500/220/132kV

FAISALABAD WEST SUBSTATION

NATIONAL TRANSMISSION & DESPATCH COMPANY

NTDC

GRID SOLUTIONS SAS

500/220/132kV FAISALABAD WEST SUBSTATION

48V DC Battery Banks & Charger Design

NATIONAL ENGINEERING SERVICES

PAKISTAN (PVT) LTD

FWS-000-SUP-S2090-0086-TS
 LIST OF CONTENTS

REV. No. Of
S.No. TITLE No. Sheets

1 Title Sheet B 01

2 List of Contents B 01

3 48VDC Telecom System Technical Data (AEG Format) - 11

4 48VDC System - Technical Data (Customer Format) - 04

5.1 48VDC Panel Layout - 02

5.2 48VDC Single Line Diagram - 02

6 FIAMM Battery - Technical Manual - 15

7 FIAMM Battery - Design Standards - 01

8 FIAMM Battery - Production Information Sheet - 07

9 FIAMM Battery - Quality Certifications - 06

10 FIAMM Battery - Capacity with respect to Temperature - 01

11 FIAMM Battery Reference List - 01

12 FIAMM Battery - Test Report - 04

48V DC Battery Banks & Charger Design

500/220/132kV FAISALABAD WEST SUBSTATION FWS-000-SUP-S2090-0086-TS

 TECHNICAL DATA
(48VDC System for Telecom Equipment)
DATE: 03/05/2021
Project: 500/220/132KV FAISALABAD WEST SUBSTATION
 SUMMARY

Item Qty. Description

4 1 DUAL 48V TPRe 263A @ 50°C

4.1 1 Protect RCS 48 V – 300A (Dual)

4.2 2 Battery 24 x 9 GroE 900

4.3 2 Battery Rack SGS 3-27HH

4.4 2 Battery Protection Box 160 A

4.5 1 Voltage Dropper

4.6 1 DC Distribution + Change Over (30 feeders)

4.7 1 Spare Parts MODULE (rectifier Bridge)

4.8 1 Packing

48VDC System for Telecom Equipment - AEG page: 2

Item 4) 1 off DUAL 48V TPRe 262.5A @ 50°C
Operating temperature min: -5°C
Operating temperature max: 50°C
Storage temperature min: -30°C
Storage temperature max: 75°C
Battery temperature min: 0°C
Battery temperature max: 20°C
Operating humidity (noncondensing): <95%
Max. installation altitude: 1000m
Local conditions: Indoor
Atmosphere corrosive: No

Item 4.1) 1 off AEG DC UPS Protect RCS 48V (Dual)

System configuration
System setup Redundant Operation
Battery configuration Individual battery
The Protect RCS DC UPS System is a microprocessor based thyristor controlled rectifier. It
provides high quality DC power for electronic equipment loads.
Below is the specification for one rectifier.
Mechanical specification
Enclosure free standing metal suitable
for floor mounting type V2000 cabinet
Metal sheet thickness Frame 2 mm
Panels 1.5 mm
Door 2 mm
Protection class (according to
IEC 60529) IP43
Painting RAL7032
Ventilation Air inlet from front and back cabinet bottom, outlet
through the top
Acoustic noise <66 dB(A)
Cable entry from Bottom
Dimensions:
Height 2000 mm
Width 900 mm
Depth 800 mm
Weight approx. 360 kg
Electrical specification
Rectifier type: 6 pulse (SCR) thyristor
Nominal input voltage 400 VAC
Input voltage tolerance ±10%
Exceptional variation of the mains input voltage +15%, -20%
Number of phases 3
Input frequency 50 Hz
Input frequency tolerance ±6%
Max. input current (10% mains, in high
rate charge and Inom on the output) 39 A AC
Rectifier input current total harmonic
distortion (THDi) < 33%

48VDC System for Telecom Equipment - AEG page: 3

 Input power factor at nominal voltage and
float charge 0,81
Nominal DC output voltage 48V DC
Nominal DC output current 300A (262.5A @ 50°C)
Voltage regulation
Static: ±0.5%
at float charge
0 100% DC load current
input mains voltage within the range ±10%
input frequency within the range ±6%
battery temperature within 0°C to 40°C
Dynamic:
With single LC filter with a battery connected
(capacity >5 x nominal current of the rectifier
load variation 10% => 90% : 5%
load variation 90% => 10% : +8%
Current regulation +2% at the maximum current level
Ripple voltage:

Ripple voltage without batteries 1% RMS

Heat losses at rated power 2601 W
Long term stability for 1000 hours
(of output voltage) 0.15%
Charger regulation characteristic
per IEC 478: IU
High voltage insulation between
input/output and electrical earth 2500V AC
(With disconnected electronic boards in the rectifier).
Insulation resistance with disconnected electronic boards in the
Rectifier >200MΩ
Input to ground 500V DC
Input to output 500V DC
Output to ground 500V DC
Protection:
Slow start function
Short circuits
Limited at 100% of rated current
Internal DC fuse
Nonvolatile storage of system parameters and user settings
Mains failure shutdown, Rectifier failure shutdown
High voltage DC shutdown
History function for time stamped alarm and system events

Battery adjustments
(If battery is included in scope of supply, it must appear as a separate line in the quote)
Type GRoE
Capacity 990 Ah
Number of cells 24
Number of strings 1
Float charge voltage 52,80 V
High rate voltage 58,32 V

48VDC System for Telecom Equipment - AEG page: 4

 High rate charge time (range 0-15h): 15 h
High rate charge timer mode settings Post
Commissioning voltage 60,00 V
End of discharge voltage 43,20 V
Measurements – Alarms
Measurements available on LCD display:
AC input voltage
DC charger voltage
DC charger current
DC battery current
Battery capacity
DC load voltage
DC load current
Alarm indications:
Mains voltage alarm
Charge fault alarm
Battery voltage alarm
 DC voltage alarm
Charger current limit alarm
Battery current limit alarm
High charger current alarm
High battery current alarm
high temperature alarm
Temperature sensor error alarm
Internal communication error alarm
Battery test alarm
High battery temperature alarm
Long charge time alarm
No power supply voltage alarm
Battery in operation alarm
Service alarms
List of installed items
EMI filter (CE)
Relay card 2x8 contacts
AC Input analog meters (voltage and current)
DC charger analog meter (voltage and current)
DC load analog meter (voltage)
Special input alarms
Voltage temperature compensation (cable length 30m)
Bridge temperature alarm
AC input protection: Circuit breaker with alarm
Load protection: Circuit Breaker with alarm
Protection accessories: fuse handle
Ground fault (by With separate board)
Cabinet colour: RAL7032
Cabinet protection degree: IP43
Cabinet: gland plate
Cabinet: lifting lugs

48VDC System for Telecom Equipment - AEG page: 5

 Cabinet: light
Cabinet: heating resistor
Cabinet: AC mains socket type E and F with differential protection circuit breaker 220V
Cabinet: earthing copper bar
Cabinet: additional rating label Standard + Stainless steel label
Cabinet: braided earth strap
Tropicalisation (PCBs)
Item 4.2) 2 off Battery
Essential technical data:
Nominal DC voltage: 48 V
Number of cells / blocks: 24 pieces
Number of strings:
Total battery capacity: 990 Ah C10

Dimensions block (WxHxD): 330 x 590 x 270 mm

Weight / block: 125,70 kg
Total weight: 3016,80 kg
Manufacturer / series: FIAMM

For further information on the battery see the attached battery calculation documents.

Item 4.3) 2 off Battery Rack SGS 3-27HH

Rack Info
Quantity of Elements
24 x GroE, ' 9 GroE 900'
Article No., Rack Type
SS3272, SGS 3-27 HH
Rack Dimensions
Length = 2700,00 mm
Width = 870,00 mm
Height = 385,00 mm
B = 810,00 mm
HB = 975,00 mm
Battery Weight
24 x 125,7 kg = 3016,8 kg
Rack Weight
70,6 kg
Total Weight
3087,4 kg
Projected Surface Load
1314,35 kg/m²
Load per Insulator
514,57 kg

Maintenance Space

48VDC System for Telecom Equipment - AEG page: 6

 Center of Gravity
X = 435 mm
Y = 1350 mm
Z = 488 mm

48VDC System for Telecom Equipment - AEG page: 7

 HB
385

185
L 870
B

880 900 880

2700

48VDC System for Telecom Equipment - AEG page: 8

 The selected packing options consists of 1 packings:
1. Packing
QTY...............................................: 1
Article Number....................................:
SEAPAK1575237
Article Name......................................: Cardboard
crate
Length............................................: 1570,00 mm
Width.............................................: 520,00 mm
Height............................................: 390,00 mm
Weight............................................: 17,00 kg

Item 4.4) 2 off Battery Protection Box

Metal enclosure suitable for wall mounting
Metal sheet thickness: 1.5 mm
Protection class (conformity IEC 60529): IP65
Mechanical protection: IP20 open door
Painting: RAL7032
Ventilation: Natural ventilation
Input cables: At the bottom
Dimensions: 800x600x250mm
Protection class: Circuit Breaker
Rating: 160A

48VDC System for Telecom Equipment - AEG page: 9

Item 4.5) 1 off AEG DC UPS Voltage Dropper

External diode dropper cabinet controlled by External card

Below is the specification for one diode dropper.

