1. Introduction.............................................................................................................

2
2. Advantages of the Ferak NiCd pocket plate batteries............................................. 2
3. Electrochemistry of nickel-cadmium batteries......................................................... 3
4. Structural components of pocket plate batteries..................................................... 4
5. Battery types and applications................................................................................ 5
6. Operating features.................................................................................................. 6
7. Battery dimensioning principles ............................................................................ 12
8. Battery charging ................................................................................................... 14
9. Special operating factors ...................................................................................... 18
10. Installation and storage....................................................................................... 19
11. Maintenance of batteries in operation................................................................. 22
 1. Introduction
The nickel-cadmuim battery is the most reliable battery system that is available on the
market. Its exceptional properties allow it to be used for applications in environments that are
usually unacceptable for the other battery systems that are currently available.
Nickel-cadmium batteries are sought by users who demand a reliable and durable system
which does not require sophisticated maintenance.
This manual details the characteristic design and operating features of the Ferak battery
range, advising the user on how to set up a successful battery system.
The Ferak batteries uphold all the technical advances and advantages achieved in almost 45
years of pocket plate technology development.

2. Advantages of the Ferak NiCd pocket plate batteries

2.1 Very high reliability

The Ferak batteries are not suscetiple to power failures due to "sudden death", which is
common in lead batteries (see section 4.1 Plate design).

2.2 High number of charge/discharge cycles in terms of service life

The Ferak batteries are capable of a high number of charge / discharge cycles in terms of
their service life and it does not have to be completely discharged in one cycle (see section
6.7 Cycles).

2.3 Exceptionally long service life

In many applications, Ferak battery service life can exceed twenty years. Under raised
temperatures their life is incomparably longer than that of the other battery systems that are
currently available (see section 6.8 Temperature to life effect).

2.4 Low maintenance

Due to a sufficient electrolyte supply, Ferak batteries can be left at remote locations without
maintenance for long periods (see section 6.9 Water consumption and gas generation).

2.5 Wide range of operating temperatures

The electrolyte used in Ferak batteries allows them to operate in temperatures ranging from -
20°C to + 50°C and to withstand even extreme temperatures of -50°C to +60°C (see section
4.3 Electrolyte).

2.6 Rapid recharging

Ferak batteries can be recharged by a current that allows for very quick charging (see
section 8.3 Charging time).

2.7 Physical damage resistance

The design of the Ferak batteries provides a very sturdy physical strength, allowing them to
withstand rough treatment associated with transportation over difficult terrain without
sustaining any damage (see section 9.2 Physical damage).

2.8 High electrical overload resistance

ferak batteries can endure all the overloads such as overcharge, deep discharge or the high
blips that would destroy lead batteries (see section 9.1 Elektrical overload).

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2.9 Easy installation
Ferak batteries can be used for a wide range of both stationary and mobile applications,
because they generate no corrosive vapours, use polypropylene containers and have a
simple screwed connector system (see section 10 Installation and storage).

2.10 Extended storage life

When stored empty, discharged and in the recommended conditions, ferak batteries can be
stored for many years (see section 10 Installation and storage).

2.11 Well-tried pocket plate design

Saft Ferak a.s. has almost 50 year experience in the manufacture and the application of
nickel-cadmium accumulators with a pocket plate design that leads to the very long life of the
batteries (see section 4 Structural members of pressed plate batteries).

2.12 Environment friendly

Saft runs a specialised recycling centre where materials such as nickel, cadmium, steel and
plastics are extracted and then reused in battery production.

2.13 Low cost of cycle and life

Considering all the factors - long life, low maintenance requirements, easy installation, easy
storage and high damage resistance, Ferak batteries present the most effective solution for
many professional applications.

3. Electrochemistry of nickel-cadmium batteries

Nickel-cadmium batteries use nickel dihydroxide as the active material for the positive plate
and cadmium hydroxide as the active material for the negative plate.
The electrolyte is a water solution of potassium hydroxide containing a small amount of
lithium hydroxide to improve both life during the cycle and functioning in high temperatures.
The electrolyte is used only for ion transfer, it does not engage chemical changes or
depreciation during the change / discharge cycle. In the case of lead batteries, the positive
and negative active components chemically react with the electrolyte (sulphuric acid), which
leads to aging.
Both the positive and negative plate supporting structures are made of steel. It remains
untouched by the electrolyte and upholds its strenght for the whole life period of the cell. The
basic structure of both plates of a lead battery is made of lead and lead oxide. These
substances take part in electrochemical processes and naturally corrode during the battery
life.

The following is the nickel-cadmium battery charge / discharge reaction:

discharge ==> 2 Ni(OH)2 +

2 NiOOH + 2 H2O
Cd(OH)2
+ Cd <== charge
During discharge, trivalent hydrated nickel oxide is reduced to divalent nickel oxide and
cadmium of the negative plate is oxidised to cadmium hydroxide.
During charging, the opposite reaction takes place until the cell potential reaches a level
when hydrogen is released at the negative plate and oxygen at the positive plate, leading to
the loss of water.
Unlike lead batteries, a minimum change of the electrolyte density occurs during charge and
discharge. This allows the use of a considerable electrolyte reserve without affecting
electrochemical processes between the plates.

