds a fixed safety value. The self-
closing vent has an integral porous disk,
There are two types. for flame-arresting function, to prevent an
3.2 Separator
a) The standard type concentration is external ignition from spreading into the
The separator is a key feature of the
such as to allow the cell to be operated Vantex cell.
Vantex battery. It is a polypropylene
fibrous material which has been used and to temperature extremes as low as - 20°C
proven by Alcad in the Vantage ultra-low (- 4°F) and as high as + 70°C (+ 158°F). 3.6 Cell container
maintenance product over more than 20 This allows the very high temperature The Vantex is built up using the well-
years and has been further optimized for fluctuations found in certain remote proven Alcad block battery construction.
this product to give the features required. regions to be accommodated. The tough polypropylene containers
b) For continuous temperatures below are welded together by a heat sealing
Using this separator, the distance between - 20°C (- 4°F) an arctic electrolyte is used. technique. The assembly of the blocks
the plates is carefully controlled to give It is a special high density electrolyte. is completed by a clip-on terminal cover
the necessary gas retention to provide which gives protection to IP2X according
the level of recombination required. 3.4 Terminal pillars to IEC 60529 standard for the conductive
By providing a large spacing between Short terminal pillars are welded to parts.
the positive and negative plates and a the plate bus bars using a well-proven
generous quantity of electrolyte between battery construction method. They are
plates, the possibility of thermal runaway constructed of nickel-plated steel and are
is eliminated. internally threaded.

4. Principles of the oxygen

recombination cycle
In a conventional flooded electrolyte This corresponds to a theoretical loss of state and then becomes the main reaction
pocket plate nickel-cadmium battery 36 g of water for 107 Ah of overcharge i.e. when the fully charged condition is
water is lost from the battery on 0.335 cm3 per Ah. Hence a conventional reached. However, the cadmium negative
overcharge due to the following reactions: cell requires periodic addition of water. The plate has a better charge acceptance than
At the positive plate frequency of this operation depends upon the positive plate and hydrogen is not
4OH- 2H2O + O2 + 4e- the cumulative amount of charge received evolved until this plate is virtually fully
(Oxygen evolution) and the operating temperature. charged.

At the negative plate

During the charging process evolution of The oxygen which is produced at the
4H2O + 4e- 2H2 + 4OH-
oxygen begins to occur a little before the positive plate surface is collected by
(Hydrogen evolution)
positive plate reaches its fully charged the special porous separator and thus

5
not allowed to escape from the region in turn it suppresses the evolution of pressure vent on each cell. On overcharge
between the plates. Some displacement hydrogen gas. In the Vantex design, the the cells have an internal pressure above
of electrolyte within the separator occurs, separator and plate stack are optimized to atmospheric pressure. The vent acting as
thus generating extra unfilled pores for minimize hydrogen evolution and water a valve provides an outlet for the release
the diffusion of oxygen directly to the usage when operated as recommended. of small quantities of hydrogen and non-
adjacent cadmium negative plate. This ensures a long service life without the recombined oxygen and thus controls the
need to replenish with water. The Vantex internal pressure. When the pressure falls
As soon as the oxygen reaches the recombination is exceeding the IEC 62259 below the release pressure either on open
negative plate it reacts either chemically minimum requirement level of 70 % and circuit or on discharge the vent reseals to
or electrochemically. In both cases, the achieves more than 95 %. prevent ingress of air and to minimise self-
oxygen recombination prevents the discharge reactions.
negative plate from fully charging and The Vantex battery is fitted with a low

5. Battery features
Complete reliability corrosion-free polypropylene containers deep discharging, and high ripple currents
Does not suffer from the sudden death and has a simple bolted connector without damage (see section 8.1 Electrical
failure due to internal corrosion associated assembly system (see section 10 abuse).
with other battery technologies. Installation and operating instructions).

