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Introduction 1
Important recommendations 2
3. Installation
3.1. Assembly into batteries 10
3.2. Ventilation and cooling 11
3.3. Assembly of centralized water filling system 11
3.3.1. Precautions and recommendations 11
3.3.2. General instructions for assembly 12
4. Placing into service
4.1. Procedure before use 13
4.2. Commissioning cycle and water topping-up 13
5. Operation
5.1. Operating temperature 14
5.2. Two-level charge 14
5.2.1. Normal charge 14
5.2.2. Fast charge 14
5.2.3. Maintenance charge 14
5.2.4. Recommended charging method 15
5.3. Discharge 17
5.3.1. Discharge current 17
5.3.2. Voltage in discharge 17
6. Maintenance
6.1. Periodic maintenance 18
6.2. Topping-up operation 18
1
Important recommendations
2
1. Characteristics of STM MR-MRE
monoblocks
3
1.1.2. Description of ! Electrodes its lowest. After consumption of
STM MR-MRE nickel-cadmium The STM monoblocks are the electrolyte reserve, the density
monoblocks constituted of sintered positive of the electrolyte is at its highest.
electrodes and plastic bonded The construction of a monoblock
The low maintenance STM negative electrodes. does not permit electrolyte
monoblock consists of 5 nickel-
The positive electrode is created sampling of an STM battery
cadmium cells of 1.2 V nominal
by chemical impregnation of with integrated ramp without
voltage each.
nickel hydroxide and additives mechanical destruction of the
These 5 cells are assembled into
into a sintered nickel structure, monoblock. Measuring the density
a polypropylene monoblock
container to obtain a nominal placed onto a perforated nickel- of the electrolyte is therefore
voltage of 6 V. plated steel strip. impossible.
4
1.2. Mechanical characteristics
5
1.4. Description of the automatic regulation of the
centralized filling system electrolyte level in each cell
during topping-up.
! Assembly instructions
see chapter 3.3.
! Operating instructions
(topping-up)
see chapter 6.2.
The water filling system connects
a number of monoblocks in
hydraulic series.
During normal operation of
the battery, a significant amount
of the gases produced during
overcharge recombines in the
batteries. The remaining gas is
exhausted through the hydraulic
system.
When topping-up of the battery
is necessary, water filling is done
from a reservoir that feeds the
battery with a low-pressure pump
or through gravity. The topping-up
is being effected cell by cell to a
predetermined level. The filling of
an hydraulic system is completed
when all batteries are filled and
water appears at the end of its
hydraulic system. The filling of a
battery is completed when all
cells of the battery are filled.
The main component of the
system is the water filling ramp
that guarantees the evacuation of
the gases, as well as the
6
1.4.2. Working principle of The water flows across the ramp The centralized filling ramp has no
a centralized filling ramp through a plunging siphon (6) and moving parts and offers full
into the cell through the exhaust operational security. Further, this
The concept is to fill a cell with hole (7), while the air escapes system prevents the cell electrolyte
water up to a specified level (N) from any contact with the next cell,
through the exhaust tube (5).
allowing gas which is in the cell thus avoiding any risk of current
The lower edge of the gas exhaust
to escape. When the maximum level leakage between several cells in
is reached, the electrolyte closes tube (5) settles the expected
electrolyte level of the cell. a battery.
the gas exhaust tube and the
consequent excess pressure stops & Filling through gravity
the water flow into the cell. When the electrolyte reaches
The water will then flow to the next this level, the remaining air in the The flow rate of the water
cell and so on, to the last cell of the cell can no longer escape through must be between 0.7 and
hydraulic circuit. the gas exhaust tube (5) and 1 liter/minute and the relative
the water reserve generated by pressure under 0.15 bar.
The centralized filling ramp is a
soldered assembly of the monoblock the plunging siphon (6) ensures
a safe obstruction of the gas & Low pressure filling
cover (1) and a ramp (2) equipped
on the upper part with a tubular inside the cell. When the filling The flow rate of the water must
water inlet (3) and a tubular water of the cell is finished, the water be lower than 0.7 liter/minute
outlet (4), and an exhaust tube (5) flows to the next cell or the next and the relative pressure below
on the lower part (see fig.1 below). monoblock. 0.3 bar.
Figure n° 1
7
2. Precautions and practices
2.1. Transport, storage 2.2. Water and electrolyte 2.2.2. Harm caused in using
sulfuric acid or acidious water
Low maintenance STM batteries The water and electrolyte used
are delivered filled with electrolyte in Saft Ni-Cd batteries must be Sulfuric acid (as it is used in
and electrically discharged. It is chemically pure. lead- acid batteries) seriously
normal that the electrolyte level is damages alkaline batteries.
