Nicdoperationmanual
Nicdoperationmanual
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CONTENTS
1. Applications ……………………………………………………………………. (3)
2. Main properties of the cell and the battery ………………….………………..... (3)
3. Main performance of the battery ………………………………………………. (3)
4. The battery’s start using and preparation before start using ………………….... (4)
5. The battery operation and maintenance ……………………………….……….. (5)
6. The storage of the battery …………………………………………………….... (8)
7. Troubles and trouble shootings ……………………………………………..….. (8)
Appendix 1. The electrolyte selection, preparation, and storage …………………. (10)
Appendix 2. External dimensions, weight&other data of the Models GN22~GN100
cells (batteries) with steel case ……………………………………..(11)
Appendix 3. External dimensions, weight&other data of the Models GN100~GN250
cells (batteries) with steel case …………………………………… (12)
Appendix 4. External dimensions, weight&other data of the Models GN100~GN250
cells (batteries) with plastic case …………………………...……. (13)
Appendix 5. External dimensions, weight&other data of various medium rate cells
(batteries) ……………………………………………….………… (14)
Appendix 6. Reference charge and discharge curves (1-9) of low and medium rate
batteries …………………………………………………..…….…. (15)
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1. Applications
Nickel-cadmium pocket type alkaline storage batteries can be divided into
low rate and medium rate based on their application (various discharge current). They
can be operated at the temperature of -40 ~45 after charging at normal charge
rate at an ambient temperature of 25 1 . They are widely used in the electric
equipment, tele-communications, lighting&UPS as the standby or DC power supply.
They can also be used in oil motor or DC electric motor for starting, in transport
vehicles and solar energy cells.
2. Main properties of the battery
The cells are characterized by excellent electrical performance, long cycle
life. Strong construction, good resistance to overcharge and overdischarge, low
self-discharge. High reliability, easy maintenance, etc.Their electrodes construction
can be varied by different discharge current rates.
2.1 Cell construction:
The positive and negative active materials are pocketed respectively in the
perforated steel strips and pressed into the plates which form into positive and
negative electrodes. There is a separator between the positive and negative
electrodes. The electrode groups are firmly mounted in the plastic container. There
is an electrolyte filling hole in the cover; this hole is usually equipped with a
plastic gas-plug. It can be opened at any time when it is needed to fill electrolyte.
The plug can release the gas which generated inside the battery and also can keep
the impurities and dust from entering the battery.
2.2 Battery construction
The required individual cells are firmly installed in steel, wooden or plastic
frames and are connected in series by steel(or copper) intercell connectors. The
construction has a high mechanical strength; it can be operated under the
condition of shock and vibration.
2.3 Operating principle of the battery
On charge, oxide reaction takes place in the positive electrode, and reduction
occurs in the negative electrode. On discharge, the opposite reactions take place.
The reactions of charge and discharge can be illustrated by the following
simplified equation:
Charge
2Ni(OH)2+Cd(OH)2 Cd+2 NiOOH+2H2O
Discharge
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number of the cells which are connected in series)
3.2 The cell discharge performance
3.2.1 The cell should be charged for 8h at 0.2C5A and an ambient temperature of 20
.The discharge duration at various discharge rates should be not less than the
minimum specified in Table 1.
Table 1
Discharge conditions Minimum discharge duration
Rate constant of current(A) Final voltage(V) Low rate Medium rate
0.2C5 1.0 5h 5h
1 C5 0.9 40min
2 C5 0.9 10min
3.2.2 Discharge performance at -18
The cell should be charged for 8h at an ambient temperature and
0.2C5A.The cell shall be then discharged at temperature of –18 , the discharge
duration shouldn’t be lower than the requirements in Table 2.
Table 2
Discharge conditions Minimum discharge duration
Rate of constant current(A) Final voltage(V) Low rate Medium rate
0.2 C5 1.0 2h 30min 3h
1 C5 0.9 10min
Note: the data show in Table1 and Table2 conform to the discharge
performance standards. The approach actual practical data are included in the
discharge curves of Appendix 6.
3.3 Self-discharge of the cell
The cell can be charged at 0.2 C5A for 8h at an ambient temperature of
20 5 , then store it in the same conditions for 28 days and nights. Then discharge it
at 0.2C5A to end voltage of 1.0V, its discharge duration should not be less than 4h.