3
Considering its electrochemical principle, the nickel-cadmium battery performance is more
stable than that of the lead battery, it has longer life, better parameters and stronger
resistance to adverse conditions.
The rated voltage of the nickel-cadmium cell is 1,2 Volt.

4. Structural components of pocket plate batteries

4.1 Plate design

A nickel-cadmium cell consists of two groups of plates: the positive plates contain nickel
dihydroxide, the negative plates cadmium hydroxide.
Active components of the Ferak pocket plate batteries are placed in pocket made of
perforated steel trips.
These pockets are mechanically connected, trimmed to the size corresponding with the plate
width and pressed into the final plate size. The result of this process is reflected in the
mechanical strength of the plate. Moreover, the steel bushing in which the active part of the
plate is placed improves conductance and minimises electrode expansion.
Subsequently, the plate are welded or bolted to a conducting bus-bar set, which provides the
mechanical and electrical stability of the battery.
Nickel-cadmium batteries have exceptionally long lives and are capable of a high number of
cycles because their electrodes are not gradually weakend by corrosion - the plate structural
component is made of steel. The plate active component is not structural, only electrical.
Alkaline electrolyte does not react with steel, which means that the battery supporting
structure remains untouched and unchanged for the whole battery service life. There is no
corrosion and no risk of "sudden death".
In contrast, lead battery plates consist of structural as well as active material, which leads to
the wear of the positive electrode material or to a structural collapse.

4.2 Insulation
Separation of plates is secured by injecting moulded plastic separators, which separate and
the electrode plates from each other.

4
Because there is sufficient space and a sufficient amount of electrolyte between the positive
and negative plate, good circulation of electrolyte and gas dispersion is ensured and no
electrolyte break-down occurs as in the case of lead / acid batteries.

4.3 Electrolyte
The electrolyte used in Ferak batteries - a solution of potassium hydroxide and lithium
hydroxide - is optimised so that it provides the best combination of output, power efficiency
and a wide temperature range.
The standart electrolyte is concentrated to such a level that the cell can work in extreme
temperature - minimum of -20°C and maximum of +60°C. This allows is to adapt to very high
temperature fluctuations in certain areas.
A special electrolyte with higher density can be used for operation in very low temperatures.
An important feature of Ferak batteries is the fact that the electrolyte is not subject to
changes during charging and discharging. It maintains the ability to transfer ions between the
cell plates regardless of the charge level.
In most applications, the electrolyte upholds its efficiency for the whole battery life period and
there is no need to replace it. Under certain circumstances, such as long use under high
ambient temperatures, the amount of carbonates in the electrolyte can increase.
If this occurs, the battry output can be increased by replacement of the electrolyte (see
section 11.4).
The standart electrolyte used for the first cell fill (see section 10.5 Discharged and empty
cells) is E22, and E13 is used for replacement during service.

4.4 Pole terminals

Pole terminal bolts are welded to the plate bus-bars in a well-tested method. These bolts are
made of steel bars, nickel-coated and fitted with a thread enabling the connecting material to
be attached.
The space between the vessel cap and the bolt pan is sealed with a compressed elastic
rubber sealing fixed with a bottom bolt nut. This structure is designed so that it provides a
satisfactory tightness for the whole accumulator cell life period.

4.5 Plug
Ferak accumulators are fitted special plugs with hinged caps, which create an effective and
safe ventilation system.

4.6 Accumulator cell vessel

The cell vessel is made of a resistant translucent polypropylene material that is well-
established in battery design. The cell cap and vessel are fitted with special melting frames
providing a homogenous connection after welding.

5. Battery types and applications

Ferak batteries are made in three output ranges so that an optimal solution for a wide range
of battery applications is ensured.

5.1 L type
The L type is suitable for the applications where the battery should provide a reliable power
supply for a relatively long discharge time. The current is usually low compared to the total
amount of stored energy and discharge occurs relatively seldom. Typically, it is used as a
back-up power supply and for storing a large amount of energy .

5.2 M type
The M type is suitable for applications where the battery must usually cover the electrical
load for a time period between 30 minutes and 3 hours or the "mixed" loads where there are

5
discharges with both low and high discharge currents. Discharging can occur often as well as
seldom. Products of this range are usually used as back-up power supplies.

5.3 H type
The H type is suitable for applications where there is a requirement for a relatively high
current for a short time period, usually less than 30 minutes. Discharge can occur both often
as well as seldom. Products of this range are typically used in start-up and back-up
applications.

5.4 Type selection

As for the output, these ranges cover the whole time spectrum from quick discharge with
high currents of duration of seconds to a very long discharge with low currents that take
several hours. Table 1 shows a general division of all Ferak battery types according to their
method of discharging. The selection depends on the discharging time and on final discharge
voltage. Obviously, there are different kinds of discharging in different applications, so the
optimal type range must be calculated.

5.5 Application
Ferak batteries provide stanby, back-up and emergency power supplies for industry, trade,
government and defence section, for power supply and distribution equipment, railway
offices, hospitals, airports, public buildings, bus and car transport companies, communication
networks, oil and petrochemical industry etc. The industrial applications include all kinds - for
example emergency lighting, switch cintrols, UPS, production control, data and information
systems, signalling, starting turbines and motors, and electrical control of trains.