Under normal operating
not visible after a long storage Never put sulfuric acid in nickel-
conditions, it is neither necessary
and transport period, even in the cadmium batteries.
nor possible to change or add
monoblocks STM 5-100 MR and electrolyte (KOH). Also prevent the use of topping-up
5-140 MR. It will become visible water recommended for lead-acid
during charge (refer to chapter 4). It is only a matter of readjusting
batteries since it may contain
water that was consumed during
Depending on customer sulfuric acid.
overcharges, in adjusting the
specifications, low maintenance levels regularly (see chapter 6.2.). When in doubt about water
STM monoblocks can be purity, effect a litmus test (or
delivered completely assembled & If monoblocks have lost their equivalent).
into batteries, partly assembled, electrolyte by accident (drop,
spills, mishandling, etc...) & Never check or top up the
or as a kit of monoblocks and
it may be necessary to batteries with instruments used
accessories.
replenish the electrolyte. for lead-acid batteries
In the latter two cases, to avoid This can only be done in a
any spilling of electrolyte during Saft factory by Saft specialists.
transport, the monoblocks are Please contact us without fail.
fitted with transport plugs.
& Measuring the electrolyte
& Never drain the electrolyte in specific density
the monoblocks
The low maintenance STM
The battery units can be stored monoblocks that are equipped
in whatever their state of with a centralized filling ramp
charge. After a storage period should be considered sealed.
of more than one year, it is Measuring or reconcentrating the
necessary to carry out a electrolyte density is impossible.
commissioning charge before
use (see chapter 4.2.) 2.2.1. Water quality
lt is absolutely necessary that
chemically pure water, distilled
or demineralized, is used for
topping-up (see appendix 9).
Prevent the use of tap water as
it contains impurities, that will
adversely effect the electrolyte,
operation quality, and the useful
life of the monoblocks. Store
water in hermetically sealed
plastic containers.
8
2.3. Electrical shocks 2.4. Possible dangers
and burns through hydrogen
Batteries assembled from a large Low maintenance STM
number of monoblocks can attain monoblocks are connected in
high voltages. Therefore great hydraulic series. The hydraulic
care caution must be taken during circuit exhausts oxygen and
the installation and maintenance hydrogen gases that are
of a battery system to avoid produced during overcharge.
serious burns or electrical shocks.
& The hydraulic system can
& Cut off the AC and DC circuits contain highly explosive gases
before working on batteries. at any moment.
Make sure that people understand All interventions on the battery
the risk of high voltage batteries require particular attention to
and that all manipulation is prevent of any kind of leakage.
carried out with insulated tools If a leak is detected, it must be
and other adequate protection repaired immediately.
equipment. Furthermore, general safety rules
must be strictly observed:
dispersion of gases as they leave
the hydraulic system to avoid the
forming of dangerously
concentrated hydrogen gas
pockets; and good ventilation.
Keep the battery away from any
heat or ignition source.
9
3. Installation
10
3.2. Ventilation and cooling The basic design rules for a liquid 3.3. Assembly of centralized
cooling system are as follows: water filling system
During operation (charge or
- the maximum number of fluid
discharge), STM batteries generate
chambers in a hydraulic series 3.3.1. Precautions and
heat, like all electrochemical
is limited to 3 with a pressure recommendations
systems. In daily use, a steady heat
loss of < 80 mbar.
accumulation must be avoided.
- in the best interest of thermal The centralized water filling
As a result, the battery needs a
balance, two fluid chambers that system links a number of
good cooling system in order to
monoblocks in hydraulic series.
disperse the dissipated heat belong to one monoblock will
efficiently. be connected through two The installation of such a system
independent cooling circuits. must therefore be effected with
The free space of 10 mm to 20 mm
a maximum caution to avoid any
between rows of STM 5-100 MR - water flow of 40 l/h/series of
risk of gas or electrolyte leakage
and STM 5-140 MR monoblocks 3 fluid chambers with a
to ensure good operation
on their large sides serves as a maximum pressure of 0.3 bar in
compliant with required safety
cooling corridor. the hydraulic circuits must be
regulations.
homogenous. It must be assured
In addition, heat dissipation that no preferential waterflow Important:
can be improved by providing exists that would cause uneven
ventilation space above and/or • To ensure that the hydraulic
cooling of the monoblocks. system is sealed, (no gas and/or
underneath the STM 5-100 MR When replenishing the cooling
and STM 5-140 MR monoblocks. water leakages), the connection
liquid, care should be taken that of the ramp with hoses must be
In the case of forced air cooling, no air bubbles form that would done carefully. Whenever a
the ventilators will blow cold air cause partial or no cooling at all, leakage occurs (possible after
vertically and horizontally across thus accelerating the aging some period of operation), it
the batteries. All cooling systems process or the destruction of the must be repaired immediately.
will be dimensioned to ensure the monoblocks or the battery.