Well-proven pocket plate

Long cycle life Wide operating temperature construction
The Vantex battery has a long cycle life range Alcad has nearly 100 years of
even when the charge/discharge cycle Vantex employs an electrolyte which manufacturing and application experience
involves 100 % depth of discharge (see allows a normal operating temperature of with respect to the nickel-cadmium
section 6.7 Cycling). from - 20°C to + 40°C (- 4°F to + 104°F) pocket plate product. This expertise has
and accepts extreme temperatures, been built into the twenty-plus years’
Exceptionally long floating ranging from as low as - 40°C with arctic design life of the Vantex product (see
electrolyte to + 70°C (- 40°F to + 158°F) section 3 Construction features of the
lifetime
(see section 3.3 Electrolyte). Vantex New Generation battery).
A lifetime in excess of twenty years is
achieved by Vantex in many applications,
and at elevated temperatures it has a Fast recharge/improved Extended storage
superior life when compared to other chargeability When stored in the filled and charged
available battery technologies. Vantex can be recharged at high currents state in normal condition (0°C to
which allow very fast recharge times + 30°C / + 32°F to + 86°F), Vantex can be
Maintenance-free to be achieved (see section 7.4 Charge stored for up to 2 years (see section 10
With its special recombination separator efficiency). Installation and operating instructions).
combined with its low pressure vent
and generous electrolyte reserve, Vantex
Resistance to mechanical Environmentally safe
eliminates the need for topping-up with Alcad operates a dedicated recycling
water under recommended operating abuse center to recover the nickel, cadmium,
instructions – from - 20°C (- 4°F) to Vantex is designed with a high mechanical
steel and plastic used in the battery (see
+ 40°C (+ 104°F) at 1.42 V/cell with strength. It withstands all the harsh
section 12 Disposal and recycling).
temperature compensation (see section treatment associated with transportation
7.2 Temperature compensation). over difficult terrain (see section 8.2
Mechanical abuse). Low life-cycle cost
Note that it is possible to add water if
When all the factors of lifetime, low
required.
maintenance requirements, simple
High resistance to electrical installation and storage and resistance
Simple installation abuse to abuse are taken into account, Vantex
Vantex can be used with a wide range Vantex will survive abuse which would becomes the most cost effective solution
of stationary and mobile applications destroy other battery technologies. For for many professional applications.
as it produces no corrosive vapors, uses example, it can withstand overcharging,

6
6. Operating characteristics
6.1 Capacity when sizing batteries with conventional For lower states of charge the values
The Vantex battery capacity is rated in fully charged open cell data (see section 9 increase. At 50 % discharged, the internal
ampere-hours (Ah). Its rated Ah is the Battery sizing principles). resistance is about 20 % higher, and at
quantity of electricity at + 20°C (+ 68°F) 90 % discharged, it is about 80 % higher.
which it can supply for a 5 hours runtime When the temperature decreases below
6.2 Cell voltage
to 1.0 V/cell after being fully charged. This 20°C, the internal resistance increases.
The cell voltage of nickel-cadmium cells
is in accordance with both IEC 62259 and At 0°C (+ 32°F), the internal resistance is
results from the electrochemical potentials
IEC 60623 standard. about 40 % higher.
of the nickel and the cadmium active
materials in the presence of the potassium
In accordance with these IEC standards, 6.4 Effect of temperature on
hydroxide electrolyte. The nominal cell
the current can be expressed as a function
voltage is 1.2 V. performance
of this 5 hours capacity or the C5 capacity.
Variations in ambient temperature affect
For example, the expression 0.2 C5 A
the performance of Vantex and this needs
is equal to 20 % of the C5 capacity in 6.3 Internal resistance
to be taken into account when sizing the
Amps. The expression follows the IEC The internal resistance of a cell varies with
battery.
specification since the declared nominal the temperature and the state of charge.
capacity (Cn) is the runtime of 5 hours. So
Low temperature operation reduces the
in that case, 100 % of the Ah is delivered In the fully charged state and at high
discharge performance but at the high
in 5 hours of runtime at C5/5 A or 0.2 C5 A. temperature, the internal resistance is
temperature, the discharge performance is
When the discharge current deviates from the lowest. The internal resistance is
similar to those at normal temperatures.
0.2 C5 A so will the delivered capacity or characterized by measuring the response
runtime. in discharge voltage with a change in
Temperature de-rating factors for L and
discharge current.
M type cells are given in Figure 1(a) and
In practice, Vantex is used in floating
Figure 1(b) for operating temperature
conditions and so the tabular data is The internal resistance of a Vantex cell
- 20°C to + 40°C (- 4°F to + 104°F).
based upon cell performance after several has the values given in the product
months of floating. This eliminates certain literature for fully charged cells at normal
correction factors which need to be used temperature.