Table 1 - general selection of the cell type range

6. Operating features

6.1 Capacity
The capacity of the nickel-cadmium battery is expressed in ampere-hours (Ah) and it
presents the amount of electrical power that the battery can supply during a five-hour
discharge at 1,0 V after it has been recharged for 7,5 hours at 0,2 C5 A. This value complies
with the IEC 623 standard.

6
6.2 Cell voltage
The voltage of one nickel-cadmium cell is given by a difference of electrochemical potentials
of nickel and cadmium active materials within the enviroment of the potassium hydroxide
electrolyte. The rated voltage of this electrochemical pair is 1.2 V.

6.3 Internal resistance

The internal resistance of the cell changes depending on the temperature and the charge
condition and therefore it is difficult to define and measure it precisely. The most important
parameter for general applications is the dependence of the discharge voltage on the change
of the discharge current.
The internal resistance of the Ferak pressed electrode cell depends on the performance of
the particular type range and on the cell capacity. Normal values for the internal resistance
are specified in the catalogues with performance data.
Normal values apply for totally charged cells. For a lower charge, the internal resistance
values increase. For a 50 % cell discharge, the internal resistance increases by about 20 %
and for 90 % by about 80 %. The internal resistance of the totally discharged cell has no
practical effect.
A drop in temperature also raises the internal resistance it increases by about 40 % at 0°C.

6.4 Temperature to output effect

Temperature changes affect the cell performance and must be considered when designing
the battery.
Operation in low temperatures decreases the performance while the parameters for higher
temperatures are closer to the normal temperature parameters. A low temparature effect is
more evident at the higher discharge rate.
Performance decrease coefficients, which should compensate the temperature fluctuation in
battery dimensioning, are graphically show on figure 1(a) for the H type, on figure 1(b) for the
M type and 1(c) for the L type, for operating temperatures ranging between -30°C and
+50°C.

Figure 1(a) - Decrease of the H type cell performance depending on the temperature and the discharge mode
Note - a special electrolyte must be used for a long-term use in temperatures below -20°C

7
Figure 1(b) - Decrease of the M type cell performance depending on the temperature and the discharge mode
Note - a special electrolyte must be used for a long-term use in temperatures below -20°C

Figure 1(c) - Decrease of the L type cell performance depending on the temperature and the discharge mode
Note - a special electrolyte must be used for a long-term use in temperatures below -20°C

6.5 Short-circuit current

A typical value for the short-circuit current for Ferak batteries equals approximately six-fold
value of the ampere-hour capacity of the L type cell, ten-fold of the ampere-hour capacity of
the M type cell and twenty-fold of the ampere-hour capacity of the H type cell.
A battery made of copper couplings bolted down to the pole terminal bolts can bear a shor-
circuit current of this value without suffering any damage for several minutes.

8
6.6 No-load losses
The state of the cell charge for a disconnected circuit decreases slowly in time due to self-
discharging. In fact, this decrease is relatively fast in the first two weeks of use but then it
stabilises to about 2 % a month at 20°C.
The nickel-cadmium cell self-discharge parameters depend on temperature. The charge
decrease is lower for low temperatures than for normal temperatures and thus the losses are
lower for a disconnected circuits. However, the self-discharge increases considerably for
higher temperatures. Figure 2 shows typical losses for a nickel-cadmium pocket plate cell for
a disconnected circuit.

Figure 2 - Decrease of the NiCd cellcapacity for a disconnected circuit

6.7 Cycling
The Ferak battery is designed so that it can bear the wide range of cycle types occuring in
different applications. It ranges between a very small discharge and 100% discharge while
the number of cycles that the product is capable of depends on the discharge depth in each
cycle.
The deeper the cycled battery discharge is, the more cycles the battery can provide during
its life period. The Ferak battery can provide as many as several thousand cycles with a
shallow discharge while it can provide only several hundred cycles with a deep discharge.
Figure 3 shows typical values of the effect of depth to the number of possible cycles. It is
clear that the number and depth of cycles have a significant effect on the system life forecast
in battery dimensioning for an application with cycles.

9
Figure 3 - Typical life of the NiCd cell depending on the discharge depth

6.8 Temperature to life effect

The designed life of a Ferak battery is 20 years, but the expected life decreases under
conditions of elevated temperature, as in other battery systems. However, the decrease of
the nickel-cadmium battery life, due to the elevated temperature, is much slower than for
lead batteries.

Figure 4 - Temperature to accumulator life effect

Figure 4 shows the decrease in the life of the nickel-cadmium battery compared to a high-
quality lead battery. The values for the lead battery are quoted from industrial sources and
can be found in the Eurobat and IEEE documents.
In general, with every increase of temperature by 10°C above the normal operating
temperature of 25°C, the nickel-cadmium battery life decreases by 20 % and the lead battery

10
life by 50 %. When dimensioning a nickel-cadmium battery, it is then necessary to consider
applications for high temperatures carefully. However, a lead battery is not the solution for
the same conditions, considering its very short life. For example, for the VRLA battery with
an expected life of about 7 years under general conditions, its life will decrease to less than 1
year if it is used at the temperature of 50°C.

