®
NCPP
Nickel Cadmium Pocket Plate Batteries
Single Cell Catalogue
Introduction:
HBL’s Nickel Cadmium Pocket Plate battery designs are based on the superior pocket plate technology.
A fully integrated modern factory, supported by strong process management and quality controls makes HBL one of the best
Nickel Cadmium battery production facilities in the world.
HBL’s single cells are offered in 1.2 voltage per cell and in wide capacity range.
NCPP single cell range is designed to comply with IS 10918 & IEC 60623.
Construction
The internal mechanical structure is made of nickel plated steel making it highly rugged and capable of withstanding
mechanical abuses. The active materials are encapsulated between specially designed folded steel strips, which are perforated
on both sides. This design increases the effective surface area by 30% which in turn results in effective utilization of active
material and makes the battery more efficient.
Single cells use special polypropylene separator system, which is chemically inert and highly immune to wear and tear.
Cells come in tough, shock resistant, fusion welded polypropylene containers and lids. A unique flame arresting flip type vent
cap in the cells prevents any unusual event and electrolyte contamination.
Single cells are supplied either in filled condition (charged or discharged) or dry & discharged condition with inter-cell
connectors, cable connectors, associated hardware and accessories that are required for normal operation and maintenance.
Powder coated Mild Steel racks to house the batteries can be provided as an option.
Cut-view of cell:
Flame Arresting Vent Cap
Prevents propagation of external flame in to the
cell & electrolyte contamination
Terminal Arrangement
Nickel-plated components (tab, stud, nut, post)
provide excellent electrical conductivity
Splash Guard
Prevents electrolyte splashing and possible
short-circuit caused by external objects accidentally
falling into the cell
Plate Groups
Bolted construction under controlled
torque conditions to withstand severe vibrations
Pocket Plate
Made of double perforated steel strips, encapsulating
the active materials
Translucent Polypropylene Container
Fusion welded to lids, makes the cell mechanically
sturdy and facilitates visual inspection of electrolyte level
Polypropylene Grid Separator
Separates the plates and insulates the
frames from each other and allows free
electrolyte
1
Benefits

High reliability

Long float life - 20 years+ at 20 C for standby applications

Long shelf life - 5 years+ for the cells supplied in dry condition & 1 year in filled
condition

Quick charging - More than 90 % capacity available within 6 hours of charging

Low internal resistance - For enhanced battery performance

Resistant to mechanical & electrical abuses - Making it ideal for deployment in
harsh environments

Wide operating temperature range (-20 C to +50 C)

Application specific designs (KPH, KPM & KPL)

Easy installation & low maintenance

Best TCO (Total Cost of Ownership) for demanding application needs

No risk of sudden death failure
0
0
0
Capacity Range
High Discharge - KPH:

Thin plates with more plate surface area

For high discharge applications with less than 1 hour backup time requirements

10 Ah to 265 Ah

33 standard cell models to choose from
Medium Discharge - KPM:

Optimized plate thickness

For medium discharge applications, between 1 to 3 hours backup time
requirements which involves high and long discharges

10 Ah to 395 Ah

42 standard cell models to choose from
Long Discharge - KPL:

Thick plates with more amount of active material

For long discharge applications, with more than 3 hours backup time requirements

11 Ah to 480 Ah

41standard cell models to choose from
2
Applications
Single cell range is specially designed for industrial markets considering the
reliability, cost-optimization and low-maintenance requirements for the following
applications and segments

Fire alarm systems

Signaling and Telecommunications

Solar Photovoltaic

Instrumentation & Process control

Switchgear protection

Emergency lighting

Switchyard

UPS

Genset starting

Diesel Locomotive cranking

Electromagnetic lifters (EOT crane)
Battery Charging
Following are recommended charge conditions:
Commissioning Charge:

Constant current charge of 10 hours at 0.2 C5 A (20 amps for 100 Ah battery)
Quick Charging:

Constant current charge at 0.4 C5 A for first 2.5 hours followed
by 0.2 C5 A for next 2.5 hours
Charging in Operation:
The recommended charging voltages for continuous parallel operation,
with occasional battery discharges:
Two Level Charging:

Float level:
1.40 V/cell for KPH & KPM
1.42 V/cell for KPL
Float charging current: 1 to 2 mA per Ah

*Boost level:
1.45 to 1.70 V/cell for KPH & KPM
1.47 to 1.70 V/cell for KPL
Current limit: 0.2C5 A
Single Level Charging:

1.43 – 1.50 V/cell
(may increase water consumption)
* Refer charge curves at page#13
(A higher voltage will keep the battery at high state of charge)
3
H Range
Cell dimensions and weight details
Cell dimensions in mm
Cell type
KPH 10 P
Capacity
(C5 Ah)
Height
Width
Length
229
86
46
10
Approx. weight
per cell
in kg
Cell
connection
bolt size
Container
size
reference
Approx. reserve
electrolyte
cc/cell
M6
S1
100
1.45
1.50
KPH 12 P
12
KPH 16 P
16
229
86
61
1.90
M6
S2
130
KPH 20 P
20
239
134
44
2.15
M6
S3
140
KPH 24 P
24
KPH 30 P
30
M10
S4
200
KPH 35 P
35
3.70
KPH 40 P
40
4.50
KPH 45 P
45
M10
S4A
200
KPH 50 P
50
5.00
KPH 57 P
57
6.30
KPH 63 P
63
6.50
KPH 69 P
69
M10
S5
420
KPH 76 P
76
6.80
KPH 80 P
80
6.85
KPH 85 P
85
9.40
KPH 94 P
94
9.70
KPH 100 P
100
2 x M10
S6
580
KPH 110 P
110
10.2
KPH 120 P
120
10.5
KPH 130 P
130
12.5
KPH 140 P
140
2 x M10
S7
740
2 x M10
S7A
960
2 X M10
S8
1210
3.20
289
374
374
391
134
134
134
134
59
59
74
101
3.55
4.80
6.70
9.80
13.0
417
159
106
KPH 145 P
145
13.2
KPH 155 P
155
13.6
KPH 160 P
160
14.2
KPH 170 P
170
KPH 180 P
180
14.9
KPH 190 P
190
15.2
KPH 210 P
210
20.0
KPH 230 P
230
20.8
KPH 240 P
240
KPH 255 P
255
22.0
KPH 265 P
265
22.4
417
443
159
163
138
166
4
14.5
21.6
M Range
Cell dimensions and weight details
Cell dimensions in mm
Cell type
Capacity
(C5 Ah)
Height
Width
Length
Approx. weight
per cell
in kg
Cell
connection
bolt size
Container
size
reference
Approx. reserve
electrolyte
cc/cell
KPM 10 P
10
229
86
46
1.3
M6
S1
100
KPM 13 P
13
229
86
61
1.5
M6
S2
130
KPM 19 P
19
239
134
44
1.9
M6
S3
140
KPM 25 P
25
2.4
KPM 32 P
32
2.7
KPM 38 P
38
M10
S4
200
KPM 43 P
43
3.8
KPM 50 P
50
4.0
KPM 54 P
54
4.2
KPM 60 P
60
4.7
M10
S4A
200
M10
S5
420
2 x M10
S6
580
2 x M10
S7
740
2 x M10
S7A
960
2 X M10
S8
1210
289
374
134
134
59
59
3.2
5.1
KPM 64 P
64
KPM 70 P
70
KPM 75 P
75
5.9
KPM 80 P
80
6.2
KPM 90 P
90
6.4
5.6
KPM 95 P
95
KPM 105 P
105
7.0
KPM 112 P
112
7.3
KPM 120 P
120
7.6
KPM 128 P
128
9.3
KPM 136 P
136
KPM 150 P
150