Figure 1(a): Temperature de-rating factors for Figure 1(b): Typical de-rating factors for
L type cell for cell final voltage 1.00 V M type cell for cell final voltage 1.00 V

1.1 1.1

1.0 1.0

0.9 0.9
De-rating factor

De-rating factor

0.8 0.8

0.7 0.7

0.6 0.6

0.5 0.5

0.4 0.4
- 20°C - 10°C 0°C + 10°C + 20°C + 30°C + 40°C - 20°C - 10°C 0°C + 10°C + 20°C + 30°C + 40°C
- 4°F + 14°F + 32°F + 50°F + 68°F + 86°F + 104°F - 4°F + 14°F + 32°F + 50°F + 68°F + 86°F + 104°F

Temperature Temperature
5 hour rate 5 hour rate
1 hour rate 1 hour rate
30 minute rate
Typical de-rating factors for publishedperformance data for cells in Typical de-rating factors for publishedperformance data for cells in
floating applications floating applications

7
6.5 Short-circuit values loss is reduced. At high temperature the involved. For example, in a poor power
The typical short-circuit value of a Vantex self-discharge is increased and the open quality stationary application, the Vantex
cell is given in Table 1. The Vantex battery circuit loss is also increased. battery can provide superior cycling duty
is designed to withstand a short-circuit with infrequent or no watering intervals
current of this magnitude for many The open circuit loss for Vantex is shown (see section 8).
minutes without damage. in Figure 2 for a one year period.

6.8 Water consumption

Table1: Short-circuit currents at 6.7 Cycling The Vantex battery works on the oxygen
+ 20°C (+ 68°F) for fully charged cells Vantex is a maintenance-free product recombination principle and therefore
Type Amperes when used under recommended has a reduced water consumption. The
L 6 * C5 A conditions in stationary and not Vantex recombines at least at a level of
M 11* C5 A continuous cycling applications. 95 % when float charging (as per IEC
Nevertheless, it is designed using 62259 methodology). It has a water usage
conventional pocket plate electrode reduced by a factor of up to 10 times
6.6 Open circuit loss technology and has therefore an of that of an open flooded cell. When
The state of charge of Vantex on open equivalent cycling capability. operated as recommended, the Vantex
circuit slowly decreases with time due to will not need topping-up during its entire
self-discharge. In practice this decrease is If Vantex is used in a continuous cycling service life.
relatively rapid during the first two weeks application, the water consumption may
but then stabilizes to about 2 % per be significantly increased. In that case,
6.9 Gas evolution
month at + 20°C (+ 68°F). watering the cells during their useful
Gas is generated during overcharge
life will be necessary. However, there
through electrolysis when gas doesn’t
The self-discharge is affected by the are cycling applications where Vantex
recombine, it will eventually exhaust from
temperature. At low temperatures the self- can be beneficial. This will depend on
the cell. The electrolysis of 1 cm3 of water
discharge decreases and so the open circuit the frequency and depth of discharge
produces about 1865 cm3 of gas mixture
and this gas mixture is in the proportion
Table 2: Values for current Igas producing gas of 2/3 hydrogen and 1/3 oxygen. Thus the
when charging at constant current or potential electrolysis of 1 cm3 of water produces
about 1243 cm3 of hydrogen.
Igas (mA/Ah)
Under float charge conditions 1.42 V/cell 2
Under boost charge conditions 1.45 V/cell 5 Table 2 gives the values for Igas used to
Under all commissioning charge conditions estimate ventilation needs in accordance
100
Constant current charge and constant potential charge with IEC 62485-2 / EN 50272-2.