6.9 Water consumption and gas generation

When being discharged, but battery receives more ampere-hours than its discharge capacity.
These redundant ampere-hours are needed for the full recharge of the battery. However, the
cell will not retain all of them and not all of them contribute to chemical changes of the active
substances. This surplus charging, or overcharging, decomposes water contained in the
electrolyte to oxygen and hydrogen and it is this necessary to compensate this loss by
replenishment with clear distilled or demineralized water.
The loss of water is associated with the current used in overcharging. A battery that
passes through cycles continually, i.e. it is charged and discharged regularly, then
consumes more water than a battery in the standby mode.
Theoretically, the amount of used water can be calculated using the Faraday
equation, according to which every ampere-hour of overcharging decomposes 0.366
cubic centimetres of water. But in practice, the water consumption will be lower
because a part of the overcharging current is consumed, preventing the self-
discharging of electrodes.
The overcharging current is a function of voltage and temperature, so the water
consumption is affected by both quantities. Figure 5 shows some typical values of
water consumption for different voltages and different cell types.

Figure 5 - Water consumption for charging with a constant voltage

Example:
The KPL 160 P battery is maintained by a constant charge voltage of 1,42 V per cell. The
electrolyte supply of such a cell is 360 ml. From figure 5, the L type cell will consume 0.16
cubic centimetres of water a month per capacity of one Ah at the voltage of 1.42 V. It means
that the KPL 160 P battery will consume 0.16 x 160 = 25.6 cubic centimetres of water a
month and the electrolyte supply will be consumed in 360 : 25.6 = 14.06 months.

11
The amount of the gas generated depends on the amount of water decomposed by the
electrolysis to hydrogen and oxygen. Gas starts to generate predominantly at the end of the
charging period. No gas generates when the battery is discharged normally.
1865 cubic centometres of gas mixture will be generated by the electrolysis of 1 cubic
centimetre of water; this mixture will be made up by 2/3 of hydrogen and 1/3 of oxygen.
Electrolysis of 1 cubic centimetre of water will thus produce about 1240 cubic centimetre of
hydrogen.

7. Battery dimensioning principles

Dimensioning of nickel-cadmium batteries for steady standby applications can be done in
several ways. For example, we can use "Hoxie" method, IEEE 1115. All these methods
consider multiple discharging, temperature decrease of performance, efficiency for charging
with a constant voltage and a vpltage window associated with the battery. All these methods
are more or less approximate.
A significant advantage of nickel-cadmium batteries compared to the lead ones is the fact
that they can be totally discharged without a negative effect on their life or the possibility of
futher charging. It is then advantageous to discharge the used battery totally to obtain
maximum energy.

The following are the basic parameters for dimensioning:

7.1 Voltage window

It is the maximum vpltage range on the battery terminals that is acceptable for the system.
The maximum voltage is the voltage that will charge the battery and the minimum vpltage is
the lowest voltage acceptable for the system to which the battery can be discharged. When
discharging, the final voltage of the cell should be as low as possible so that the battery
provides the most economic and efficient system.

7.2 Discharge profile

It is the electrical performance required from the battery in an application. The discharge
profile is usually expressed in amperes during a specified period or as an output in wattts or
kilowatts during a specified period. It can be a simple discharge or a more complex one that
consists of several different discharges.

7.3 Temperature
Maximum, minimum and the usual temperature of the environment also affect battery size.
The battery performance decreases with decreasing temperature and therefore the
requirement for the battery size increase when they are dimensioned for low temperatures.
The performance decrease curves, depending on temperature, are available for all cell types
so that they can be used in calculations.

7.4 Charge state or charging time

Some applications require that the battery provides a high current only after the lapse of a
specified time period from the last discharge. Performance decrease coefficients will depend
on the discharge depth, discharge mode and on the charging voltage and current (see
section 8.3). However, the battery size will only be affected by that part of the voltage that
exceeds the level of the maintaining voltage (see section 7.6).

7.5 Aging
Some customers require an increase of battery capacity that ensures its sufficient function
for the whole battery life period. It can be the value that is required by the customer himself,
e.g. 10 %, or another value which ensures meeting specified requirements.

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7.6 Maintaining voltage effect
If a nickel-cadmium cell is maintained in the charged state by a constant voltage for a certain
time, there will be a decrease of the discharge curve volatge level. This effect occurs after
one week and reaches its maximum after about three months. It can only be eliminated by
total discharge/charge cycle. It cannot be eliminated by a stronger discharge.
This effect must be taken into consideration in any calculations regarding batteries in
applications where they are charged (recharged) with a constant voltage power supply
(operation of the battery with a supply unit). The result of the voltage decrease in discharging
is a reduction of the battery function; it is necessary to use the performance decrease
coefficients. These coefficients for Ferak batteries are shown in Table 2. It is then possible to
use the performance data for the total charge and to multiply them by the performance
decrease coefficient, or to use the performance data calculated from the results of the
accumulator cell measurements by the application of this effect. The dimensioning procedure
mentioned below uses the first possibility.