Mechanical specification
Enclosure free standing metal suitable
for floor mounting type V2000 cabinet
Metal sheet thickness Frame 2 mm
Panels 1.5 mm
Door 2 mm
Protection class (according to
IEC 60529) IP43
Painting RAL7032
Ventilation Internal fans.
Air inlet in the front doors, front and back cabinet
bottom, outlet through rear panel on the top
Cable entry from Bottom
Dimensions:
Height 2000 mm
Width 600 mm
Depth 800 mm
Cabinet colour: RAL7032
Cabinet protection degree: IP43
Electrical specification
Load voltage range Min. 43,20V
Max. 52,80V
Output current in steady state 150A
Number of contactors 1
Number of diodes
in step 1 (driven by contactor 1) 8
List of installed items
Cabinet: gland plate
Cabinet: lifting lugs
Cabinet: light
Cabinet: heating resistor
Cabinet: AC mains socket type E and F with differential protection circuit breaker 220V
Cabinet: earthing copper bar
Cabinet: additional rating label Standard + Stainless steel label
Cabinet: braided earth strap
Tropicalisation (PCBs)

Item 4.6) 1 off DC Distribution 48V / 200A

Cabinet(s) Qty
(W x H x D) 900mm x 2200mm x 600mm :1
List of installed items:
DC load analog meter (voltage)
DC load analog meter (current)

48VDC System for Telecom Equipment - AEG page: 10

 Cabinet color: RAL7032
Cabinet protection degree: IP43
Cabinet: gland plate
Cabinet: lifting lugs
Cabinet: light
Cabinet: heating resistor
Cabinet: AC mains socket type E and F with differential protection circuit breaker 220V
Cabinet: earthing copper bar
Cabinet: additional rating label Standard + Stainless steel label
Cabinet: braided earth strap
Tropicalisation (PCBs)
Distribution
The distribution consists of incoming isolation device with 30 feeders + changeover (ATS)
No. Type Rate(A) Qty.
1 DC MCB 2 poles/alarm C or UC-K curve 50 5
2 DC MCB 2 poles/alarm C or UC-K curve 20 7
3 DC MCB 2 poles/alarm C or UC-K curve 16 18

Item 4.7) 1 off Spare Parts MODULE (rectifier Bridge)

Item 4.8) 1 off Packing

Packing Type: Cardboard

48VDC System for Telecom Equipment - AEG page: 11

18.5 48V DC POWER SUPPLY SYSTEM
A. General
1 Nominal system voltage (V) 48V DC

B. Battery Chargers
1 Manufacturer AEG Power Solutions
2 Country of manufacture Singapore
3 Model number Protect RCS TPRe300
4 Duplicated configuration (Yes/No) Yes
5 Rated current of each charger, A. 262.5 @ 50°C
6 Type of rectifier bridge SCR
7 Operation mode Duty Standby
8 Duty class As per IEC 60146
9 AC mains voltage/tolerance (V±%) -15%~+10%
10 Input frequency/tolerance (Hz±% 6
11 Rated output DC voltage (V) -48
Output voltage variation for specified fluctuation
12 +/- 0.5%
in AC mains and ± 5% frequency change (± %)
13 Audible noise (dB) ~ 45 to 65
14 Insulation resistance (Mohm) 10
Time to 100% charge a fully discharged battery
15 10.5Hrs to 90% and 45Hrs to 100%
(hours)
16 Input power factor at:
a) lightly loaded condition 0.81
b) full load 0.81
17 Charger efficiency at 100% load (%) 85%
Operating temperature range for guaranteed
18 0°C - 50)c
operation (Deg C)
Relative humidity at maximum ambient
19 < 95
temperature (%)
Controls and alarms, as specified, provided
20 Yes
(Yes/No)
C. Charger Cabinet
1 Manufacturer AEG Power Solutions
2 Country of manufacture Singapore
3 Model number TPRe
4 Material of cabinet Steel
5 Cabinet is dust & vermin-proof (Yes/No) Yes
6 Protection class is IP54 (Yes/No) No / IP43
7 Cabinet is floor mounted (Yes/No) Yes
ON/OFF main switches with green LEDs provided
8 Yes
(Yes/No)
 Red LED to indicate manual boost operation
9 Yes
provided (Yes/No)
Specified DC and AC ammeters and voltmeters
10 LCD Display
provided (Yes/No
Specified DC and AC ammeters and voltmeters
11 LCD Display
provided (Yes/No
12 Weight (kg) 360Kg
D. Instrumentation and DC Distribution Cabinet
1 Instrumentation:
a) Instruments, as specified, provided
Yes
(Yes/No)
b) Manufacturer OMEGAPANO
c) Country of manufacture Turqey
d) Tolerence of meters (± %) 5
2 DC distribution cabinet:
a) Manufacturer OMEGAPANO
b) Model number OMG PANO
c) Design according to IEC 60439
(Yes/No) YES
d) Material of cubicle
e) Cubicle is vermin-proof (Yes/No) Yes
f) Type of arrangement within cabinet
for connection to common grounding Entry bottom
system
g) Weight (kg) Estimate 200kg
h) Installation mode Floor
i) Number of outgoing circuits 30
j) Battery DC voltmeter installed (Yes/No) Yes
k) Battery DC contactor installed (Yes/No)
Yes
I) Battery
l) DC contactor disconnect voltage (V) Yes
m) Battery DC contactor reconnect voltage
110
(V)
n) Manufacturer of MCBs Siemens
o) Type number of MCBs C type
p) Ratings of breakers provided (A) İncomings 250A
q) Alarms, as specified, provided(Yes/No) No
E. Batteries
1 Manufacturer FIAMM
2 Country of manufacture Italy
3 Model number SGH 19D (850214)
4 Duplicated configuration (Yes/No) Yes each battery 50%
5 Rated capacity of each battery 990
6 Battery is single cell type (Yes/No) Yes
7 Number of cells in each battery 24
8 Positive plate is plante type (Yes/No) Yes
9 Float voltage per cell (V) 2,23 V at 20°C
10 Boost voltage per cell (V) 2,40 V
11 End voltage per cell (V) 1,8 V per cell
12 Minimum aging factor 1.25
13 Self discharge at 25°C (%) < 2% per month at 20°C
14 Name of electrolyte Sulphuric Acid
15 Material of cell terminals Copper
16 Material of intercell connectors Tinned Copper
17 Material of battery racks Steel
18 Racks are treated with acid-resistant paint (Yes/No) Yes
19 Mode of installation of cells Series
20 List of accessories provided (Yes/No) Yes
21 List of similar installations provided with Bid (Yes/No) Yes
Operating temperature range for guaranteed operation 20 °C recommended calculated at 2°C- -20 to +50
22
(°C) °C operating temperature
23 Relative humidity at maximum ambient temperature (%) >90%
24 Guaranteed life (years) 25 years design life
AEG REF : 120008441
CIENT / REF : GE Grid Solutions Pakistan
PACKAGE NAME : 500/220/132KV FAISALABAD WEST SUBSTATION
AEG DOC NO : 120008441-AEG-DWG-GA-0001_2
DOC TITLE : 48TPRe250 Charger Cubicle Drawing
DATE : 5/5/2021
AEG REF : 120008441
CIENT / REF : GE Grid Solutions Pakistan
PACKAGE NAME : 500/220/132KV FAISALABAD WEST SUBSTATION
AEG DOC NO : 120008441-AEG-DWG-SLD-0001_2
DOC TITLE : 48TPRe250 Single Line Diagram
DATE : 5/5/2021
 1 2 3 4 5 6 7 8 9 10

=CH1 =BOX1
Battery BAT1
Q3
-X2 2

I>
Int Int -SD1

-P3
400A-0-400A 160A 24 x 9GROe900

400A - 100mV
A -R3

-P9 -P10
0-60A
0-500V V A -P2
+RC
0-75V
-P1
-TH2 Θ
0-400A
-S9 -S8 V
Z1
-TH1 Θ
A
Mains
-F27 3
-T1 Filtering 1% Load
-Q1 48TPRe300 -Q2
400V 3Ph 50Hz

-L1 -F1 -V21

-X3

1
-X1 3 3 3 3 3 2 1 2
I>

I>
Int
3 -R2
3 400A
-CT1 400A - 100mV
-H10 +
400A

-C10-C11
63A-D -C1
-F42 2
(SET AT 340AT)
displayed or duplicated to any third party without the concent of the company

A2
A5.2 A5.1 2 2
TPC PCB

=DDR
M M
A4 -X0 -1P6 -1P7
1~
This document is property of AEG Power Solutions and must not be