Figure 2: Typical open circuit loss variation

with time

110
Percentage of initial capacity %

100

90

80

70

60

50

40
0 50 100 150 200 250 300 350 400

Open circuit period (days)

+ 40ºC (+ 104ºF)
+ 20ºC (+ 68ºF)
0ºC (+ 32ºF)

8
7. Battery charging
In order to ensure that the maintenance- After this first stage the charger should When the temperature decreases below
free properties of the Vantex battery are be switched to a second maintenance stage + 20°C (+ 68°F), at a fixed voltage, the
achieved, it is necessary to control the at a float voltage of 1.42 ± 0.01 V/cell. reverse occurs, i.e. the float current
charge input to the battery to optimize After a prolonged mains failure the first decreases, the charge efficiency increases
the rate of water loss during the life of the stage should be reapplied manually or and the water consumption decreases. As
product. automatically. a result, to maintain an optimized balance
between state of charge (SOC) and water
The Vantex battery must be properly b) Single level float charging consumption the voltage should increase.
commissioned (see section 10) before Vantex batteries are float charged at
putting in service and applying the 1.42 ± 0.01 V/cell from a fully discharged When the temperature increases, then
following charging methods. condition to a high state of charge. This the electrochemical behaviour becomes
is detailed in section 7.2. Temperature more active and so, for the same charge
It is important therefore that the compensation is required to avoid the voltage, the current at the end of charge
recommended charge conditions are need for water topping over its useful life. increases. This increases the water usage.
complied with. For this reason it is recommended to
operate with Temperature Compensated
7.2 Temperature
Voltage (TCV) control active. Water
7.1 In service compensation consumption, when operating at high
– charging methods At + 20°C (+ 68°F) and at a fixed temperatures, is reduced allowing the
The single level float charging method voltage of 1.42 VPC, Vantex operates Vantex to operate without the need of
is adequate to maintain the Vantex in a with an optimized balance between watering maintenance over its useful life.
good state of operation over its useful life. stabilized state of charge (SOC) and
It should not be required to implement water consumption. Vantex gives, in When operating at low temperatures,
a two level constant potential charging this case, the highest performance and the reverse occurs. For that reason
method if Vantex is used in a stationary no watering maintenance benefits over it is recommended to operate with
power application and the installation, its useful life. In order to maintain this Temperature Compensated Voltage (TCV)
commissioning and operation is done in optimized condition in standby operation, control in order to increase the charge
accordance with Alcad Installation and Temperature Compensated Voltage (TCV) acceptance. This control contributes to
Operating instructions (see section 10). control is recommended. maintaining a high state of charge and
Vantex batteries may be charged quickly in turn an acceptable level of discharge
and simply by the following methods: When the temperature increases above performance.
+ 20°C (+ 68°F) at a fixed voltage,
a) T
 wo level constant potential the float current increases, the charge Table 3 gives the TCV control slopes
charging efficiency decreases and the water according to the temperature in dual and
The initial stage of two-rate constant consumption increases. As a result, single control method. In dual control,
potential charging consists of a first to maintain an optimized balance the TCV control slopes are different
charging stage to a maximum voltage between state of charge (SOC) and below and above + 20°C (+ 68°F). If only
of 1.45 ± 0.01 V/cell. Up to 12 hours of water consumption, the voltage should one TCV control can be implemented
recharge time with this initial stage of decrease. then use the slope that corresponds best
charge is necessary when fully discharged. with the temperature range expected
in the application. In single control, the
Table 3: Temperature Compensated Voltage (TCV) control TCV slope is the same below and above
as a function of temperature for dual and single method + 20°C (+ 68°F). If no TCV control is
Control method Dual Single available, operate with a fixed voltage
VPC (Volt Per Cell) < + 20°C (+ 68 °F) > + 20°C (+ 68 °F)
-3.0 mV / °C / Cell -2.0 mV / °C / Cell -2.5 mV / °C / Cell setpoint of 1.42 V/cell.
T (°C) T (°F)
(-1.68 mV / °F / Cell) (-1.12 mV / °F / Cell) (-1.4 mV / °F / Cell)
-20 -4 1.540 1.520
-10 14 1.510 1.495
0 32 1.480 1.470
20 68 1.420 1.420 1.420
30 86 1.400 1.395
40 104 1.380 1.370
50 122 1.360 1.345

9
7.3 Charge acceptance floating and 1.45 ± 0.01 V for the first dependent on the state of charge of the
The performance data sheets for Vantex stage of a two step charge. Up to 0.2C5 A battery and the temperature. For much of
are based upon several months’ floating of recharge current can be used. After its charge profile it is recharged at a high
and so are for fully float charged cells. A 2 hours charge continues whereby a full level of efficiency. In general, at states
discharged cell will take a certain time to state of charge will be reached in 1 to 3 of charge less than 80 % the charge
achieve the state of charge. Figure 3 gives months. efficiency remains high. When the battery
the available capacity during charge. For approaches a fully charged condition, the
stationary application, the recommended 7.4 Charge efficiency charging efficiency decreases rapidly until
charge voltage is 1.42 ± 0.01 V for The charge efficiency of Vantex is fully charged when overcharge begins.