Table 2(a) - performance decrease coefficients due to the maintaining voltage of the fully charged H type cells
Time
Final
voltage seconds minutes hours
1 5 30 60 5 10 15 20 30 1 1,5 2 3 5
1,14 V/cell 0,71 0,71 0,71 0,71 0,72 0,75 0,79 0,81 0,89 0,94 1,00 1,00 1,00 1,00
1,10 V/cell 0,76 0,76 0,76 0,76 0,77 0,81 0,85 0,87 0,92 0,99 1,00 1,00 1,00 1,00
1,05 V/cell 0,81 0,81 0,81 0,81 0,83 0,88 0,92 0,95 1,00 1,00 1,00 1,00 1,00 1,00
1,00 V/cell 0,84 0,84 0,84 0,84 0,88 0,93 0,97 1,00 1,00 1,00 1,00 1,00 1,00 1,00

Table 2(b) - performance decrease coefficients due to the maintaining voltage of the fully charged M type cells
Time
Final
voltage seconds minutes hours
1 5 30 60 5 10 15 20 30 1 1,5 2 3 5
1,14 V/cell 0,67 0,67 0,67 0,67 0,67 0,67 0,67 0,68 0,69 0,72 0,75 0,77 0,85 1,00
1,10 V/cell 0,71 0,71 0,71 0,71 0,71 0,71 0,72 0,73 0,74 0,77 0,80 0,84 0,93 1,00
1,05 V/cell 0,75 0,75 0,75 0,75 0,75 0,76 0,76 0,76 0,78 0,82 0,85 0,90 1,00 1,00
1,00 V/cell 0,80 0,80 0,80 0,80 0,80 0,80 0,81 0,82 0,83 0,87 0,93 1,00 1,00 1,00

Table 2(c) - performance decrease coefficients due to the maintaining voltage of the fully charged L type cells
Time
Final
voltage seconds minutes hours
1 5 30 60 5 10 15 20 30 1 1,5 2 3 5
1,14 V/cell 0,65 0,65 0,65 0,65 0,65 0,66 0,67 0,68 0,68 0,71 0,73 0,74 0,76 0,81
1,10 V/cell 0,70 0,70 0,70 0,70 0,70 0,71 0,72 0,73 0,73 0,76 0,78 0,80 0,83 0,90
1,05 V/cell 0,74 0,74 0,74 0,74 0,75 0,76 0,76 0,77 0,78 0,81 0,84 0,86 0,91 1,00
1,00 V/cell 0,79 0,79 0,79 0,79 0,80 0,80 0,81 0,82 0,83 0,87 0,90 0,95 1,00 1,00

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 8. Battery charging

8.1 Charging in general

Ferak batteries can be charged using all the usual methods. Generally, batteries are charged
with a constant voltage in parallel connection with a charger and a load. In cases when the
battery is charged separately from the load, it is possible to charge it with a constant or
decreasing current. Charging with high current values or overcharging will not damage the
battery, but the redundant charging will increase water consumption.

8.2 Charging with a constant voltage

Batteries in standard applications are usually charged using a constant voltage system.
There are two types of these system: a two-stage charge, when the initial constant charge
voltage is later replaced with a lower maintaining voltage, or a type with only one voltage
level.
The charge voltage value in the system with a flat charge voltage level must be a
compromise btween a voltage high enough for a reasobably long charge and low enough for
low water consumption. A Simpler charging system, however, will allow for a lower voltage
window than the two-stage charger.
The two-stage charger works with a higher voltage in the first stage of charging, after which
there is a stage with a lower maintaining voltage. This allows a rapid battery recharge without
consuming a large amount of water.
Table 3 shows the values of charging and maintaining voltages used for each Ferak battery
type range.

Table 3 - charging and maintaining voltages for the Ferak battery types

One-level Two-level
self-
minimum maximum minimum maximum
discharging
H 1,43 1,50 1,45 1,70 1,40
M 1,43 1,50 1,45 1,70 1,40
L 1,43 1,50 1,47 1,70 1,42

It is appropriate to use a low value for the cell charge voltage lest high water consumption
occurs. Generally, it is recomended to use the maximum value for the voltage as the value of
one-stage and two-stage charge voltage. Thus the most effective final cell voltage is ensured
at the same time within the range of the voltage window (see the section Battery
dimensioning).
The above mentioned maximum values of the voltage are acceptable for the battery, but they
are usually not used in practice, especially for the one-stage charging, considering the high
water consumption.

8.3 Charging time

It takes a certain time for the discharged battery to reach its full charge. Fugures 6 (a), (b)
and (c) show the capacity reached with the typical charging voltages recommended for the
pocket plate battery type during the first 30 hours of charging after total discharge.

14
Figure 6(a) - Obtainable capacity depending on the charging time using a constant voltage from the state of total
discharge for the H type cells

Figure 6(b) - Obtainable capacity depending on the charging time using a constant voltage from the state of total
discharge for the M type cells

These charts show the capacity to which a nickel-cadmium battery can be charged with a
constant voltage at the current constraint of 0.2 C5 amperes, depending on the charging
time. If a lower current constraint is used, e.g. 0.1 C5 amperes, charging of the battery will
take longer.
If a higher current is used charging will be quicker but less effective, so this dependence is
not directly proportional.
The figure 6 (d) shows the capacity to which a nickel-cadmium M type battery can be
charged with a constant voltage at a different current constraint, depending on the charging
time.