Interface PCB 0-130A 0-75V

-FAN11-FAN12 -FAN1
=DIST
A V

A1 -Q10...Q14
LOAD CURRENT = 103.3A/600min
GCAU PCB 2 -X10

I>
-TH -1F53
-HT 2
-1V30...1V37
Θ A6 -1Q4 -Q2
x8 5 x 50A-C
-1X3 2 -1X4 -X1 3

I>

I>
Int
-Q15...Q16
1/N/PE

-Q24 2 -X10
-1K27 -1R2 1A21
A310

I>
2 A300 130A-100mV 125A-C
I>

-X20 250A

10A-C -X12
-S31 -H31 Common alarm
1A201
2 x 20A-UC

220Vdc BUSBAR A
-Q17...Q24
2 -X10

I>
8 x 16A-C
-1FAN21
-1F45
-1X10 1 2
M -P11 -P15
V
1~
A

-TH
-HT
Θ -R11

130A - 100mV

AUX SUPPLY 230VAC 50Hz

1/N/PE
-Q24 -R10
130A - 100mV
-X8 2

I>
-X20
I>
10A-C -H31 -Q8
-S31
130A - 100mV 250A
-R21 3
etre diffuse ou duplique a un tiers sans le consentement de la compagnie

-P25
V
-2F45
-2FAN21 A
-2X10 1 2
M -P21
Ce document est la propriete de AEG Power Solutions et ne peut

1~
=CH2

-Q30...Q34
2 -X20
-P10 -2P6 -2P7

I>
220Vdc BUSBAR B
-P9
0-60A 0-130A 0-75V
0-500V V A -P2
+RC 0-75V
-P1 5 x 20A-UC
-TH2 Θ 0-400A A V -Q35...Q44
-S9 -S8 V 2 -X20

I>
Z1 LOAD CURRENT = 103.3A/600min
-TH1 Θ
A
-2F53
-T1 2
Mains
-F27 3 Filtering 1% Load -2V30...2V37 10 x 16A-C
-Q1 48TPRe300 -Q2 -2Q4 -Q7
400V 3Ph 50Hz

-L1 -F1 -V21 x8

-X3 -2X4
1

-X1 3 3 3 3 3 2 1 2 -2X3 2 -X2 3

I>

I>

I>

I>
Int Int
3 -R2 400A
3
-CT1 -2K27 -2R2 2A21
-H10 400A - 100mV +
400A 130A-100mV 125A-C
-C10-C11
63A-D -C1 250A
-F42 2
(SET AT 340AT)
2A201
A2
A5.2 A5.1 2 2
TPC PCB

M M -TH
-E50
A4 -X0
1~ Θ
Interface PCB
-FAN11-FAN12 -FAN1

AUX SUPPLY 230VAC 50Hz

1/N/PE
-Q4
-X4 2

I>
A1 -X20
GCAU PCB
-P3 10A-C
-TH -S6 -E1
-HT 400A-0-400A
400A - 100mV

Θ A6
-R3 A =BOX2
Battery BAT2
1/N/PE

-Q24 Q3
M:\SystemData\Projects\AEG PS\Order\120008441\48TPRe300_REV1.elk

2
A310 A300 -X2 2

I>
Int Int -SD1
I>

-X20
10A-C -X12
-S31 -H31 Common alarm
160A 24 x 9GROe900

Date 15-01-21 48TPRe300

Job: 120008441 Mat'l No:
Creator WEN BING POWER
01 04-05-21 YUAN FENG Check SWEE ENG SOLUTIONS
Single line diagram Page 4
S/N: EN A3
Modification Date Name Scale NTS Page 23
SG_FN1_001_CHR_TP
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

TABLE OF CONTENTS

INTRODUCTION
BATTERY INSTALLATION

CONSTRUCTION FEATURES ♦ Installation

♦ Battery room requirements
♦ Plates
♦ Containers

SAFETY
♦ Separators
♦ Electrolyte ♦ Protective Equipment
♦ Vent Plugs ♦ Battery disposal
♦ Terminal post
♦ Inspection hole
APPLICABLE STANDARDS

MAINTENANCE

OPERATING FEATURES

♦ Capacity ♦ Battery care

♦ Capacity in relation to discharge rate ♦ Cleaning
♦ Capacity range of FIAMM Flooded Lead Acid ♦ Voltage checks
Batteries ♦ Specific gravity reading
♦ Capacity in relation to the temperature ♦ Cell Appearance
♦ Internal impedance and short circuit current ♦ Pilot Cell
♦ Storage of filled and charged cells ♦ Periodic Inspections
♦ Storage of dry charged cells
♦ Service life
BATTERY TEST
♦ Gassing
♦ Service/Functional test
♦ Operation of batteries in parallel
♦ Capacity test
♦ Electrolyte Specific Gravity - State of charge

ELECTROLYTE

COMMISSIONING CHARGE / FIRST
CHARGE
VENTILATION
♦ Dry charge cells
♦ Determination of openings
♦ Filled and Charged Cells
♦ Close vicinity to the battery

CHARGING

♦ Floating charge
♦ Boost charge (Recharge following a discharge)
♦ Equalize voltage

Page 2 of 15
This document and the confidential information it contains shall be distributed, routed or made available solely with written permission of FIAMM.
FIAMM S.p.A. reserves the right to change or revise without notice any information or detail given in this publication.
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

INTRODUCTION
♦ Terminal posts D
In a high technological environment it is extremely Suitable threaded or flag post are provided to ensure
important to have a backup power source whenever low ohmic losses. Post to lid seals are designed to
possible. In fact mains power failure could cause severe prevent leakage over a wide range of internal pressures
losses and damages anytime. and conditions of thermal cycling.
FIAMM has been developing throughout years of
research and experience several ranges of Flooded Lead Special plastic terminal caps F are provided for
Acid Batteries to ensure the best reliability and quality. transportation assuring a protection against short circuit
during transportation.

CONSTRUCTION FEATURES ♦ Inspection Hole G

Special hole provide in models SGL-SGH to control the
The main construction features of FIAMM Flooded
electrolyte density and temperature without remove the
batteries are shortly described in the below section.
recombination plugs.
♦ Plates A
Cutaway drawing of FIAMM cells with positive tubular plate
FIAMM flooded lead acid batteries can be offered in
three different positive plate types to fit all customer
needs as performances and type of application as given
below: C
FIAMM Type of positive Type of
Battery range plate negative plate
PMF, LM Tubular Flat A
SD, SDH Flat Flat A
SGL SGH Plantè Flat
B
♦ Containers B
Battery cases and lids are made of SAN (Styrene
acrylonitrile) with high transparency, very good
dimensional stability, heat and chemical resistance
(PMF range use polypropylene container). D D

♦ Separators C
These separators are made of microporous PVC
material which assures a good ionic exchange in the
Rectangular “nut and bolt” Female (Bolt) terminal
electrochemical process. Terminal

♦ Electrolyte
The electrolyte is diluted sulphuric acid with a specific
gravity below indicated:

FIAMM Battery Electrolyte Specific

range Gravity at 20°C [kg/l]
PMF 1.25
LM 1.24 E F
SD - SDH 1.21 or 1.24 or 1.27
SGL - SGH 1.22

Vent plugs E G
Each cell has one or more vent plugs to permit the
release of gases from the cell during the charging
process; the ceramic part prevents explosion of the
gases inside the battery; they are fix by bayonet lock or
by screw (PMF range). A plain vent without the ceramic
part is available for some types as an option.

Page 3 of 15
This document and the confidential information it contains shall be distributed, routed or made available solely with written permission of FIAMM.
FIAMM S.p.A. reserves the right to change or revise without notice any information or detail given in this publication.
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

OPERATING FEATURES ♦ Capacity range of FIAMM Flooded Lead Acid

Batteries
♦ Capacity
FIAMM Capacity range
The battery capacity is rated in ampere hours (Ah) and Battery range [Ah]
is the quantity of electricity which it can supply during PMF from 25 to 300
discharge. The capacity depends on the quantity of the LM from 100 to 3500
active materials contained in the battery (thus on SD from 80 to 440
dimensions and weight) as well as the discharge rate, SDH from 480 to 2320
and temperature, and minimum voltage. SGL from 75 to 450
The nominal capacity of FIAMM batteries refers to SGH from 500 to 2600
the 10 hrs discharge rate (indicated with C10) with
constant current at 20°C to 1.80 volt per cell.
♦ Capacity in relation to the temperature

2.00 The capacity available from a battery, at any

I = 0.1 C10
particular discharge rate, varies with temperature.
1.90
I = 0.18 C10
Batteries which have to operate at temperatures
different from the nominal (20°C) need a higher or
Cell Voltage [V]

I = 0.27 C10
1.80 I = 0.37 C10
I = 0.59 C10
lower capacity as per the factor indicated in the
1.70 I = 0.89 C10 following graph (required capacity has to be
multiply by the correction factor stated in the
1.60 graph).

5 10 15 30 1 2 3 4 5 6 7 8 9 10

Minutes Hours
Fig. 1
Typical discharge curves for FIAMM Lead Acid Flooded batteries

♦ Capacity in relation to discharge rate

The available capacity of all lead acid batteries depend

on discharge rate (discharge current); this is due to
internal electrochemical process and type of
construction (i.e. type of positive plate).

Fig. 3
Capacity Correction factor versus temperature for a 10 hours
discharge rate for FIAMM Lead Acid Flooded batteries

♦ Internal impedance and short circuit current

The internal impedance of a lead acid battery is a

direct result of the type of internal construction,
plate thickness, number of plates, separator material,
electrolyte sp. gr., temperature and state of charge.
The internal resistance and the short circuit current
of FIAMM flooded at 100% state of charge and
20°C is indicated in the relative Product Sheet.
These values are calculated in accordance with IEC
60896 part 11.
Different instruments are available to detect the
internal resistance or impedance of lead acid
Fig. 2 batteries. These instruments use a different way to
Average available capacity versus discharge rates for FIAMM Lead
Acid Flooded batteries
determinate these values. The values obtained from
these instruments will be different to the values
stated in FIAMM Product Sheet.