Figure 3(a): Available capacity after constant Figure 3(b): Available capacity after constant
voltage charge voltage charge
Available charge current 0.1C5 A or 0.2C5 A, for L type cell. Available charge current 0.1C5 A or 0.2C5 A, for M type cell.

100 100

90 90

80 80
% of rated capacity

% of rated capacity
70 70

60 60

50 50

40 40

30 30

20 20

10 10

0 0
0 2 4 6 8 10 12 14 16 18 20 22 24 0 2 4 6 8 10 12 14 16 18 20 22 24

Charging time (hours) Charging time (hours)

1.45 Vpc at + 20ºC (+ 68ºF), 0.2C5 A 1.45 Vpc at + 20ºC (+ 68ºF), 0.2C5 A
1.45 Vpc at + 20ºC (+ 68ºF), 0.1C5 A 1.45 Vpc at + 20ºC (+ 68ºF), 0.1C5 A
1.42 Vpc at + 20ºC (+ 68ºF), 0.1C5 A 1.42 Vpc at + 20ºC (+ 68ºF), 0.1C5 A
* For charging voltages higher than 1.45 V/cell, a current limit of * For charging voltages higher than 1.45 V/cell, a current limit of
0.1 C5 A is recommended 0.1 C5 A is recommended

8. Special operating factors

8.1 Electrical abuse 8.1.3 Overcharge tests at 5 g, 10 g and 25 g) and IEC
Overcharge is the effect of forcing current 60068-2-77 (shock test 3 g), where
8.1.1 Ripple effects
through a battery when it is fully charged. g = acceleration.
The nickel-cadmium battery is tolerant
to high ripple from standard charging
In the case of Vantex, with its generous 8.2.2 Vibration resistance
systems. Vantex accepts ripple currents
electrolyte reserve, a small degree of The Vantex block battery concept
up to 0.2 C5 A Ieff. In general, any
overcharge will not significantly alter complies with IEC 60068-2-77 where it
commercially available charger or
the maintenance period. In the case of was subjected to 2 hours at 1 g, where
generator can be used for commissioning
excessive overcharge or excessive cycling, g = acceleration.
or maintenance charging of Vantex.
water replenishment may be required but
there will be no significant effect on the 8.2.3 External corrosion
8.1.2 Over-discharge Vantex nickel-cadmium cells are
life of the battery.
If more than the designed capacity is taken manufactured in durable polypropylene,
out of a battery then it becomes over- all external metal components are
discharged. This is considered to be an 8.2 Mechanical abuse
nickel-plated and these components are
abuse situation for a battery and should be 8.2.1 Shock loads protected by an anti-corrosion oil and a
avoided. However, the Vantex battery is The Vantex block battery concept rigid plastic cover.
designed to recover from this situation. complies with IEC 60068-2-29 (bump