15
Figure 6(c) - Obtainable capacity depending on the charging time using a constant voltage from the state of total
discharge for the L type cells

Figure 6(d) - Obtainable capacity depending on the time of charging with a constant voltage at a different charging
current constraint

If the particular charging time is required in the given application, it must be taken into
consideration when dimensioning the battery.

8.4 Charge effectiveness

The battery charge effectiveness depends on the battery charge state and on the
temperature. Charging proceeds with high effectiveness within the major part of the charging
profile range.
The effectiveness generally remains high in charges to less than 80 %, but it decreases
when the battery approaches the full charge state. This is shown graphically in figure 7.

16
Figure 7 - Obtainable capacity as a function of the capacity provided by charging

8.5 Temperature effects

The higher the temperature, the higher the electrochemical process activity. The charging
(recharging) current will thus increase with the constant maintaining voltage. When the
temperature decreases, a reverse process starts. A current increase will cause a higher
water loss, when the current decreases an insufficient cell charge may occur. It is therefore
appropriate to maintain the charging current at the required level through changes of
maintaining voltage according to the temperature changes. Recommended voltage
adjustment required for the temperature compensation is -3mV/°C/cell, starting from an
environment temperature of +20 to +25°C.

8.6 Initial charge

Initially the battery should be well charged before it is first put into operation. This operation
cannot be repeated and therefore it is necessary to prepare the battery carefully for its long
service life. This is important even for discharged and recharged cell in a state of total
discharge.
The first charge should be carried out with a constant current and it should give the cell 300
% of its rated capacity. A cell with the capacity of 250 Ah will then need 750 Ah for the first
charge, for example 50 amperes during 15 hours.
Cells that were stored less than one year shouldbe charged with the recommended charging
current for 15 hours before putting into operation.
Cells that have been stored for more than one year or were delivered discharged and then
recharged should be charged with the recommended charging current for 15 hours, then
discharged to 1.0 V per cell and recharged with the recommended charging current for 10
hours.
If charging with a constant current cannot be provided, you can use the method of charging
with a constant voltage of a higher level instead. For example, a voltage of 1.65 V can be
used for a time period of 20 to 30 hours if the current constraint approximately equals the
recommended charging current. If the current constraint is lower, the charging time must
likewise be extended.
If the charger has a maximum voltage that is too low to be able to charge with a constant
current, divide the battery into two parts and charge them separately.
The battery can be put into operation after the initial charge.

17
 9. Special operating factors
9.1 Electrical overload

Ripple effect
Nickel-cadmium batteries are resistant to a high ripple effect and they can bear the peak-
peak current ripple of 0.5 C5 A. The only manifestation of a high current amplitude is
increased water consumption. In general, any commercially available type of charger or
generator can be used for the initial or maintaining charging of Ferak batteries. It is a
considerable difference compared to tube electrode lead batteries (VRLA), which can get
overheated by even a small current ripple and subsequently their life and performance are
reduced. For VRLA batteries, the voltage ripple effect cannot exceed 2.5 % of the
recommended maintaining voltage.

Underdischarge
IIf a greater capacity is drawn from the battery than is its designed value, a battery
”underdischarge” occurs. This condition overloads the battery and therefore it should be
avoided.
For lead batteries, underdischarge is unacceptable because it causes a fault in the battery.
Underdischarge does not damage the Ferak battery, it is necessary, however, to
compensate it by recharging.

Overcharging
Ferak batteries have a sufficient supply of the electrolyte so a mild short-term overcharging
does not considerably affect the maintenance time. If extensive overcharging occurs, water
must be replenished, but the battery life will not be considerably affected.

9.2 Physical damage

Load by surges
The Ferak battery design has passed the IEC 77 standard tests.

Vibration resistance
The Ferak battery design was tested in accordance with the IEC 77 standard.

External corrosion
Ferak battery is made of durable polypropylene. All external metal components are nickel-
coated or made of stainless steel, protected by neutral Vaseline and finally covered with a
solid plastic cover.

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 10. Installation and storage
10.1 Batteries after delivery
Open the battery package after its delivery and check whether it has been delivered safely
and undamaged. Take out the cells including their accessories from the package and check
whether the contents are in the appropriate condition.
Any damage must be reported immediately to the transport company or to the manufacturer
or its representative.
If the batteries are not for immediate operation, they should be stored on open shelves in a
clean, dry, cool and well ventilated storage room. They should not be stored in hermetic
packing. The cells should not be exposed to direct sunlight.
Before storing, make sure that:

a. cells are kept clean and protected by a proper coating, such as neutral Vaseline applied
on the terminals and connectors
b. electrolyte in cells has been filled to the required level
c. plugs are mounted properly and held tightly in place, packing foil used during
transportation has been left in place.

If you discover upon delivery that a significant drop in the electrolyte level has occurred in
filled cells during transportation, you must replenish the cell electrolyte to the proper level
before storing.

Filled cells
The cells containing electrolyte can be stored for a maximum of one year. They should be
sealed with plastic transport foils with a small hole. Check the state of these transport foils
upon delivery.
If filled cells are stored longer than one year, the following maintenance must be followed:

• remove the transport foil from the cell

• discharge the battery to the value of 1.0 V per cell at the recommended charging current
• charge it with the recommended charging current (see Maintenance rules) for 10 hours
• wait 24 hours until all the gas generation ceases
• replace the plastic transport foil and return the cell into the storage room.