KPM 158 P
158
374
134
74
6.6
9.6
391
134
101
9.9
10.3
KPM 164 P
164
10.5
KPM 170 P
170
10.8
KPM 180 P
180
11.3
KPM 188 P
188
11.7
KPM 200 P
200
KPM 212 P
212
KPM 220 P
220
12.9
KPM 235 P
235
13.2
KPM 250 P
250
13.6
KPM 260 P
260
14.5
KPM 270 P
270
KPM 280 P
280
KPM 300 P
300
16.0
KPM 320 P
320
20.0
KPM 330 P
330
20.2
KPM 345 P
345
KPM 354 P
354
21.0
KPM 370 P
370
21.5
KPM 395 P
395
22.0
417
417
443
159
159
163
106
138
166
5
12.2
12.6
14.9
15.4
20.6
L Range
Cell dimensions and weight details
Cell dimensions in mm
Cell type
Capacity
(C5 Ah)
Height
Width
229
86
Length
Approx. weight
per cell
in kg
KPL 11 P
11
KPL 17 P
17
KPL 23 P
23
KPL 27 P
27
3.20
KPL 32 P
32
3.50
KPL 36 P
36
KPL 41 P
41
4.20
KPL 45 P
45
4.30
KPL 55 P
55
4.50
KPL 60 P
60
KPL 69 P
69
5.60
KPL 75 P
75
5.90
KPL 80 P
80
6.10
KPL 88 P
88
6.20
229
289
374
86
134
134
46
1.4
61
1.60
59
1.90
59
74
3.80
5.00
KPL 92 P
92
KPL 100 P
100
6.40
KPL 115 P
115
6.60
KPL 120 P
120
6.80
KPL 135 P
135
9.50
KPL 150 P
150
10.0
KPL 160 P
160
KPL 170 P
170
10.7
KPL 180 P
180
11.0
KPL 190 P
190
12.5
KPL 210 P
210
12.8
KPL 220 P
220
13.0
KPL 235 P
235
KPL 255 P
255
13.8
KPL 270 P
270
14.0
KPL 285 P
285
14.3
KPL 300 P
300
KPL 310 P
310
18.4
KPL 335 P
335
18.8
KPL 355 P
355
19.2
KPL 370 P
370
21.5
KPL 390 P
390
22.0
KPL 410 P
410
22.4
KPL 425 P
425
KPL 445 P
445
22.9
KPL 460 P
460
23.2
KPL 480 P
480
23.5
374
391
417
417
443
134
134
159
101
106
138
159
163
6.30
10.4
13.5
18.0
166
6
22.6
Cell
connection
bolt size
Container
size
reference
Approx. reserve
electrolyte
cc/cell
M6
S1
100
M6
S2
130
M10
S4
200
M10
S4A
200
M10
S5
420
2 x M10
S6
580
2 x M10
S7
740
2 x M10
S7A
960
2 X M10
S8
1210
Battery Arrangement as per Standard Rack Designs
(NORMAL ARRANGEMENT)
2TIER
1TIER
Container
size
reference
1STEP
3STEP
4STEP
W
H
W
H
W
H
S1 & S2
222
668
323
783
424
898
S3
318
678
467
793
616
S4
318
728
467
843
616
S4A
318
813
467
S5
318
813
S6
318
S7
1STEP
W
2STEP
W
H
908
318
1070
958
318
928
616 1043
467
928
830
467
368
856
S7A
368
S8
376
W
H
2STEP
3STEP
W
H
467 1300
616
1550
1250
467 1450
616
1700
318
1450
467 1670
616
1900
616 1043
318
1450
467 1670
616
1900
945
616 1060
318
1470
467 1700
616
1950
542
971
716 1086
368
1550
542 1760
716
2000
856
542
971
716 1086
368
1550
542 1760
716
2000
882
554
997
732 1112
376
1650
554 1860
732
2100
H
W
4STEP
H
(All dimensions in mm. Height is including cells)
Evaluation of Rack Length
Normal Arrangement
Length of rack= (X + 1) x No. of cells in a row for S1 to S5 containers