10
9. Battery sizing principles
in stationary applications
There are a number of methods which 9.3 Temperature concerning batteries in float applications.
are used to size nickel-cadmium batteries The maximum and minimum
for standby floating applications. The temperatures and the normal ambient This is used in the IEEE sizing method
method employed by Alcad is the IEEE temperature will have an influence on the and is included in the published data for
1115 recommendation which is accepted sizing of the battery. The performance Vantex.
internationally. This method takes into of a battery decreases with decreasing
account multiple discharges, temperature temperature which increases the battery As the effect of reducing the voltage level
de-rating, performance after floating size. Temperature de-rating curves are is to reduce the autonomy of the battery,
and the voltage window available for the provided to allow sizing adjustments. the effect can be considered as reducing
battery. the performance of the battery and so
performance down-rating factors are
9.4 State of charge or
A significant advantage of the nickel- used.
cadmium battery is that it can be fully recharge time
discharged without a significant impact in Some applications may require that the Note: for your battery sizing needs, please
terms of life or recharge. Thus, to obtain battery shall give a full duty cycle after a contact your local sales representative.
the most cost efficient battery, it is an certain time after the previous discharge.
advantage to discharge the battery to the The factors used for this will depend
lowest practical value in order to obtain on the depth of discharge, the rate of
the maximum energy from the battery. discharge, and the charge voltage and
current. A requirement for a high state
The principle sizing parameters are: of charge does not justify a high charge
voltage if the result is a high end of
discharge voltage.
9.1 The voltage window
This is the maximum voltage and the
minimum voltage at the battery terminals 9.5 Ageing
acceptable for the system. In battery terms, Some customers require a value to be
the maximum voltage gives the voltage added to allow for the ageing of the
which is available to charge the battery, battery over its lifetime. This may be
and the minimum voltage gives the a value required by the customer, for
lowest voltage acceptable to the system example 10 %, or it may be a requirement
to which the battery can be discharged. In from the customer that a value is used
discharging the nickel-cadmium battery, which will ensure the service of the
the cell voltage should be taken as low as battery during its lifetime. The value to be
possible in order to find the most economic used will depend on the discharge rate
and efficient battery. of the battery and the conditions under
which the discharge is carried out.

9.2 Discharge profile

This is the electrical performance 9.6 Floating effect
required from the battery for the When a nickel-cadmium cell is maintained
application. It may be expressed in terms at a fixed floating voltage over a period
of amperes for a certain duration, or of time, there is a decrease in the voltage
it may be expressed in terms of power level of the discharge curve. This effect
(watts or kW) for a certain duration. The begins after one week and reaches its
requirement may be simply a one step maximum in about 3 months. It can only
discharge or a many step profile. In order be eliminated by a full discharge/charge
to utilize all of the charged capacity, it’s cycle, and it cannot be eliminated by a
recommended to discharge the battery boost charge. It is therefore necessary to
until 1.00 V/Cell. take this into account in any calculations

11
10. Installation and operating
instructions
Type VTX1 L and VTX1 M
For cells delivered before May 2012, use the Installation and Operating instructions VTX4.1 – April 2008

Important recommendations
• Never allow an exposed flame or spark near the batteries, particularly while charging.
• Never smoke while performing any operation on the battery.
• For protection, wear rubber gloves, long sleeves, and appropriate splash goggles or face shield.
• 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, and obtain immediate medical attention.
• Remove all rings, watches and other items with metal parts 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.

10.1 Receiving the shipment 10.3 Installation The connectors and terminal should be
Do not overturn the package. Check the 10.3.1 Location corrosion-protected by coating with a thin
packages and cells for transport damage. Install the battery in a dry and clean layer of anti-corrosion oil.
room. Avoid direct sunlight and heat. The
The battery is shipped filled and charged, battery will give the best performance and 10.3.4 Electrolyte
and is ready for immediate use. maximum service life when the ambient When checking the electrolyte levels, a
temperature is between + 10°C to + 30°C fluctuation in level between cells is not
(+ 50°F to + 86°F). abnormal and is due to the different
10.2 Storage
amounts of gas held in the separators of
Store the battery indoors in a dry, clean,
each cell. There is normally no need to
cool location (0°C to + 30°C / + 32°F to 10.3.2 Ventilation
adjust the electrolyte level except if the
+ 86°F) and well ventilated space on open During the last part of charging, the
level is 30 mm below the minimum level
shelves. battery is emitting gases (oxygen and
mark. The cells have to be topped-up with
hydrogen mixture). At normal float charge
E22 electrolyte.
Storage of a filled battery at temperatures the gas evolution is very small but some
above + 30°C (+ 86°F) can result in loss ventilation is necessary. Do not top-up prior to initial charge.
of capacity. This can be as much as 5 %
After commissioning, when the level is
per 10°C (18°F) above + 30°C (+ 86°F) per Note that special regulations for
stabilized, it should be not less than 5 mm
year. ventilation may be valid in your area
below the maximum level mark.
depending on the application.
Do not store in direct sunlight or expose
to excessive heat. 10.3.3. Mounting 10.4 Commissioning
Verify that cells are correctly Verify that the ventilation is adequate
Vantex batteries are supplied filled with interconnected with the appropriate during this operation.
electrolyte and charged, they can be polarity. The battery connection to load
stored in this condition for maximum 24 should be with nickel-plated cable lugs. A good commissioning is important.
months from date of shipment. Recommended torques for terminal bolts Charge at constant current is preferable.
are: If the current limit is lower than indicated
Never drain the electrolyte from the cells. • M6 = 11 ± 1.1 N.m (97.4 ± 9.8 lbf.in) in the table on the Installation and
• M8 = 20 ± 2 N.m (177.0 ± 17.7 lbf.in) Operating Instructions sheet, charge for a
Store without opening the boxes. • M10 = 30 ± 3 N.m (265.0 ± 26.6 lbf.in) proportionally longer time.