3.4 Cycle life
One cycle means a cell is fully charged and discharged. The cell’s cycle life
should not be less than 900 cycles. According to IEC Standard, it should be 500
cycles at least. In case of float charge application, its cycle life may be longer.
3.5 Storage
The electrical performance of the cell which is stored for 4 years in accordance
with the storage specifications should meet the requirements of items of 3.2, 3.3, and
3.4.
4. The battery’s start using and preparation before start using.
The battery leaves factory in discharged state without electrolyte. Before start
using, it is needed to do following preparation:
4.1 Check
4.1.1 Check accessories as specified in the packing list, check if there is damage on
the battery case, if the damaged is found, pick them out.
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4.1.2 Measure the cell’s open circuit voltage one by one, If the value is lower than
0.5V, a small amount of electrolyte can be filled in, then measure it again, if the
voltage goes up to 0.5V.it will be regarded as the qualified.
4.1.3 Check the tightening parts of cell, if necessary, tighten them again.
4.2 Filling with the electrolyte
Unscrew the battery plug, fill the required electrolyte into the battery with
funnel and graduated cylinder (electrolyte standard and preparation method is shown
in Appendix 1.) Adjust electrolyte level between two limit lines. Clean the electrolyte
which flow out of the battery.
4.3 Connection
The battery must be soaked for 4 hours after filling, with electrolyte, and then
regulate the electrolyte level. Connect the battery in series with connecting plate
(lines). The positive terminal should be connected with the neighbor battery’s
negative terminal; the rest may be deduced by analogy. In the end, connect the last
positive terminal with the positive lead of charger, and the negative terminal is
connected with the charger’s negative lead. Mistake connection is forbidden.
4.4 Initial charge
After the above connection, check to ensure that there is no mistake, the
charge the battery as the following:
4.4.1 The battery which has been stored for 3-6 months should be charged at
0.2C5A for 15 hours, and then they can be put into operation.
4.4.2 The new battery and the battery which stored for more than 6months should
be charged at 0.2C5A for 12 hours, and then discharged to 1.0V/cell. Repeat the above
charge and discharge for 3-5 cycles. If the discharge duration isn’t less than 5 hours
and the battery voltage isn’t less than 1.0V/cell, the battery can be put into the normal
operation according to Table 3.
5. Battery operation and maintenance
5.1 Charge (See Table 3)
Table 3.
Charge regime Charge current-A Charge voltage(V) Charge duration(h) Charge temperature( )
Normal charge 0.2 C5 8
Over-charge 0.2 C5 12
Complementary charge 0.2 C5 Not stipulate
0.4C5 2.5
Fast charge turn into
2.5
0.2 C5
1.48~1.50V/cell 20
Float chart (for medium rate cell)
1.42~1.45V/cell
(for medium rate cell)
Equilibrium charge 1.55~1.60V/cell 12
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Note: The voltage of power supply for one cell is 1.90V in the normal charge.
In the cold region, the voltage should be set 2.20V/cell.
5.1.2 The selection of various charge regimes:
Usually, the battery can be charged by normal charge rate. In the case of
emergency, the fast charge method can be used. The battery must be overcharged
when it is overdischarged, reverse charged at small current, interval discharged or
when the capacity is not enough in case of long time not use. When battery is stored
for 1-3 months after charge, it is needed to charge by complementary method before
its operation.
If the battery is used as standby power supply and is connected parallel with load,
float charge should be used, when float charge and load supply is stopped, equilibrium
charge should be used firstly, then change into float charge; if the battery is in float
charge for a long time, it should be charged by equilibrium method for 1~3 times
every year.
5.2 Discharge
The low rate battery can be discharged at the current of 0.1C5A~0.5C5A (1
C5A is for short time discharge). The medium rate battery can be discharged at 0.2
C5A~3.5 C5A. During discharge, the temperature of electrolyte shouldn’t exceed 45 .
If exceed, reduce the discharge current or take cooling measures immediately. The
battery discharge regime is shown in Table 4.
Table 4.