• To minimize the risk of current
most homogenous temperature of - the thermal exchange system of leaking into the hydraulic
the monoblocks in one battery. the cooling liquid/air is not system (which is carrying gases
Furthermore, it is recommended to included in the supplies from and water) verify the following:
control the battery temperature by Saft, except under special
contract. This includes: - the hydraulic connection must
sensors or thermostats, which can always follow the electrical one,
be supplied by Saft on request. distribution hoses, draining
accessories, pump, radiator. in order not to create a potential
The optimized solutions for a difference higher than that
cooling system must be designed - during the mounting of the between two cells at opposing
battery and specifically during ends of the hose connection.
for every battery, depending on
the installation of the electric
the type of car, its use, the type - the number of monoblocks that are
and hydraulic circuits (filling and
of battery etc. connected in hydraulic series is
cooling), particular care must be
& Special case of STM 5-100 MRE taken that none of these three limited to 10 (50 cells maximum),
liquid cooled monoblocks which in turn limits the nominal
circuits is interconnected.
voltage of one ramp to 60 V.
Cooling of these monoblocks is - for details about the material and
effected by circulation of liquid in dimension of the hoses of the
fluid chambers on the large sides. cooling system see appendix 7.
11
All Saft monoblocks to be For distances greater than
equipped with a centralized 200 mm (between the battery
water filling system, are equipped and the water tank for example),
with the water filling ramp. or to form a loop, use flexible
reinforced PVC pipe with a
All necessary accessories, such diameter of 10 x 16 mm, part
as hoses, pipes, elbows, can be number 208 859.
supplied with each battery. For very tight loops it is preferable
List of part numbers, see app. 5. to use a 90° polypropylene
elbow, part number 444 103.
3.3.2. General instructions Avoid any nipping or squeezing of
for assembly the flexible pipes or hoses during
the assembly of the system.
! Levels
Avoid forming vertical loops in
The whole system should always be
which water would remain after
installed at the same level. However, the filling operation.
if different levels exist, start the
hydraulic circuit at the highest point, ! Inlets and outlets
such that the water can always flow During normal operation (not
downward and without causing topping-up), the hydraulic circuit
more pressure than that due to the must be closed on one side (inlet),
loss of content in the ramps of the such that any gas can escape
monoblock. through the outlet on the other side.
12
4. Placing into service
Current (I) 7A 10 A 9A
Time (t) 21 h 15 h 22 h
Voltage (V) no limit *
* Voltage can reach 9 V per monoblock.
13
5. Operation
14
5.2.4. Recommended charging overcharge while assuring the The relation between threshold
method necessary overcharge. voltage and temperature can be
The change-point threshold, is viewed as linear.
For ambient temperature between indicated in the diagram by a
0°C and + 35°C. The voltage threshold for STM
small circle. batteries is indicated at a
& The charging method described First level: constant current at temperature of +10°C and is
below is generally applicable for 0.2 C5A up to predetermined adjusted according to the battery
STM MR-MRE batteries installed threshold voltage. temperature with a negative
in electric vehicles. However, coefficient in millivolts per °C.
individual charging methods Second level: constant current
might be required for specific reduced to 0.05 C5A without ' Voltage threshold
customer needs, depending on voltage limitation. The voltage threshold that
the application, climatic ends the first level is set at
The charge coefficient is 1.15. 1.63 V/cell, i.e. 8.15 V
conditions, etc. For exceptional
cases, consult Saft. The maximum charging time per monoblock.
of a fully discharged battery is ' Temperature coefficient:
The recommended charging
approximately 8 hours. For T>10°C
method for Saft STM MR-MRE
batteries is two-level constant ! Temperature compensation – 0.003 V/°C/cell,
current charge IOla, as shown in i.e. – 0.015 V/°C/monoblock.
the diagram below. It is essential that the battery
reach the threshold voltage For T<10°C
! Principle before it is fully charged. As the – 0.006 V/°C/cell,
voltage characteristics of Ni-Cd i.e. – 0.03 V/°C/monoblock.