For batteries stored longer than one year, at least one charge/discharge cycle must be
carried out before the initial charge.

Discharged and empty cells

Discharged and empty cells can be stored for many years if the appropriate conditions are
met. The cells should be stored on open shelves in a clean, dry, cool (+10 to +30 °C) and
well ventilated storage room. It is important that they are tightly sealed with plugs and with
transport foil. They should be checked at least once a year and replaced if necessary. Leaks
will cause leakage of carbon dioxide from the atmosphere and a subsequent deposition of
carbon on the electrode surface. This may affect the battery capacity in an adverse way.
Storing of batteries at temperatures of over +30 °C may lead to the loss of capacity, reaching
as much as 5 % a year per every 10 °C exceeding 30 °C. Discharged and empty cells must
be replenished with electrolyte; then proceed as for full cells stored longer than one year.

Cells after storing

After storing, all cells must be prepared for operation and charged as described in the section
8.6.

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10.2 Oil in cells
An oil film floats on the level of electrolyte in the filled cells for the special use preventing
them from self-discharging and also stopping water loss through evaporation. This film is
approximately 5 millimetres thick. If the cells are delivered empty, this oil film must be formed
after the electrolyte has been replenished.

10.3 Location
Batteries should be installed in a dry and clean place out of direct sunlight.
Ferak batteries can be installed on stands, on the floor or in cabinets.
The battery will provide the highest output and achieve the optimum service life if its
surrounding environment temperature ranges between +10 and +35 °C.
Local standards or regulations usually define the correct procedure for battery installation. If
no such regulations exist, you can follow these point.
When installing the battery it is important to make sure that all the cells can be accessed
easily. The distances between the stands themselves and between the stands and the wall
should be set in light of this requirement of accessibility.
When choosing the battery location, you should consider the total battery weight and the
stress it will place on the floor. When you are in doubt, you should consult your Ferak
company dealer.
When installing the battery, make sure that the cells are connected properly, observing their
polarity. To connect the battery to the load, use nickel-coated cable lugs.
Recommended torque for the connecting nuts is as follows:
M4 nut 2,0 ± 0,5 Nm
M5 nut 4,5 ± 0,5 Nm
M10 nut 18 ± 2 Nm
M16 nut 50 ± 5 Nm
M22 nut 70 ± 7 Nm

To avoid accelerated aging of the plastics due to direct UV light, the cells in plastic vessels
should not be exposed to direct sunlight or strong daylight for a prolonged period.
If the battery is stored in a cabinet or other closed room, it is important to ensure sufficient
space for gas dispersion during charging and avoid its condensation.
It is recommended that there is minimally 200 mm of space over the cells which will ensure
access easy during maintenance and replenishment and that there is enough space between
the cells and the cabinet wall so that the possibility of short-circuiting is eliminated. The
hinged plugs can be rotated by 180 °C to provide the most comfortable position for
replenishment.

10.4 Ventilation
If the battery is located in a cabinet or in a closed room, sufficient ventilation must be
provided.
In the last stage of the high-level charging, the battery produces a gas mixture of hydrogen
and oxygen.
To ensure an adequate rate of room ventilation, it is necessary to calculate the amount of
hydrogen generated and make sure that its concentration in the room falls within safe limits.
The usual acceptable hydrogen concentration limit is 3.8 %. However, some standards
require a more strict concentration limit, sometimes as low as 0.8 %.
The following procedure may be used to calculate the ventilation demands:
1 Ah of overcharging will decompose 0.366 cubic centimetres of water; 1 centimetre of water
will decompose to 1.865 l of gas of the ratio of 2/3 of hydrogen and 1/3 of oxygen. One Ah of
overcharging will thus produce 0.45 l of hydrogen. Thus the amount of hydrogen generated
inside the battery in an hour equals:
the number of cells charging current 0.45 l
or

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the number of cells charging current 0.00045 cubic metres.

The amount of hydrogen determined by this calculation can be expressed as a percentage of

the volume of the room containing the battery and thus allow the number of times the air
must be replaced in order to keep the hydrogen concentration below a certain limit be
determined.

Example:
The KPH 280 P type battery with 96 cells on a three-tier stand with two rows is placed in the
room with dimensions of 3 x 5 x 5 m.
The charging system is able to charge at 0.1 C5 so the charging current will be 28 A.
The volume of hydrogen released in an hour equals the product 96 x 28 x 0.00045 cubic
metres = 1.21 cubic meters in this worst case.
The total volume of the room is 3 x 5 x 3 m = 45 cubic metres.
The approximate volume of the battery and the stand does not exceed 2 cubic metres, so the
volume of the free air in the room is 43 cubic metres.
The hydrogen concentration after charging lasting one hour at the maximum gas production
potential at 0.1 C5 will then be 1.21 : 43 = 2.8 %.
For the concentration limit of (for example) 2 %, the air in the room will have to be replaced
2.8 : 2 = 1.4 times per hour.
A natural room ventilation in practice is usually 2.5 air replacements per hour, so it would not
be necessary to establish forced ventilation in this case. Ventilation holes must be okay close
to the ceiling.
The self-discharging current is much lower than in charging the cell and the gas generation is
minimum; it can be calculated using the typical currents for the self-discharge.