Constant discharge Discharge end Discharge duration Remarks
current(A) voltage(V)
0.1 C5 1.10 About 10h
0.2 C5 1.0 About 5h
Final discharge
0.33C5 1.0 About 3h voltage is 0.9v/cell
for low rate cell
Final discharge
0.5 C5 0.9 About 2h voltage is 0.7v/cell
for low rate cell
1 C5 0.9 About 40min Only for medium
rate cell
Only for starting
2C5 0.8 About 10min application of the
medium rate cell
5.3 Maintenance during operation
5.3.1 Water replenish of battery
The electrolyte density will increase because the water evaporating and
charge electrolysis, it’s necessary to check the electrolyte level and density. In case of
continuously constant current charge and discharge, it must be checked. In case of
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constant voltage charge, check it one time every three months. In case of float charge,
check one time every half a year (the water replenish may depend on the temperature),
the water requirements of electrolyte should be comply with the standard.
5.3.2 If the battery is used at the temperature of 20 10 , its electrolyte should
contain LiOH. Otherwise, its service life will be reduced.
5.3.3 If battery is used at the temperature of above 35 , its electrolyte should
be NaOH electrolyte contained with LiOH, it will be good for battery’s capacity and
life. Because of the high ambient temperature, the battery charge efficiency will
decline; it is good to take cooling measures during charge.
5.3.4 If the battery is used at the temperature of –40~0 , the electrolyte of No.3 or
No.4 in Table 6 should be used, this will keep electrolyte from freezing, so that the
charging efficiency will not be effected.
Because low temperature will affect charge efficiency, it is better to charge at
the normal temperature, and then operates in the cold temperature; this will be good
for the battery performance. If the battery has to be charged at low temperature,
overcharge rate should be adopted.
5.3.5 During the storage, storage room should be dry and ventilated with
temperature of 25±10 ; it is prohibited to store the alkaline battery with the acid
battery or other acid materials in the same room. All the tools and instruments should
not be used for acid battery.
5.3.6 The battery can’t be struck by metal tool. When tightening the nuts, the tool
can’t touched positive and negative terminals in the same time. Negative pole should
not contact with the metal container of the battery to protect from short-circuit.
During charge, it is forbidden to make a fire near the battery.
5.3.7 The battery should be clear and if electrolyte leak outside, clean them
quickly. The plastic container can be cleaned by clear water, alcohol is forbidden to
use.
The rust points in the steel container or metal parts can be cleaned by a cloth
with electrolyte, then paste a thin layer of Vaseline oil.
5.4 Electrolyte replacement
5.4.1 Electrolyte replacement period
During the operation, the electrolyte within the battery absorbs the CO2 in the
air easily and turns into carbonate. This will increase internal resistance. When the
carbonate content exceeds 60g/L, or the electrolyte is contaminated and it will cause
capacity decreased, replace new electrolyte. In case of float charge, check the
carbonate content every 3 year, if necessary, replace the electrolyte.
5.4.2 Method of electrolyte replacement
When is discharged to 1.0V/cell, open the plug and place the battery upside
down and shake to pour the electrolyte out, if the electrolyte is very dirty, wash the
battery 2-3 times with water (used for electrolyte), then fill new electrolyte.
5.5 Performance check
During operation, if the individual cell capacity is found to decrease, it
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should be replaced. Otherwise, it will affect the performance of the battery.
5.6 When battery is being used, special person should be assigned for maintaining
it, especially during charge, the accuracy of charge current and enough charge time
must be guaranteed. Otherwise, the battery will not be charged enough.
5.7 Instruments calibration
The gavanometer, voltmeter and thermometer hydrometer etc, must calibrated
periodically so as to keep their accuracy.
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Bubbles appear The electrolyte contains organic impurities Replace the electrolyte
in the inside of
the cell
The cell 1. The positive plate swells. If necessary, change the cell.
container swells 2. The vent is blocked up. Clean with hot water or replace it.
3. The inner circuit of cell is short, or there are too Check and replace the electrolyte.
many impurities in the electrolyte.
Creeping of 1.The level of electrolyte is too high Drain out the superfluous electrolyte.
electrolyte 2.The vent of terminal is unsealed Replace the sealing parts and screw tightly.
3. Too much electrolyte overflows. Clean and keep dry
Electrolyte leaks There are pores or cracks caused by transportation Adhere the cracks with adhesive which is made up
out from plastic or operation. Or the container and the cover haven’t by dissolving ABC resin in dichloromethane or in
container adhered well. acetone. Clean the alkaline away from the adhering
zone before adhering.