12
• Cells stored up to 6 months: temperature exceeds + 45°C (+ 113°F) As a periodic maintenance, the following
A commissioning charge is normally during charging, then it must be is recommended:
not required and the cells are ready for stopped to reduce the temperature. • Keep the battery clean using only
immediate use but the full performance The charging can be resumed when water. Do not use a wire brush or
will be available only after a long period electrolyte temperature drops below solvents of any kind.
of charging in service (see section 7.3 + 40°C (+ 104°F).
• Check the charging voltage. In parallel
Charge acceptance)
Note: When full battery performance is operation, it is of great importance that
• Cells stored more than 6 months and up the recommended charging voltage
to 2 years: required for capacity test purposes, the
battery has to be charged in remains unchanged. The charging
A commissioning charge is necessary:
accordance with IEC 62259 section 7 voltage should be checked at least
• Commissioning at ambient
(7.1 & 7.2). once yearly. If a cell float voltage is
temperature between + 10°C to + 30°C
found below 1.35 V, high rate charge
(+ 50°F to + 86°F)
is recommended to apply to the cell
- Constant current charge: 10.5 Charging in service concerned.
20 h at 0.1 C5 A recommended. The recommended charging voltages
for continuous parallel operation, with • Check visually the electrolyte level.
Note: At the end of charge, the cell Never let the level fall below the
occasional battery discharges, are:
voltage will reach about 1.75 V, minimum level mark. Use only distilled
thus the charger shall be able to
• Two level charge:
• float level: 1.42 ± 0.01 V/cell or de-ionized water to top-up.
supply such a voltage. • high rate (boost) level: 1.45 ± 0.01 V/cell
Topping-up of the Vantex battery shall
When the charger maximum voltage • Single level charge: be carried out when battery is fully
setting is too low to supply constant 1.42 ± 0.01 V/cell
charged.
current charging, divide the battery
into two parts to be charged To have the full maintenance-free Note: There is no need to check
individually at constant current. feature in terms of topping-up for high the electrolyte density periodically.
- Constant potential charge: temperature, the correction factor to Interpretation of density
1.55 V/cell for a minimum of 24 h, apply is - 2.0 mV/°C (- 1.12 mV/°F) starting measurements is difficult and could be
current limited to 0.1 C5 A. from an ambient temperature of + 20°C misleading.
If these methods are not available, (+ 68°F) (see section 7.2 Temperature
compensation). • Check every two years that all
then charging may be carried out connections are tight.
at lower voltages, 1.50 V/cell for 36
hours minimum. 10.6 Periodic maintenance • The connectors and terminal bolts
should be corrosion-protected by
• Commissioning at ambient Vantex is a maintenance-free battery
coating with a thin layer of anti-
temperature above + 30°C (+ 50°F) under the recommended operating
corrosion oil.
- Only constant current charge: conditions, from - 20°C (- 4°F) to + 40°C
20 h at 0.1C5 recommended. (+ 104°F) at 1.42 V/cell, with temperature • High water consumption is usually
The electrolyte temperature is to compensation and requires only caused by improper voltage setting of
be monitored during charge. If the preventive maintenance. the charger.