= (X + 2) x No. of cells in a row for S6 to S8 containers
Where, X = Length of cell
The value of length should be rounded-off to nearest to 50 mm and 5 mm should be added to arrive at the final length of rack.
Standard Arrangement of Cells
KPH 85 - KPH 265
KPM 128 - KPM 395
KPL 135 - KPL 480
KPH 10 - KPH 80
KPM 10 - KPM 120
KPL 11 - KPL 120
7
Battery Rack Arrangement
SINGLE TIER RACK
2STEP 1TIER RACK
SINGLE TIER RACK
3STEP 1TIER RACKS
H
H
L
L
W
W
SINGLE TIER RACK
4STEP 1TIER RACK
TWO TIER RACK
2STEP 2TIER RACK
H
H
L
L
W
W
TWO TIER RACK
3STEP 2TIER RACK
TWO TIER RACK
4STEP 2TIER RACK
H
H
L
L
w
W
8
Typical Characteristics
KPH
KPH
KPH
KPH
Charge
Discharge
Charging Voltage
1.
2.
3.
4.
5.
6.
7.
%
Amp.
I/C
0.2
1.40
1.45
1.50
1.55
1.60
1.65
1.70
Volts
Volts
Volts
Volts
Volts
Volts
Volts
/
/
/
/
/
/
/
Cell
Cell
Cell
Cell
Cell
Cell
Cell
7 6
5
7
Available Capacity %
Volts/Cell
1.4
1 2 3 4
1.3
100
1.2
6
1.1
1
4
1.0
2
0.9
5
2C5A
0.8
0.1
0.2C5A
0.5C5A
1C5A
3C5A
50
0.7
Current
5C5A
0.6
0.5
3
1
10
5
2
10
20
20
30
40
60
70
100
90
80
% in Capacity
50 Hours
KPM
KPM
50
KPM
Charge
Discharge
Charging Voltage
Amp.
1.
2.
3.
4.
5.
6.
7.
%
I/C
0.2
1.40
1.45
1.50
1.55
1.60
1.65
1.70
Volts
Volts
Volts
Volts
Volts
Volts
Volts
/
/
/
/
/
/
/
Cell
Cell
Cell
Cell
Cell
Cell
Cell
7
6
5
7
Available Capacity %
2
Volts/Cell
3 4
1.4
100
1.3
1.2
1
1.1
0.1C5A
0.2C5A
0.5C5A
1.0
1
2
0.9
0.1
1C5A
0.8
50
6
0.7
0.6
4
5
2C5A
0.5
10
Current
20
30
40
50
60
70
100
90
80
3
1
5
2
10
20
% in Capacity
50 Hours
KPL
KPL
KPL
KPL
Charge
Discharge
Discharge
Charging Voltage
Amp.
%
I/C
0.2
1.
2.
3.
4.
5.
6.
7.
1.40
1.45
1.50
1.55
1.60
1.65
1.70
Volts
Volts
Volts
Volts
Volts
Volts
Volts
/
/
/
/
/
/
/
Cell
Cell
Cell
Cell
Cell
Cell
Cell
Volts/Cell
6
7
1.4
Available Capacity %
100
5
4
3
2
1
2
1.3
1.2
1.1
7
1.0
4
0.1
50
0.5C5A
0.8
Current
1C5A
0.7
6
1
0.1C5A
0.2C5A
0.9
5
3
0.6
0.5
1
2
5
10
20
50 Hours
10
20
30
40
50
60
% in Capacity
9
70
80
90
100
Certifications
HBL Power Systems Ltd.
Road No. 10, Banjara Hills,
Hyderabad 500034, TG, INDIA
E-mail:contact@hbl.in
www.hbl.in
HBL America Inc.
712, Brook Street
Rocky Hill, CT 06067
www.hblbatteries.com
E-mail:contact@hblbatteries.com
+1 860 257 9800
HBL Germany GmbH
Emilienstraße 24A
08056 Zwickau
Germany
www.hblpower.de
Email: info@hblpower.de
Corp Comms /single cell Brochure / April 2016
Tel: +49 375 390 965 97
Fax: +49 375 390 965 99
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