Electrolyte 1. There are pores or the welding seam of the Dip the battery in dilute alkaline solution after
leaks out from container and the cover rends. pouring out the electrolyte, the welding seam
steel container should be emerged 10~15mm above the
alkaline solution. Reweld the cracks by small
type welding torch No.4 or No.5 welding tip.
It is advisable to seal the filling vent when
putting the battery upside-down. The
container should be replaced if electrolyte
leaks from other place besides of the welding
seam on the connection of container and the
cover.
2.Leakage caused by electrochemical If corrosion is on the welding seam of the
corrosion during operation bottom and cover, it can be rewelded with
small type welding torch. If corrosion is on
other parts of the container, the container must
be replaced and kept isolated and dry.
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Appendix 1. The electrolyte selection, preparation, and storage.
1. The selection of electrolyte.
Table 6
No. Operating temp. Density Composition of Weight ratio
3
( ) (g/cm ) electrolyte (alkaline : water)
1 10~45 1.18 0.02 NaOH+20g/L LiOH 1:5
2 -10~35 1.20 KOH+40g/L LiOH 1:3
3 -25~10 1.25 KOH 1:2
4 -40~15 1.28 KOH 1:2
1.2 The technical requirements of electrolyte see Table 7.
(The reference density is 1.20 )
Table 7
Items Technical requirements
New electrolyte Limiting value during operation
Outward appearance Colourless,transparent,no
suspended substance
Density(15 ) 1.20 1.20 0.02
Content(g/L) KOH : 240~270,NaOH : 215~240 KOH : 240~270,NaOH : 215~240
Cl-(g/L) 0.1 0.2
K2CO2(g/L) 20 60
2+ 2-
Ca Mg (g/L) 0.19 0.3
Fe/KOH(NaOH)(%) 0.05 0.05
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vessel, add alkali slowly with constant stirring, then add the required lithium
hydroxide into the vessel, stir to dissolve thoroughly. Cool to 20±5 . Finally,
determine the density and adjust to the required value.
3.2 Storage
The prepared electrolyte or electrolyte in storage must be well-sealed in plastic
or porcelain vessels. Keep away from acid or other impurities.
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17 7GN45 8.4 45 511 164 257 M5 23.90 3.15
18 7GN45A 8.4 45 567 152 259 M5 24.50 3.15
19 10GN45 12.0 45 710 168 257 M5 34.20 4.50
20 10GN45A 12.0 45 766 156 256 M5 34.70 4.50
21 14GN45 16.8 45 553 295 257 M5 38.50 6.30
22 4GN60 4.3 60 261 188 393 M10×1 24.00 3.00
23 4GN60A 4.8 60 327 176 395 M10×1 24.50 3.00
24 5GN60 6.0 60 318 188 393 M10×1 29.60 3.75
25 5GN60A 6.0 60 384 176 395 M10×1 30.10 3.75
26 6GN60A 7.2 60 441 176 395 M10×1 35.50 4.50
27 10GN60 12.0 60 603 188 393 M10×1 57.60 7.50
28 10GN60A 12.0 60 669 176 395 M10×1 57.63 7.50
29 4GN100 4.8 100 377 195 393 M10×1 33.70 4.80
30 4GN100A 4.8 100 443 183 395 M10×1 34.20 4.80
31 5GN100 6.0 100 452 195 393 M10×1 39.30 6.00
32 5GN100A 6.0 100 528 183 395 M10×1 39.80 6.00
33 10GN100 12.0 100 887 195 393 M10×1 76.50 12.00
34 10GN100A 12.0 100 953 183 395 M10×1 77.00 12.00
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Appendix 4. External dimensions, weight & other data of various low-rate cells
(batteries) with plastic case.