Page 4 of 15
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FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

♦ Storage of filled and charged cells All Lead Acid Batteries emits gases during the
charge process. Please refer to “VENTILATION”
The state of charge of lead acid batteries slowly for information on required air exchange.
decreases on open circuit stand due to self
discharge. During prolonged storage it is necessary ♦ Operation of batteries in parallel
to recharge the battery every 3 months when the
storage temperature is 20°C or lower. When the When the required capacity exceeds the capacity of
storage temperature is above 20ºC a shorter storage a single string of batteries, it is possible to connect
time will result. Contact FIAMM for further details. more strings in parallel paying attention to the
The charging shall be according to the instructions following guidelines:
in paragraph “CHARGING” (we suggest a charge at
2.4 volt per cells for 24 hours) to maintain a fully • in each string only cells or monoblocs of the
charged condition of the battery; excessive open same type, model and quantity should be used;
circuit storage of any lead acid battery without • a symmetrical layout of the batteries should be
recharge will result in some permanent loss of designed (i.e. length and type of connector) to
capacity. minimize possible resistance variations;
• in the quantity of strings in parallel should be
♦ Storage of dry charged cells reasonable in terms of layout and application.
Usually 4 strings could be connected in parallel.
In this situation there is no electrolyte inside the However, depending on strings voltage and
cells so no electrical reaction can take place. In this cables length, a higher number of strings could
condition FIAMM batteries can be stored for many be safely connected to reach required total
years. capacity.

♦ Service life
♦ Electrolyte Specific Gravity - State of charge
According to the main international standards a
battery is considered at the end of its service life The measurement of the specific gravity of the
whenever delivering less than 80% of its nominal electrolyte (when it is at the MAX level) provides an
capacity. The recommended operating temperature approximate indication of the state of charge of the
range is between 10°C to 30°C. FIAMM flooded cells.
batteries can operate over a temperature range of –
20 to +50°C; operation at temperature higher than
20°C reduces life expectancy according to the graph
in figure 4.

Fig. 5
Electrolyte specific gravity in relation to the state of charge of the cell
(PMF-LM- SD- SDH cells)

Fig. 4
Expected service life vs working temperature

♦ Gassing

Page 5 of 15
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FIAMM Industrial Batteries

COMMISSIONING CHARGE /
FIRST CHARGE
Lead acid flooded batteries can be offered in two
different conditions:
♦ Dry Charge Cell
♦ Filled with electrolyte
Dry charge cells can be storage for long time
(many years).
Filled and charged cells should be installed and
connected to a rectifier within 3 months.
Be sure that ventilation equipment is on when
charging a battery.
♦ Dry charge cells
Electrolyte obtained locally. Please refer to paragraph
“electrolyte” for information about specific gravity for
first filling and impurities; we recommend that an
additional 10% spare is purchased to allow for losses
and spillage when handling and filling.
Electrolyte supplied by FIAMM. Check the specific
gravity of the electrolyte before filling the cells. Minor
adjustments may be made by adding water to lower the
specific gravity or by adding acid to raise the specific
gravity.
1. Filling the cells. It is recommended that the cells are
filled with electrolyte after installation on battery
racks.
2. The quantity of electrolyte required to fill each cell
is given in “Product Sheet” document.
3. Remove vent plugs.
4. Fill with the electrolyte. Use glass or plastic jugs and
funnels for filling the cells. DO NOT use metallic
materials.
5. Fill the cells with electrolyte to the "MAX" level
line and leave to allow the acid to soak into the
separators and plates.
6. In case of electrolyte spilling, neutralize it using 1kg
of soda to 10 litres of water. Be careful, the soda
DOES NOT entry in the cells.
7. After approximately 3 hours, if necessary, top up the
electrolyte to the "MAX" level line.
8. Give the initial charge as soon as possible after 3
hours stand, cells must not stand longer than 18
hours before initial charge is started.
9. Take individual cell readings of voltage, specific
gravity and temperature before starting initial
charge.
10. Charge the battery setting the rectifier voltage at
Vn where Vn = 2.7 x N (N= number of cells
connected in series).
Charge with a current rate to 0.10 C10 Amps for
approx. 15 to 16 hours. Higher or lower current will
reduce or increase the recharge time. During
charging it is suggested that voltage as well as sp. gr.
readings are taken at least at 3 hour intervals.
Voltage readings should be taken on each cell whilst
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Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA
sp. gr. may be taken on sample cells (one out of
five).
11. At the end of this process, the Ah delivered to the
battery must be 1.5 to 1.6 times the C10 rated
capacity (i.e. 150 to 160 Ah for a 100 Ah cell).
12. set the battery voltage to the FIAMM recommended
float voltage.
♦ Filled and Charged Cells
For batteries which have been supplied in a filled and
charged condition we suggest charging at a constant
current equal to 5% to 10% of the cell Ah capacity
should be used. In all cases the cells must have constant
voltages and specific gravities for at least two hours
before the charge is complete.
• the gravity readings in the cells have reached the
nominal specific gravity (see product sheet of specific
battery range)
• the cell voltages is equal to or greater than 2.6 VPC
• the values of individual cell voltage and specific
gravity must remain constant for at least two hours
under charge.
Alternative Method
As an alternative method, a constant voltage may be
used as follows.
A charge at 2.40Vpc (or higher up to 2.70Vpc) for a
minimum period of 24 hours (set rectifier at 2.4 x N;
N = number of cells connected in series). The current
available from the charging source must be not less than
5% of the C10 Ah capacity of the battery being charged.
The initial charge may be terminated when the specific
gravity readings of all cells have remained constant for
at least 2 hours. It may be required to extend the
charging time to 48h or even 60h if the batteries have
been stored for an extended period before
commissioning.
In all cases the cells must have constant voltages and
specific gravities for at least two hours before the
charge is complete.
At the end of this initial charge, set the battery voltage
to the FIAMM recommended float voltage.
During Charging
Make sure that the electrolyte temperature does not
exceed 40°C during the charge process. Should the
electrolyte temperature exceed 40°C then decrease the
charging current to a lower rate (half the current) or
discontinue the charge. In this case allow to stand on
open circuit until the temperature falls to 35°C. After
that the charging process has to be resumed
End Of Commission Charge
At the end of this initial charge, set the battery voltage
to the FIAMM recommended float voltage.
Page 6 of 15
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

CHARGING ♦ Equalize charge

In order to ensure the best protection against power
failures in any moment, it is necessary that batteries are
kept in the following conditions:
• in float charging throughout all their standby period;
• fully recharged soon after a discharge.
♦ Floating charge
Floating charge battery systems are those where the
charger, the battery and the load are connected in
parallel.
The "float" setting will maintain the battery in a fully
charged state with minimal water consumption.
The recommended float voltage setting for FIAMM
lead-acid cells is indicated in the following table:
Equalizing is required to reduce the spread of float
voltage among the cells under float charging conditions.
A short equalizing charge (from 30 minutes to some
hours) is also required after addition of distilled water to
make sure the acid and water are well mixed (check
electrolyte density value).
Equalizing should be carried out at 2.7 Volts per cell, or
at a constant current between 5% and 10% of the cell
nominal capacity in Ah. During this charge vent plugs
have to be removed and safety precaution must be
strictly observed.
Temperature has to remain lower than 40°C.

Cell type Float Voltage at

20°C
SD - SDH – PMF - LM 2.23 Volts per cell
SGL – SGH 2.23 Volts per cell

♦ Boost charge (Recharge following a

discharge)
Boost charge has to be used to recharge a battery after a
discharge it will restore the battery to a fully charged
state within relatively short period).
Boost charge has to be carry out at 2.4 volt per cell with
a current limited to 0.15 C10. Lower current will
increase the recharge time. Recharge time is usually 24
hours or when the current passing through the battery
has decreased to 5% of the C10. Temperature has to
remain lower than 40°C. Electrolyte density has to reach
the nominal value and remain constant for at least 2
hours; in case provide an equalize charge to the battery.

Fig. 6
Recharge curves at 2.4 volt per cell with different limit of current

Page 7 of 15
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FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

BATTERY INSTALLATION connector ends (it is not necessary to coat the central
part of the connector).
All necessary precaution must be taken when working 11. Fasten the inter-cell and inter-tier connectors in
with lead acid batteries as per electrical risk, explosives place using the bolts, nuts and washers supplied.
gasses, heavy components, corrosive liquids. Use Use the insulated wrenches supplied to tighten the
insulated tools and wear protective equipment. parts firmly together.