The battery is charged at constant
current. Its voltage increases. batteries vary with their Cut-off can be manual,
As soon as the predetermined temperature (higher voltage when controlled by a time switch,
charging voltage has been cold and lower voltage when or electronically.
reached, the charge current is hot), it is imperative to correct the
reduced in order to limit useless voltage threshold according to
heat dissipation during the battery temperature.
Set voltage
threshold
Voltage (V)
First level
Current
First level
Second level
15
STM 5-100 MR and MRE STM 5-140 MR
First level
Constant current 20 A 28 A
0.2 C5A
Voltage threshold 8.15 V/monoblock 8.15 V/monoblock
Time t1 until the voltage threshold is reached
Second level
Constant current 5A 7A
0.05 C5A
Voltage threshold open open
Temperature – 0.015 V/°C/monoblock T>10°C
coefficient – 0.03 V/°C/monoblock T<10°C
Overcharge 1.15
coefficient
16
5.3. Discharge
17
6. Maintenance
6.1. Periodic maintenance 6.2. Topping-up operation Water is filled into the hydraulic
system from a reservoir by gravity
Under normal operating ! Measuring the electrolyte level or by vacuum, according to
conditions, when charging the principles described in
recommendations are respected, Topping-up with distilled or
chapter 1.4.
and correcting factors are demineralized water (for water
applied, low maintenance STM quality refer to chapter 2.2.) When topping-up is effected using
batteries require no regular is necessary, because Ni-Cd gravity, the flow rate at the inlet
maintenance apart from topping- batteries consume water through must be between 0.7 and
up (see chapter 6.2.). electrolysis during overcharge. 1 liter/minute and the relative
pressure at the inlet of the first
A brief overall inspection of the The electrolyte level is visible
cell of the first monoblock must
battery system during a general through the plastic container of
be less than 0.15 bar relative.
revision of the vehicle should be the STM 5-100 MR monoblocks
carried out. The following points during charge. The electrolyte Stop filling a few seconds after
are to be verified: level is not visible in the water spills over at the vent
STM 5-100 MRE monoblocks due pipe(s). The inlet pipe will close
• the state of the fans, if present, to the double walls of the fluid and the flow of water will stop
• the tightness of the connections, chambers, and barely visible in automatically when the inlet
the STM 5-140 MR monoblocks. connector(s) are being removed.
• the seal of the hydraulic circuit The only reliable time to measure
(filling, cooling), When topping-up is effected using
the electrolyte level is at the end
gravity, the flow rate at the inlet
• cleaning the batteries with of charge or a few minutes after
must be between 0.7 and
soapy water (detergents must the end of charge (when the
1 liter/minute and the relative
be avoided). electrolyte is at its highest level).
depression in the monoblock must
The verification of the electrolyte In practice, topping-up is done be less than or equal to 0.3 bar.
density is both unnecessary and according to overcharged
impossible. amperehours.
! Frequency of topping-up
After a number of cumulated
overcharged amperehours
according to model:
• STM 5-100 MR et MRE: (1) During the first 30 minutes following
1 000 Ah overcharged the end of the overcharge, the residual
gases from the overcharge process can
• STM 5-140 MR: disturb the filling operation and, most
800 Ah overcharged importantly, decrease the water quantity
filled into the cells.
! Topping-up operation (2) After the 30 minutes period following
a controlled term of the peak charge, the
& Topping-up must not be carried
electrolyte level is too low, such that the
out during the first 30 minutes monoblocks will be overfilled, thus
after the end of an overcharge seriously risking an overspill of electrolyte
(1), but it can be carried out during the following charge and
during a peak charge period consequently a dilution of the electrolyte
during the next topping-up.
and after its controlled term (2).
18
7. Equipment repair and overhaul
of batteries
19
Appendix 1
20
Appendix 2
21
Appendix 3
22
Appendix 4
23
Appendix 5
Reinforced soft PVC hose10 x 16 208 859 for connections > 200 mm
Polypropylene elbow 444 103 hose-to-hose connection
Female connector 280 604 plug, normally closed
Male connector 280 605 plug, normally closed
Female connector 280 602 free
Male connector 280 603 free
Male connector 280 804 free
(wall penetration)
Male connector 280 805 self-closing
(wall penetration)
24
Appendix 6
25
Appendix 7
26
Appendix 8
Base material: baseline inspected annealed copper, as per chapter 4.2.1 of regulation NF A 51.119
Protection: nickel-plated, adhesion as per chapter 4.2 of regulation NF A 91.101
Recommended cross chapter: 40 mm2 16 x 2.5
Boring: ∅ 8.25 ± 0.2
27
Appendix 9
Physical characteristics
Chemical Characteristics
•5 pH 7
28
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