Nominal Nominal Max. dimensions Max.weight Quantity of
No Model voltage capacity (mm) Thread with electrolyte
(V) (Ah) of pole electrolyte (L)
L W H
(Kg)
1 GN10-(2) 1.2 10 85 39 126 M5 0.66 0.12
2 2GN10-(2) 2.4 10 85 78 126 M5 1.34 0.24
3 2GN10-(2)A 2.4 10 170 38 126 M5 1.34 0.24
4 4GN10-(2) 4.8 10 160 91 135 M5 3.12 0.48
5 5GN10-(2) 6.0 10 197 91 135 M5 3.81 0.60
6 6GN10-(2) 7.2 10 235 91 135 M5 4.52 0.72
7 GN40 1.2 40 145 54 248 M10×1 2.70 0.60
8 GN50 1.2 50 142 67 223 M10×1 3.20 0.70
9 5GN50A 5.0 50 375 153 259 M10×1 18.10 3.50
10 5GN50B 5.0 50 375 153 259 M10×1 18.10 3.50
11 GN60-(2) 1.2 60 135 49 373 M10×1 3.90 1.00
12 GN100-(2) 1.2 100 139 79 362 M16 6.50 1.70
13 3 GN100-(2) 6.0 100 391 152 392 M16 35.00 8.50
14 5 GN100-(2)A 6.0 100 434 152 392 M16 36.50 8.50
15 GN150 1.2 150 167 162 343 M20×1.5 13.00 3.30
16 GN200 1.2 200 167 162 343 M20×1.5 14.00 3.30
17 GN250-(2) 1.2 250 174 161 557 M20×1.5 17.00 4.00
18 GN250-(3) 1.2 250 277 139 420 M16
19 GN300-(2) 1.2 300 176 161 557 M20×1.5 22.80 4.00
20 GN300-(3) 1.2 300 277 139 450 M16 21.50 6.00
21 GN350-(2) 1.2 350 176 161 450 M20×1.5 23.00 4.00
22 GN400-(2) 1.2 400 176 161 557 M20×1.5 25.00 4.20
23 GN400-(3) 1.2 400 232 172 557 M16 24.50 5.00
24 3GN400-(3) 3.6 400 555 241 410 M16 80.00 14.00
25 GN500-(2) 1.2 500 290 172 435 M20×1.5 39.00 5.00
26 GN600-(2) 1.2 600 291 174 505 M20×1.5 50.00 6.00
27 GN800-(2) 1.2 800 399 184 562 M20×1.5 63.00 18.00
28 GN1000-(2) 1.2 1000 398 184 572 M20×1.5 73.00 18.30
29 3GN200 3.6 200 563 209 362 M20×1.5 63.00 10.00
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Appendix 5. External dimensions, weight & other data of various medium rate
alkaline cells (batteries)
Nominal Nominal Max. dimensions Max.weight Quantity of
No Model voltage capacity (mm) Thread with electrolyte
(V) (Ah) of pole electrolyte (L)
L W H
(Kg)
1 GNZ15 1.2 15 124 40 205 M10×1
2 GNZ30 1.2 30 142 66 227 M10×1 3.50 0.83
3 GNZ50 1.2 50 139 79 291 M16 5.00 1.30
4 GNZ75 1.2 75 139 79 361 M16 6.50 1.67
5 GNZ100 1.2 100 164 104 345 M20×1.5 9.30 1.75
6 GNZ150 1.2 150 163 80 450 M20×1.5 12.50 2.50
7 3GNZ150 3.6 150 284 185 465 M20×1.5 40.00 7.50
8 GNZ150-(2) 1.2 150 165 160 338 M20×1.5 13.50 3.08
9 GNZ150-(3) 1.2 150 163 80 450 M20×1.5
10 GNZ120 1.2 120 167 162 343 M20×1.5 12.50 2.92
11 GNZ200 1.2 200 286 174 348 M20×1.5 24.50 5.83
12 GNZ250 1.2 250 286 174 348 M20×1.5 26.00 5.83
13 GNZ300 1.2 300 184 168 554 M20×1.5 23.00 5.00
14 GNZ300-(2) 1.2 300 176 161 540 M20×1.5 23.00 4.17
15 GNZ500 1.2 500 291 174 501 M20×1.5 39.00 7.50
16 GNZ600 1.2 600 390 176 557 M20×1.5
17 GNZ700 1.2 700 390 176 557 M20×1.5
18 GNZ800 1.2 800 390 176 557 M20×1.5
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Appendix 6 Reference charge & discharge curves (1~9) of low and medium rate
Ni-Cd batteries
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Fig 3. Discharge curves of medium rate Ni-Cd battery at 20
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20
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Fig 8.
20
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