BATTERY THREAD S TANDARD S TANDARD

♦ Installation
RANGE TYPE VALUE Nm VALUE Lbs
1. Make sure that all cell jars and covers are thoroughly LM (OPzS)
M 10 Female 20÷25 175÷220
clean and dry. SGL - SGH
2. Synthetic cleaning cloths must not be used. To clean SGL -SGH
M 10 Female 20÷25 175÷220
the cell lids and containers, use only cotton cloths SD-SDH
soaked in a solution of mild soap and completely
“wrung” out. 12. Care must be taken to avoid short circuiting the cells
3. Clean the flat contact-making surfaces of the with any of the battery hardware.
terminal posts with a soft clean dry cotton cloth If 13. Make sure that the positive terminal of one cell is
there is evidence of acid having been spilled, the connected to the negative terminal of the next
whole length of the posts should be wiped down throughout the battery leaving the main positive and
with a cotton cloth soaked in a solution of mild soap negative terminals of the battery free for connection
and completely “wrung” out or a non-caustic alkali to the charging source. Take particular care to
solution, preferably dilute ammonia or baking soda. preserve the positive to negative sequence when
This will neutralize any acid on these parts. Do not using flexible inter-tier or inter-step connectors
allow any of this solution to get into the cells. Wipe between rows of cells.
the posts dry. 14. Insulate all the connectors by means of the plastic
4. Should the terminal posts have a white film on them, covers being supplied with the battery accessories.
lightly abrade their contact surfaces, using a Connect the positive terminal of the battery to the
Scotchbrite pad or fine grit abrasive paper, to positive terminal of the charger and the battery
remove any surface oxidation. Wipe off any loose negative to the charger negative.
particles and cover the whole length of the post, 15. Some batteries may have been shipped with plastic
down to the cover, with a thin coating of "No-oxide" pre-vents caps for shipping purpose. These caps
grease. should be removed and discarded.
5. Batteries are heavy, we recommend to lift the cells 16. Install the FIAMM standard explosion proof vents.
using lifting straps together with suitable mechanical 17. Affix the cell number stickers to the cell jars making
lifting device to prevent injury to personnel or sure that the surfaces are dry and clean. It is usual to
damage to the cells, whenever possible we suggest number the cells beginning with #1 at the positive
to avoid to lift cells by its terminals. end of the battery, numbering consecutively in the
6. Place the cells or blocs in position on the rack at the same order as the cells are connected electrically,
correct spacing which will accommodate the inter- through to the negative end of the battery.
cell connectors supplied (usually the clearance
between the battery cells or monoblocs has to be ♦ Battery room requirements
between 10 and 15 mm). Most batteries have cells
connected in a simple series arrangement, so the • The battery room should be dry, well ventilated and
cells should be arranged to preserve the sequence: have its temperature as moderate as the climate will
positive (marked “+”), negative (marked “-”), allow, preferably between 10°C and 30°C.
positive (marked “+”), negative (marked “-”) etc., • DO NOT permit smoking or the use of open
throughout the battery. flames in the battery room.
7. For batteries on multiple section, double tier racks, • Adequate ventilation to change the air in the battery
start by placing the cells or blocs on the lower tier on room is essential to prevent an accumulation of the
either side of the upright where the rack sections gases given off during charge (for further
meet. Any unused rack space should be on the information please refer to “VENTILATION”
upper tier. paragraph).
8. For batteries on stepped racks, leave any unused • The battery will give the best results and life when
rack space on the back (top) step. working in a room temperature of 20°C, but will
9. Prepare the connectors by lightly abrading the function satisfactorily when operating in
contact surfaces with a Scotchbrite pad or fine grit temperatures between -20°C and +60°C. High
abrasive paper. DO NOT use a wire brush and be temperatures increase the performance, but decrease
especially careful not to break through the lead the life of the cells; low temperatures reduce the
plating. performance.
10. Apply a light coating of "No-oxide" grease to the • Do not allow direct sunlight to fall on any part of the
contact-making areas of each connector. This is best battery.
done by carefully melting the grease and dipping the

Page 8 of 15
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FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

• If a rack is not supplied by FIAMM, suitable racks
APPLICABLE STANDARDS

should be provided to support the cells. These
should be arranged to provide easy access to each FIAMM flooded batteries comply with:
cell for inspection, topping up and general
maintenance. Suitable racks may be made of wood • IEC 60896 Stationary lead-acid battery –
or metal with a coating of acid resistant paint. If Part 11: Vented Types – General requirements and
metal racks are used, they must be fitted with rubber methods of tests.
or plastic insulators to prevent the cells coming into
contact with the metal.
• EN 50272-2 Safety requirements for secondary
• To facilitate proper battery operation, maintenance, batteries and battery installations Part 2: Stationary
and care, post a battery data card/ instruction table batteries.
in a conspicuous place near the battery to provide
the attendant with service information and data
• DIN 40736-1 Lead acid batteries; stationary cells
with positive tubular plates; cells in plastic-

SAFETY containers; rated capacities, main dimensions,
weights ( for LM range).
It is recommended that full precautions be taken at
all times when working on batteries. The safety • DIN 40738 Lead storage batteries; stationary cells
standards of the country of installation must be risk, with positive Plante plates, narrow plate distance;
explosives gasses, heavy components, rated capacities, main dimensions (SGL, SGH
ranges).
♦ Protective Equipment
• BS 6290-3 Lead-acid stationary cells and batteries.
Make sure that the following equipment is available to Specification for lead-acid pasted positive plate type
personnel working with batteries: ( SD-SDH range) .

• Instructions manual. • BS 6290-2 Lead-acid stationary cells and batteries.

• Tools with insulated handles. Specification for lead-acid high performance Planté
• Fire extinguisher. positive type ( SGL, SGH ranges).
• PPE (Personal Protective Equipment) must be worn
(glasses, gloves, aprons etc ... ). • BS 6290-1 Lead-acid stationary cells and batteries.
• First aid equipment must be available. Specification for general requirements

♦ Safety Precautions

Observe the following precautions at all times:

• Batteries are no more dangerous than any other

equipment when handled correctly
• Do not allow metal objects to rest on the battery or fall
across the terminals.
• Never wear rings or metal wrist bands when working
on batteries
• Do not smoke or permit open flames near batteries or
do anything to cause sparks.
• Do not try to remove the battery cap to add water or
acid into the cell(s).
• Air exchange must be provided to prevent the
formation of explosive hydrogen concentration.

♦ Battery Disposal

Lead acid batteries must be disposed according to the

country law. It is strongly recommended to send
batteries for recycling to a lead smelter. Please refer to
the local Standards for any information

Page 9 of 15
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FIAMM Industrial Batteries

MAINTENANCE
♦ Battery care
GASES GIVEN OFF BY BATTERIES ON CHARGE
ARE EXPLOSIVE!
DO NOT SMOKE OR PERMIT OPEN FLAMES OR DO
ANYTHING TO CAUSE SPARKS NEAR BATTERIES.
1. Check the electrolyte levels in all cells regularly and
if necessary top up with distilled water. Never allow
the electrolyte level to fall below the "MIN" line. Do
not overfill the cells. For information about quality
of water to beaded please refer to “Electrolyte”
chapter. When water has been added, set the charger
to "equalize" for about 30 minutes to help mix the
electrolyte.
2. Keep the battery and surroundings clean and dry.
Wipe the cells with an antistatic clean soft cloth
dampened with clean water. If necessary, a small
amount of mild detergent may be added to the
cleaning water to remove any greasy film. Do not
use any special powders or solvents for cleaning the
battery cells, as scratching or damage to the plastic
could occur.
3. Make sure that bolted connections are properly
tightened (see table in section 6).
4. Keep connectors, posts and bolted connections
covered with "No-oxide" grease for protection
against corrosion.
5. Should any corrosion of the connections occur
because of spilled acid, etc., carefully remove
corrosion materials, thoroughly clean and neutralize
with diluted ammonia or baking soda.
6. Dry the parts before coating them with "No-oxide"
grease to protect from further corrosion. Do not let
the neutralizing solution enter the cell.
7. Keep the battery at the recommended charge voltage
(see CHARGING section). Give the battery an
equalizing charge whenever necessary.
8. The room in which the battery is installed should be
well ventilated and its temperature as close as
possible to 20°C.
♦ Cleaning
When necessary, batteries could be cleaned using a
soft dry antistatic cloth or water-moistened soft
antistatic cloth paying attention not to cause any
ground faults.
No detergent nor solvent-based cleaning agents nor
abrasive cleaners should be used as they may cause
a permanent damage to the battery plastic container
and lid.
♦ Voltage checks
All voltage measurements should be made when the
whole battery has stabilized on floating, at least 7
days after battery installation or after a discharge
cycle. To facilitate voltage reading in the
correspondence of each block terminal protection
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Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA
covers are designed with a safe and proper hole.
Measure and record individual block voltages on
float once a year. It is normal to have a spread of
+0,1
block voltages up to 2,23 /-0,08 V. particularly in
the first year of operation. In the following time the
tolerance of the voltage of each cell could be in the
+0,1
narrower range of 2,23 /-0,05 V. No corrective
action is required in this case; for higher differences
an equalize charge is suggested. Maintaining a
correct battery charging voltage is extremely
important for the reliability and life of the battery.
So it is advisable to carry out a periodical checking
of the overall float voltage to verify any possible
defect of charger or connections.
♦ Specific gravity reading
When taking specific gravity readings, care must be
taken to make sure that the electrolyte level in the cell to
be measured is at the "MAX" line and that any distilled
water added recently has been properly mixed in, by
equalizing for about 30 minutes.
The specific gravity of the electrolyte varies with
temperature; consequently, hydrometer readings should
be corrected as indicate in Electrolyte Chapter.
The specific gravity may range ± 0.01 points within a
cells at the nominal values of 20°C; during the first year
of operation a wider range could be noted; in some
cases for higher differences an equalize charge is
suggested.
NEVER ADD ACID TO INCREASE SPECIFIC
GRAVITY READINGS.
♦ Cell Appearance
Healthy cells, when fully charged, show a marked
contrast between the dark brown positive and the light
grey negative plates. For cells in transparent jars (LM,
SD, SDH, SGL, SGH), it is extremely useful to inspect
the appearance of each cell in the battery at regular
intervals.
Any cells not showing a healthy plate coloration, or
having a specific gravity or voltage noticeably lower
than the other cells, or in which the plates bubble
unevenly or not at all, should be regarded as suspect.
Such cells should be carefully examined for internal
short-circuits, such as may be caused by small pieces of
scale bridging across the plates.
An equalize charge will normally restore such cells to
the condition of the remainder of the battery, but if it
does not, expert advice should be obtained immediately
from FIAMM.
♦ Pilot Cell
For regular monitoring of the battery condition, select
one or more cells of the battery as a "pilot" cell(s); for
batteries comprising more than 60 cells, select one pilot
cell for every 60 cells. The electrolyte specific gravity
Page 10 of 15
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