10.5 Preparation for operation

Filled cells
Make sure that the cells have a clean surface, fit with a sufficient protective coating on the
terminals and connectors.
Remove the plastic transportation foil carefully and check visually whether the level of the
electrolyte in open cells reaches the MAX mark.
Replenish water if required - add approved distilled or demineralized water carefully.
Clean any liquid spilled upon the cell surface dry with a clean cloth and close the hinged
caps.
The cells can then be activated according to section 8.6.

Discharged and empty cells

Make sure that the cell surface is clean, fitted with a sufficient protective coating on the
terminals and connectors.
Determine and calculate the type and amount of the electrolyte for filling the cells according
to the operating manual. Do not remove the transportation foils at this stage.
Prepare a new electrolyte from the dry mixture or the solution as required. To fill the cells,
proceed according to the enclosed manual. Make sure that only clear distilled or
demineralized water is used.
Remove the plastic transportation foils carefully and leave the hinged plugs open.
Fill up the plastic cell vessels carefully using a filler so that the level reaches 5 to 10 mm
below the MAX mark. Let the cells stand still for 24 hours. We recommend the use of a pump
for large installations.
Replenish the electrolyte in the cells to the maximum level carefully after they have been left
stationary for 24 hours.
Dry any liquid spilled on the cell surface with a clean dry cloth and close the hinged caps.
The cells can then be activated as described in the section 8.6.

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 11. Maintenance of batteries in operation
Ferak batteries require minimum attention if they are used appropriately. We recommend
making system checks at least once a year or in the recommended replenishment intervals
so that the proper function of the charger, battery or auxiliary electronic equipment is
ensured.

11.1 Cleanliness / physical condition

The cells must be kept clean and dry because dust and moisture can cause losses of the
current. Bolts, couplings and cable lugs should be kept clean and any liquid spilled during the
maintenance should be cleaned dry with a clean cloth. Batteries may be cleaned with water.
Do not use solvents or a wire brush. Plugs can be rinsed with clear water if required.
Make sure that the plugs are tight and that there are no stains on the caps.
Make sure that the pole terminal bolts and nuts are tightened properly. Couplings and cable
lugs should be protected from corrosion with a thin layer of neutral Vaseline or anticorrosive
oil.

11.2 Electrolyte replenishment

Check the electrolyte level. Never let the level drop below the MIN mark. Use only the
approved demineralized or distilled water for replenishment. Do not overfill the cells.
High water consumption indicates operation at too high a voltage or temperature. A
negligible water consumption when the batteries remain in the charged state maintained with
a low current or maintaining voltage can indicate undercharging. An adequate water
consumption is a sign that the battery is operating under optimum conditions. Any significant
change in water consumption must be examined immediately.
The replenishment interval can be calculated as described in section 6.9. However, we
recommend checking the electrolyte levels in monthly intervals and this allows the user to
determine the replenishment frequency required for the particular installation.
Ferak supplies the complete equipment required for replenishment in order to facilitate this
operation as much as possible.

11.3 Capacity test

The testing of an electrical battery is not part of the general routine maintenance because the
battery must perform a back-up function and it cannot be disconnected so easily.
If there is a need for a capacity test, observe the following steps:

a. discharge the battery with the current of 0.1 or 0.2 C5 A (10 to 20 amperes per battery
with the capacity of 100 Ah) to the final average voltage of 1.0 V per cell (i.e. voltage of 92 V
for a battery consisting of 92 cells)
b. charge it to 200 % (i.e. to 200 Ah for a battery with 100 Ah with a current as described in
a) )

c. discharge it with the same current as in a) and at the same time, measure and record the
current, voltage and time every hour, more often at the end of discharging. This needs to be
repeated until the average final voltage per cell reaches the value of 1.0 V. Then the
condition not only of the whole battery but even that of each cell, if you make individual
measurements for each cell, can be defined.

11.4 Electrolyte replacement

The electrolyte keeps its efficiency for the whole battery life period in most stable battery
applications. Therefore, there is usually no need to replace it.
Under certain conditions of battery operation, e.g. at high temperatures or cycle alternating,
the electrolyte may be heavily contaminated by carbonates. In such a situation, its

22
replacement will improve the output of the battery. If this occurs, please consult your SAFT -
FERAK a.s. company dealer.

11.5 Recommended maintenance procedure

For the best performance of your battery, we recommend that you follow the following
procedure.
Likewise, we recommend that you keep the maintenance records containing data on the
temperature of the room or rooms where the batteries are installed and/or stored.

Once a year:
• check the charge voltage setting
• check the cell voltage (an acceptable deviation from the average is 30 mV)
• check the electrolyte level
• compensate by charging if the situation requires it
• clean cell caps and the battery area, check the tightness of the bolts and nuts and the
lubrication of the connecting material

Once every five years or as required:

• test the capacity

As required:
• replenish with water keeping to the appropriate interval (according to the maintaining
voltage, the number of cycles and the temperature).

23