11. Maintenance
In a correctly designed stationary it is recommended that the following • The batteries should also be checked
application, Vantex only requires actions should be taken: for external cleanliness, and if necessary
preventive maintenance. • Cell electrolyte levels should be checked cleaned with a damp brush using water.
visually to ensure that the level is above Do not use a wire brush or solvents of
However, it is good practice with any
the minimum and if necessary the cells any kind. Vent plugs can be rinsed in
system to carry out an inspection of the
should be topped-up. Use a specific clean water if necessary.
system once per year to ensure that the
charging system, the battery and the
tool to loosen the flame-arresting low • All the connectors must be tight. The
pressure vents to release gas pressure connectors and terminal bolts should be
ancillary electronics are all functioning
and then remove each vent completely corrosion-protected by coating with a
correctly.
and retain for refitting. Use only distilled thin layer of anti-corrosion oil.
When this system service is carried out, or de-ionized water.

13
12. Disposal and recycling
In a world where autonomous sources impact. Environmental protection is our confidence in our products, not only from
of electric power are ever more in top priority, from design and production a functional standpoint, but also in terms
demand, Alcad batteries provide an through end-of-life collection, disposal of the environmental safeguards that are
environmentally responsible answer to and recycling. built into their life cycle. The simple and
these needs. Environmental management unique nature of the battery components
lies at the core of Alcad’s business and Our respect for the environment is make them readily recyclable and this
we take care to control every stage of a complemented by an equal respect for process safeguards valuable natural
battery’s life cycle in terms of potential our customers. We aim to generate resources for future generations.

Pure New Battery

cadmium batteries use

Spent
Distillation batteries

Cadmium
plates Dismantling

Ferro Steel Nickel

nickel works plates

Standards list:
§ Certified IEC 62259 - Secondary cells and batteries containing alkaline or other non-acid electrolytes - Nickel-cadmium prismatic
secondary single cells with partial gas recombination. Vantex New Generation exceeds gas recombination requirements.
§ Certified IEC 60623 - Secondary cells and battery containing alkaline and other non-acid electrolytes - Vented nickel-cadmium
prismatic secondary single cells
§ IEC 60068-2-29 - Environmental testing - Part 2: Tests. Test Eb and guidance: Bump
§ IEC 60068-2-77 - Environmental testing - Part 2-77: Tests - Test 77: Body strength and impact shock
§ IEC 60050-482 - International electro technical vocabulary - Part 482: Primary and secondary cells and batteries
§ Complies with EN 50272-2 / IEC 62485-2 - Safety requirements for secondary batteries and battery installations - Part 2: Stationary
batteries - The protective covers for terminals and connectors, the insulated cables are compliant with IP2 level protection against
electrical shocks according to safety standard.
§ IEEE 1115-2000 - IEEE Recommended practice for sizing Nickel-Cadmium batteries for stationary applications

14
Alcad:
Preserving our planet for the future
Our environmental commitment:

• Using recycled materials ahead of raw materials

• Consistently cutting emissions from our production facilities
• Minimising water consumption
• Reducing fossil fuel usage and CO2 production
• Making provision for battery recycling

Recycling: Alcad Limited

Making a difference all over the world Sweden

Telephone: +46 491 68 100
We are committed to helping our customers find recycling solutions for depleted Facsimile: +46 491 68 110
batteries. Alcad has long links with collection companies in most EU countries, in
North America and all countries where the system can be implemented. Its collection
network receives and dispatches customers’ batteries at the end of their lives to fully Alcad Sales Offices
approved recycling facilities, in compliance with the laws governing trans-boundary
waste shipments.

Photo credits: Alcad, Fotolia. Data in this document are subject to change without notice and become contractual only after written confirmation by Alcad.
Our network of collection companies conforms to the EU batteries directive. All of
our collection locations are listed on our web site. In countries where we have thus
far been unable to set up collection sites, we assist our customers in seeking out
viable recycling options.
For more information, please get in touch with your Alcad sales representative.

United Kingdom
Telephone: +44 1279 772 555

Middle East

VTX 3.3 June 2013. Produced by Arthur Associates Limited. Printed in the UK.
Telephone: +357 25 871 816
Facsimile: +357 25 343 542

Asia
Telephone: +65 6 7484 486
Facsimile: +65 6 7484 639

USA
Telephone: +1 203 985 2500
Facsimile: +1 203 985 2539

www.alcad.com