of the pilot cell(s) will be indicative of the state of

charge of the whole battery.

♦ Periodic Inspections

Written records must be kept of battery maintenance, so

that long-term changes in battery condition may be
monitored. The following inspection procedures are
recommended:

MONTLY:
• check and record the overall float voltage at the
battery terminals (not at the charger!),

EVERY SIX MONTHS:

• Visual inspection on cells/racks ( appearance,
cracks or corrosion signs, electrolyte
leakage….)
• check and record the overall float voltage at the
battery terminals (not at the charger!),
• measure and record the pilot cell(s) voltage.
• measure and record the pilot cell(s) electrolyte
specific gravity
• measure and record the pilot cell(s) electrolyte
temperature
• electrolyte level
• room ventilation

YEARLY:
• all the controls indicated at six months
• check and record the voltage of all cells.
• measure and record electrolyte specific gravity
of all cells.
• measure and record the pilot cell(s) electrolyte
temperature
• check and in case torque the bolt connection
(refer to connection torque table); in case of
frequent high discharge current please consider
to check the bolt torque at least every six
months
• visual inspection on cells/rack ( electrolyte
level, corrosion signs…)
• clean the cells
• in case coat the connection with no-oxide
grease

Page 11 of 15
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FIAMM Industrial Batteries

BATTERY TEST
Test must be conducted in accordance with EN 60896-
11.
Before any discharging test batteries have to be properly
prepared with a boost charge (2.4 volt per cell for 24
hours at 20°C) to ensure they are in a fully charge
condition. In order to take temperature readings of a
battery, one pilot cell or block shall be chosen. The
surface temperature of the container wall centre of each
pilot cell or block shall be measured immediately prior
to the discharge test. The individual readings shall be
between 15°C and 30°C. The temperature of the
selected block shall be considered as representative of
the average temperature of the battery. It is desirable
that the average cell surface temperature and the
ambient temperature fall as nearer to the reference
temperature of 20°C or 25°C as possible.
In case of batteries having a capacity lower than 80% of
the nominal rating it is advisable to replace them within
12 months
Here below some precaution to be taken:
• Discharge must be stopped at the final discharge
voltage.
• Deeper discharges must not be carried out unless
specifically agreed with FIAMM.
• Recharge immediately the battery after each (full or
partial) discharge test.
♦ Service/Functional test
This is a test of the battery’s ability, to satisfy the design
requirements of the system. It means to discharge the
battery directly to the load (in this case take precautions
to ensure that a battery failure does not jeopardise other
equipment) or dummy load to simulate a main failure.
1. Record the floating voltage of each cell, as well as
the total system voltage
2. Check the actual load (A or W), as well as the
minimum admissible voltage of the system
3. On FIAMM discharge tables you can approx.
determinate the discharge rate (minutes of
discharge) Please note that battery performances
change (decrease) with battery age. After
switching off the rectifier, discharge the battery for a
time of 20% of that calculated discharge rate
4. During the discharge, record at regular intervals,
cell/block voltage, battery temperature, discharge
current, total battery voltage
5. For safety reason, during the test assure that the total
battery voltage remains above the minimum
depending on discharging rate in order to avoid any
failure to the system (please note that approaching to
the final voltage, the voltage curve decreases
rapidly)
6. For particular comments on test’s data, please refer
to FIAMM technical offices
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Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA
♦ Capacity test
Please carry out this test only when complete
information on the quantity of energy inside the battery
is requested. Take precautions because after this test
battery SHOULD NOT BE ABLE TO SUPPLY
ENERGY IN CASE OF MAIN FAILURE.
Dummy load is usually necessary to provide the request
discharge current. Test is usually carried out to verify
the battery capacity to a specify end voltage and
discharge rate (usually 1, 3 or 10 hours).
Test must be conducted in accordance with EN 60896-
11. Please refer to prescription indicated in the above
standard. Record at regular intervals cell/bloc voltage,
battery temperature on pilot cell, discharge current, total
battery voltage ( readings have to be made at least at
25%, 50% and 80% of the discharge time and then at
the suitable time intervals which permits the detection
oft he transition tot he final discharge voltage).
According IEC60896-11 the discharge shall be
terminated when one of the following values tdisch,
whichever comes first, has been recorded:
1. tdisch = the elapsed time of discharge of the string,
with n cells, to a voltage of n x Ufinal (V)
2. tdisch = the elapsed time when a cell or monobloc in
the string reached a voltage of
cell or monobloc voltage
ܷ = U୤୧୬ୟ୪ − ቌඨ ቍ × 0.2
2
At the end of discharging test, batteries have to be
recharged immediately.
The following formula determinates the battery
capacity:
‫ܿݏ݅݀ = ܥ‬ℎܽ‫ݐ × ݐ݊݁ݎݎݑܿ ݁݃ݎ‬ௗ௜௦௖௛
(where tdisch is indicated in hours)
For temperatures different from the nominal (20°C) and
discharge rates between 3 to 10 hours, the battery
capacity shall be corrected as follows:
C
Cଶ଴°େ =
1 + λሺθ − 20ሻ θ = initial pilot cell
Where:
λ= 0.006 for tests > 1 hour
temperature (°C)
λ= 0.01 for tests ≤ 1 hour
A new battery shall supply at least
Ca=0.95 Nominal capacity at the first cycle
Ca= Nominal capacity at the fifth cycle
Trending battery capacity during years will provide
information in predicting when the battery will no
longer meet design requirements.
Page 12 of 15
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

ELECTROLYTE Electrolyte specific gravity change with temperature, for

a correct reading the reading value must be corrected to
High quality electrolyte for Stationary Standby Batteries the nominal electrolyte temperature (usually 20°C).
(which is a solution of pure sulphuric acid diluited with Here below the formula for correction
distiller water to the correct specific gravity) is required
for filling dry charged cells d = d t + 0.0007 × (t - 20)
The following table gives specific gravity (Sp.Gr.) data
Where dt=specific gravity at ”t” temperature
at 20°C for fully charged cells with the electrolyte at the
maximum level and for electrolyte filling:

Nominal Sp. Gr. Range for Sp.Gr. for Filling Cell

Sp. Gr. filled cells Dry Charged Type Electrolyte Specific Gravity
[kg/l] at 20°C Cells
Temperature at full charge
[kg/l] at 20°C
[°C] [°F] [kg/l]
1,27 1,26 - 1,28 1,25 SD, SDH
-20 -4 1.2120
PMF, -15 5 1.2155
1.24 1.230 - 1.250 1.23
LM
-10 14 1.2190
SGL,
1.22 1.210 - 1.230 1.21
SGH
-5 23 1.2225
0 32 1.2260
5 41 1.2295
NEVER ADD ACID TO INCREASE SPECIFIC 10 50 1.2330
GRAVITY of electrolyte.
15 59 1.2365
20 68 1.2400
25 77 1.2435
Here below please find the max impurities for new 30 86 1.2470
electrolyte and refilling water. 35 95 1.2505
40 104 1.2540
Max Value 45 113 1.2575
Impurityes Unit
DIN 43 530 Teil 2 50 122 1.2610
2+
Iron (Fe ) mg/l 30 55 131 1.2645
copper (Cu2+) mg/l 0.5 60 140 1.2680
3+
Antimony (Sb ) mg/l 1.0
3+
Arsenic (As ) mg/l 1.0
3+
Bismuth (Bi ) mg/l 1.0
2+
Tin (Sn ) mg/l 1.0
3+
Chromium (Cr ) mg/l 0.2
2+
Nichel (Ni ) mg/l 1
+
Ammonium Ions (NH4 mg/l 50
Nitratw ions (NO3- mg/l 10
-
Chlorine Ions (Cl ) mg/l 5
Organic Substances (O2) mg/l 30
Other Impurityes mg/l 250

Page 13 of 15
This document and the confidential information it contains shall be distributed, routed or made available solely with written permission of FIAMM.
FIAMM S.p.A. reserves the right to change or revise without notice any information or detail given in this publication.
FIAMM Industrial Batteries Installation & Operating Instruction -Technical Manual Edition 09/2015 - EMEA

VENTILATION (in accordance with

EN 50272-2) The following picture gives an indication of the correct
opening to assure a complete battery room air exchange
During normal operating conditions, lead acid
batteries emits low quantity of gases which can
reach an explosive mixture when hydrogen concen-
tration is higher than Lower Explosion Limit (LEL)
threshold which is 4%vol.
The purpose of ventilating a battery location or
enclosure by natural or forced (artificial) ventilation
is to maintain the hydrogen concentration below the
above stated limit. Battery locations and enclosures
♦ Forced ventilation
are to be considered as safe from explosions, when
the concentration of hydrogen is kept below this safe
Where an adequate air flow Q cannot be obtained by
limit.
natural ventilation and forced ventilation is applied,
The minimum air flow rate for ventilation of a
the charger shall be interlocked with the ventilation
battery location or compartment shall be in
system or an alarm shall be actuated to secure the
accordance with European Standard EN 50272
required air flow for the mode of charging selected.
calculated by the following formula:
The air extracted from the battery room shall be
exhausted to the atmosphere outside the building.
Q = 0,05 x N x Igas x Crt x x 10-3
where: ♦ Close vicinity to the battery
Q = ventilation air flow in m3/h In the close vicinity of the battery the dilution of
N = number of cells (each 2 Volt) explosive gases is not always secured. Therefore a
Crt= capacity C10 [Ah] at 1.80 volt/cell. at 20°C. safety distance extending through air must be
observed within which sparking or glowing devices
The current Igas [mA/Ah] producing gas as indicated in the (max. surface temperature 300 °C) are prohibited.
table of the above mentioned standard con be assumed as: The dispersion of explosive gas depends on the gas
Igas = 5 For batteries on float release rate and the ventilation close to the source of
release. For calculation of the safety distance d from
the source of release the following formula applies
Igas = 20 For batteries on boost charge assuming a hemispherical dispersal of gas. The
safety distance “d” is given from the following
formula:
♦ Determination of openings

The amount of ventilation air flow shall preferably d = 28,8 x 3 N x 3 Igas x 3 Crt
be ensured by natural ventilation, otherwise by
forced (artificial) ventilation. Battery rooms or
enclosures require an air inlet and an air outlet with
a minimum free area of opening calculated by the
following formula:

A = 28 x Q
with Q = ventilation flow rate of fresh air [ m3/h]
A = free area of opening in air inlet and outlet
[cm2] where N depends on the number of cells per monoblock
battery (N) or vents openings per cell involved (1/N).

Note: For the purpose of this calculation the air velocity is For further information please refer to EN50272
assumed to be 0,1 m/s. Standard or contact FIAMM at:
info.standby@fiamm.com
The air inlet and outlet shall be located at the best
possible location to create best conditions for exchange
of air, i.e.

• openings on opposite walls,

• minimum separation distance of 2 m when
openings on the same wall.

Page 14 of 15
This document and the confidential information it contains shall be distributed, routed or made available solely with written permission of FIAMM.
FIAMM S.p.A. reserves the right to change or revise without notice any information or detail given in this publication.
 SE-201127-67-MB
SE-201127-67-MB

27 November 2020

TO WHOM IT MAY CONCERN

Subject : FIAMM DESIGN STANDARDS-SGH19D

FIAMM ENERGY TECHNOLOGY S.P.A. – FET S.p.A. - Viale Europa, 75 - Montecchio Maggiore (Vicenza) - ITALY,
hereby confirm that its complete SGL-SGH range of lead acid batteries are produced and inspected in conformity with the
requirements of its own Quality Assurance System which is in accordance to International Standards and FIAMM ENERGY
TECHNOLOGY Quality Management System is certified according to ISO 9001 Standard.

The applicable International Standards for FIAMM SGL-SGH battery range are stated:

• DIN 40738 – specification GroE cells

• IEC 60896 –Part 11 Vented types requirements & tests
• BS 6290 –Part 2 British Standard Planté Specification
• UK National Grid (with optional nut & bolt terminals)
• EN 62485-2 Safety requirements for secondary batteries and battery installations Part 2: Stationary batteries.
• 25 years design life in float operation in temperature controlled environments

We also certify that the battery model SGH19D has the following certified characteristics:

• Capacity: 990 Ah 10h , 180 VPC at 20°C

• DIN Reference: 9 GroE 900

Yours faithfully,
 PRODUCT INFORMATION SHEET N° DXK43E03en

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Title : LEAD ACID BATTERIES

GENERAL REMARK

This leaflet was prepared in cooperation with the Committee of Environmental Affairs of EUROBAT (May
2003), reviewed by EUROBAT TC members (September 2003) and CEM (October – November 2003).
Last revision: October 2016.

Batteries are “articles” according to Regulation (EC) No 1907/2006 EC, they are not "substances" nor
"mixtures", therefore there is no obligation to supply a safety data sheet (SDS) according to Regulation
(EC) 1907/2006, and Regulation CLP (EC) 1272/2008.

Information on safe handling is provided as a service to our customers.

This product information sheet contains valuable information critical to the safe handling and proper
use of the product. The details presented are in accordance with our present knowledge and
experiences, they cannot advise all possible situation.

1. PRODUCT AND COMPANY IDENTIFICATION

Product Name & Use: FIAMM Lead Acid Battery for stationary applications

Company Identification FIAMM Energy Technology S.p.A.

Viale Europa, 75 I - 36075 Montecchio Maggiore (Vicenza)
Telephone +390444709311; Fax +390444699237

E-mail: sdp@fiamm.com

2. HAZARDS IDENTIFICATION

No hazards occur during the normal operation of a Lead Acid Battery as it is described in the instructions
for use that are provided with the Battery. Lead acid Batteries have three significant characteristics:
• They contain an electrolyte which contains diluted sulphuric acid. Sulphuric acid may cause severe
chemical burns.
• During the charging process or during operation they might develop hydrogen gas and oxygen,
which under certain circumstances may result in an explosive mixture.
• They can contain a considerable amount of energy, which may be a source of high electrical
current and a severe electrical shock in the event of a short circuit.

The Batteries have to be marked with the symbols listed under item 15.

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Title : LEAD ACID BATTERIES

3. COMPOSITION / INFORMATION ON INGREDIENTS

Index Content
1) Hazards Category and
CAS no. Description
Numbers [% of weight] Statement Code
7439-92-1 082-014-00-7 Lead Grid ~ 32 Repr. 1A - H360FD
(massive lead, lead alloys) Lact– H362
STOT RE 1 – H372
7439-92-1 082-001-00-6 Active Mass ~ 32 Repr. 1A - H360Df
(Lead dioxide, inorganic lead Acute Tox. 4 - H332
compounds, with possible traces of Acute Tox. 4 - H302
additives) STOT RE 1 - H372
Lact – H362
Carc.2 – H351
Aquatic Acute 1 - H400
Aquatic Chronic 1 H410
2)
7664-93-9 016-020-00- 8 Electrolyte ~ 29 SkinCorr.1A - H 314
(diluted sulphuric acid with additives)
3)
Plastic Container / Plastic Parts ~7
1)
Contents may vary due to performance data and/or application of the Battery
2)
Density of the electrolyte varies in accordance to the state of charge
3)
Composition of the plastic may vary due to different customer requirements

Note: Batteries do not contain Cadmium (Cd) nor Mercury (Hg)

4. FIRST AID MEASURES

This information is of relevance only if the Battery is broken and this results in a direct contact with the
ingredients.

4.1 General Electrolyte (diluted sulphuric sulphuric acid acts corrosively and damages skin
acid):
Lead compounds: lead compounds are classified as toxic for
reproduction (if swallowed)
4.2 Electrolyte after skin contact: rinse with water, remove and wash wetted clothing
(Sulphuric acid)
after inhalation of acid mist: inhale fresh air, seek advice of a medical doctor

after contact with the eyes: rinse under running water for several minutes,
seek advice of a medical doctor

after swallowing: drink lot of water immediately, swallow activated

carbon, do not induce vomiting, seek advice of a
medical doctor
4.3 Lead after skin contact: clean with water and soap
compounds
after inhalation: inhale fresh air, seek advice of a medical doctor

after contact with the eyes: rinse under running water for several minutes,
seek advice of a medical doctor

after swallowing: wash mouth with water, seek advice of a medical

doctor

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Title : LEAD ACID BATTERIES

5. FIRE FIGHTING MEASURES

Suitable fire extinguishing agents:

CO2 or dry powder extinguishing agents

Unsuitable fire extinguishing agents:

Water, if the battery voltage is above 120 V

Special protective equipment:

Protective goggles, respiratory protective equipment, acid protective equipment, acid-proof clothing in case
of larger stationary battery plants or where larger quantities are stored.

6. ACCIDENTAL RELEASE MEASURES

This information is of relevance only if the battery is broken and the ingredients are released.

In the case of spillage, use a bonding agent, such as sand, to absorb spilt acid; use lime / sodium bicarbonate
for neutralisation; dispose of with due regard to the official local regulations; do not allow penetration into the
sewage system, into earth or water bodies.

7. HANDLING AND STORAGE

Store under roof in cool ambiance charged lead acid batteries do not freeze up to 50°C; prevent short circuits.
Seek agreement with local water authorities in case of larger quantities of batteries to be stored. If batteries
have to be stored, it is imperative that the instructions for use are observed.

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

8.1 Lead and Lead compounds

No exposure to lead and lead containing battery paste during normal conditions of use.

8.2 Electrolyte (Sulphuric Acid diluted solution)

Exposure to sulphuric acid and acid mist might occur during filling and charging.
 
Threshold value in occupational exposure limits for sulphuric acid mist are regulated on a national
workplace: basis.
Hazard symbol: corrosive
Personal protective protective goggles, rubber or PVC gloves, acid resistant clothing, safety boots.
equipment:
CAS No: 7664-93-9
Hazard statements: H314 Causes severe burns and eye damage.
Precautionary P102 Keep out of reach of children.
Statements:
P210 Keep away from heat, hot surfaces, sparks, open flames
and other ignition sources. No smoking

P305+P351+315 IF in eyes. Rinse cautiously with water for several

minutes. Get immediate medical advice/attention.

P309+315 IF exposed or if you feel unwell. Get immediate medical

advice/attention.

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Title : LEAD ACID BATTERIES

9. PHYSICAL AND CHEMICAL PROPERTIES

Lead and Lead compounds Electrolyte (diluted sulphuric acid solution)

Appearance
form : solid liquid
colour : grey colourless
odour : odourless odourless

Safety related data

solidification point : 327 °C approx 35 to 60 °C
boiling point : 1740 °C approx. 108 to 114 °C
solubility in water : very low (0.15 mg/l) complete
density (20°C) : 11.35 g/cm3 1.2 to 1.35 kg/l
vapour pressure (20°C) : N.A. N.A.

Lead and Lead compounds used in Lead Acid batteries are poorly soluble in water, Lead can be dissolved in
an acidic or alkaline environment only.

10. STABILITY AND REACTIVITY (referred to diluted sulphuric acid, density 1.2 ÷ 1.35 kg/l)
• Corrosive, non flammable liquid
• Thermal decomposition at 338° C.
• Destroys organic materials such as cardboard, wood, textiles.
• Reacts with metals, producing hydrogen
• Vigorous reactions on contact with sodium hydroxide and alkalis.

11. TOXICOLOGICAL INFORMATION

This information does not apply to the finished product “lead acid battery”. This information only applies to its
compounds in case of a broken product. Different exposure limits exist on a national level.

11.1 Electrolyte (diluted sulphuric acid):

Sulphuric Acid is intensely corrosive to skin and mucous membranes; the inhalation of mists may cause
damage to the respiratory tract.
Acute  toxicity  data:
 
• LD50 (oral, rat) = 2.140 mg/kg
3
• LC50 (inhalation, rat) = 510 mg/m /2h
 
11.2 Lead and Lead compounds
Lead and its compounds used in a Lead Acid Battery may cause damage to the blood, nerves and kidneys
when ingested. The lead contained in the active material is classified as toxic for reproduction.

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Title : LEAD ACID BATTERIES

12. ECOLOGICAL INFORMATION

This information is of relevance if the battery is broken and the ingredients are released to the environment.

12.1 Electrolyte (diluted sulphuric acid)

In order to avoid damage to the sewage system, the acid has to be neutralised by means of lime or sodium
carbonate before disposal. Ecological damage is possible by change of pH. The electrolyte solution reacts
with water and organic substances, causing damage to flora and fauna. The electrolyte may also contain
soluble components of lead that can be toxic to aquatic environments

12.2 Lead and Lead compounds

Chemical and physical treatment is required for the elimination from water. Waste water containing lead must
not be disposed of in an untreated condition.

Lead metal grids are not classified as eco-toxic.

13. DISPOSAL CONSIDERATIONS

Spent lead acid batteries (EWC 160601*) are subject to regulation of the EU Battery Directive and its
adoptions into national legislation on the composition and end of life management of batteries.

Spent Lead Acid batteries are recycled in lead refineries (secondary lead smelters). The components of a
spent Lead Acid battery are recycled or reprocessed.

To simplify the collection and recycling or reprocessing process, spent Lead Acid batteries must not be mixed
with other batteries.

By no means may the electrolyte (diluted sulphuric acid) be emptied in an inexpert manner. This process is to
be carried out by the processing companies only.

*200133 EWC may be used for municipal collected batteries.

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Title : LEAD ACID BATTERIES

14. TRANSPORT INFORMATION

Land Transport (ADR/RID, U.S. DOT)

UN N°: UN2794
Classification ADR/RID: Class 8
Proper Shipping Name: BATTERIES, WET, FILLED WITH ACID, electric storage
Packing Group ADR: not assigned
Packing Instruction P 801
Label required: Corrosive
ADR/RID: New batteries are excepted from all ADR/RID (special provision 598).

Sea Transport (IMDG Code)

UN N°: UN2794
Classification: Class 8
Proper Shipping Name: BATTERIES, WET, FILLED WITH ACID, electric storage
Packing Group: not assigned
Packing Instruction P 801
EmS-FIRE & SPILL: F-A, S-B
Label required: Corrosive
Marine Pollutant no

Air Transport (IATA-DGR)

UN N°: UN2794
Classification: Class 8
Proper Shipping Name: BATTERIES, WET, FILLED WITH ACID, electric storage
Packing Group: not assigned
Packing Instruction P 870
Label required: Corrosive

15. REGULATORY INFORMATION

The following legislation do not apply to lead-acid batteries:

• RoHS directive 2002/95/EC, updated by directive 2011/65/UE
• Low Voltage directive 73/23/EEC, updated by directive 2006/95/EC, if the voltage is < 75 V
• ELV directive 2000/53/EC
• EMC directive 89/336/EEC, updated by directive 2004/108/EC

In accordance with EU Battery Directive and the respective national legislation, Lead Acid batteries have
to be marked by a crossed out dust bin with the chemical symbol for lead shown below, together with the
ISO return/recycling symbol.

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Title : LEAD ACID BATTERIES

Labelling might vary due to application and dimension of the Battery. The manufacturer, respectively the
importer of the batteries shall be responsible for placing the symbols (a minimum size is specified). In
addition, consumer/user information on the significance of the symbols may be attached.

16. OTHER INFORMATION

The information given above is provided in good faith based on existing knowledge and does not constitute
an assurance of safety under all conditions. It is the user’s responsibility to observe all laws and
regulations applicable for storage, use, maintenance or disposal of the product. If there are any queries,
the supplier should be consulted. However, this shall not constitute a guarantee for any specific product
features and shall not establish a legally valid contractual relationship.

Data Prima Emissione: 01/01/2011 Indice di Revisione: 7 Data Ultima Revisione: 11/08/2017
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 SE-201127-67-MB
SE-201127-68-MB

27 November 2020

TO WHOM IT MAY CONCERN

Subject: SGL-SGH range - Available capacity according to the temperature

The Available capacity which any battery can perform depends from the temperature. The temperature used as a
reference in the calculation of the Available capacity according to the temperature time is 20 ° C. Increasing temperature
will give an increase of the backup time. It should however know that if the battery work at high temperatures is reduced
its life expectancy.
The graph below shows the trend of the capacity according to the temperature:

120
115
110
105
Available Capacity (%)

100
95
90
85
80
75
70
65
60
55
50
45
40
-20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60
TEMPERATURE (°C)

Yours faithfully,
 Montecchio Maggiore, 24th September 2020
TO WHOM IT MAY CONCERN

SUBJECT: SGL/SGH Plantè type SALES REFERENCES

FIAMM Energy Technology S.p.A., established in Viale Europa, 75, Montecchio Maggiore (VI) Italy,

Hereby confirms that the SGL and SGH range are fully available in standard production and are
designed in according with DIN 40738 - specification for GroE cells.

The production volumes in the last three years have been:

Q.ty (Pz) Q.ty (Pz) Q.ty (Pz)

2019 2018 2017
6.906 7.039 8.404

Among the most important customers we can mention:

Country End User Q.ty supplied

2017-2019
Austria OMV / Austria Telekom 1190
Belarus BELENERGO / Minsk Metro 360
Bulgaria Kozloduy Nuclear Power Plant 126
China CHINA NATIONAL ELECTRIC 106
Columbia EPM 306
Greece AHK (Electricity Authority of Cyprus) 216
Israel Israeli Electric Company 760
Italy ENEL PRODUZIONE / ENGIE Produzione 1322
Pakistan ISLAMABAD ELECTRIC SUPPLY / LAHORE ELECTRIC SUPPLY 5651
/ NATIONAL TRANSMISSION & DESPATCH
Poland PCC Rokita / Polish Coal Mine / Tauron Poland 1465
Russia FSK EES / GAZPROM 2894
South Korea HYUNDAI ELECTRIC & ENERGY SYSTEMS 166
Turkey DUNYA ENDÜSTRİ 268
United National Grid / Scottish Power / SSE / Northern Ireland 5353
Kingdom Electricity

Nicola Corradin
Marketing Manager
Reserve Power Solutions