Monday, June 23, 2025 Alcad stationary batteries, solutions you can count on! 1xSYS_-00001 20xHB255P Table of contents Page Engine starting battery sizing 2 IEC 62485-2 / EN 50272-2 ventilation requirement / heat dissipation 4 Environmental footprint 8 HB255P - Cell data sheet 11 Monday, June 23, 2025 Engine starting battery sizing Project name Project reference System name System reference Customer Customer reference Sime Darby Wassana P_26Mar25_Maven_a SYS_-00001 - Starting SYS_-00001 Sizing standard IEEE1115 Battery proposal Duty1 Proposed battery 20 x HB255P Rated capacity Cell height Battery weight 255 Ah 411 mm 434.0 Kg Definition Manufacturer Model Type Caterpillar 3516 4-cycle diesel Sizing parameters Engine displacement Starter motor voltage Number of starter motors Charge method Oil type Oil temperature Battery temperature Total cranking time Starter motor efficiency Battery state of charge Minimum cell voltage Continuous load before starting 4210.000 Cu. inch 24 V Dual Floating SAE 30 25 °C 25 °C 90 s 60 % 100 % 0.87 V 43 Ah Note: Low voltage alarm sensors should be adjusted to allow for a 3-5 second delay during voltage recovery. ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 2/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 Engine starting battery sizing Sizing standard IEEE1115 Calculation parameters - HB255P Base cranking current 1600 A Coefficients Motor type (4-cycle diesel) Oil temperature (25 °C) Battery temperature (25 °C) Total cranking time (90 s) Starter motor efficiency (60 %) Battery state of charge (100 %) Cell Number (20) Min cell voltage (0.87 V) * 1.00 1.01 1.00 1.21 1.00 1.00 1.00 1.03 Total correction factor 1.26 Required current Required capacity Rated capacity 2,020 A 255 Ah 255 Ah * Voltage drop in the load cables taken into account with 0.03 V. The starting sizing is based on a Base Cranking Current which is related to the engine displacement. The Base Cranking Current is multiplied with a number of coefficients which are dependent on the input parameters of the actual sizing. The standard values gives the coefficient 1,00. Changing the input parameters results in coefficients higher or lower that 1,00. The coefficients are multiplied to give the Total Correction Factor. The Base Cranking Current is multiplied with the Total Correction Factor and the result is the Required Current. The selected cell must be able to deliver the Required Current for 30 seconds with a minimum voltage of 0.87V/cell. ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 3/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 IEC 62485-2 / EN 50272-2 ventilation requirement / heat dissipation Battery 20 x HB255P During the last stage of high-rate charging (end of charge and during overcharge), the battery is emitting gases (oxygen-hydrogen mixture). The purpose of ventilating a battery location or enclosure is to maintain the hydrogen gas concentration below the 4% hydrogen threshold. Battery accommodation rooms are to be considered as safe from explosions, when by the natural or forced ventilation the concentration of hydrogen gas is kept below this safety limit. Note that specific local regulations for battery installation and ventilation may be valid in your area. Hydrogen gas (H2) Concentration 4% LEL Value 100% standard IEC 62485-2 / EN 50272-2 Ventilation air flow Q Q = v x q x s x n x Igas x Crt x 10 ̄ ³ (m³/h) Variable Description Value v = dilution factor to avoid a 4% hydrogen concentration ((100 % - 4%) / 4%) 24 q = maximum generated hydrogen for 1 Ah of overcharge per cell assuming no gas recombination at +25 °C 1.095 x 0.42 x 10ˉ³ m³/Ah s = general safety factor 5 n Number of cells 20 Igas = Ifloat/Boost x fg x fs Current producing gas during overcharge when charged with constant voltage vxqxs Ifloat = current for the float charge under fully charged condition at 1.4 1 mA/Ah V to 1.43 V at + 20 °C IBoost = current for the boost charge under fully charged condition at 1.5 V to 1.55 V at + 20 °C 10 mA/Ah fg = gas emission factor, proportion of current at fully charged state producing hydrogen 1 fs = safety factor taking into account faulty cells and an ageing 5 Igas = Icommissioning Current for commissioning at constant current charge at 0,2 C5 A 200 mA/Ah Crt Rated capacity 255 C5 Ah Air flow Q (m³/h) At float At boost Commissioning 1.41 14.07 56.29 Note: The charger must be protected against malfunction. If not, the ventilation should be calculated to suit the greatest current available from the charger. ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 4/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 IEC 62485-2 / EN 50272-2 ventilation requirement / heat dissipation Battery 20 x HB255P Number of air changes per hour Length (m) Width (m) Height (m) Volume (m³) Battery room volume Occupied volume 0.25 Free air volume At float Number of air changes per hour At boost Commissioning N/A Natural ventilation The amount of ventilation air flow shall preferably be ensured by natural ventilation, otherwise by forced ventilation. For natural ventilation, battery rooms or enclosures require an air inlet and an air outlet with a free area of opening calculated by the formula A > 28 x Q (cm²). The air velocity is assumed to be 0.1 m/sec. Free area of openings - inlet & outlet (cm²) At float At boost Commissioning 1.41*28=39.4 14.07*28=394 56.29*28=1576.2 The above calculations are done according to the IEC 62485-2 standard. Always check local regulations. ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 5/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 IEC 62485-2 / EN 50272-2 ventilation requirement / heat dissipation Battery 20 x HB255P H2 emissions The calculated H2 emission value is the amount of H2 that will be released from the cells under normal charging conditions without safety factors. H2 Emission = 0.42 x 0.001 x Crt x Ihydrogen x n dm³/h (litre/h) Actual gassing = 0.63 x 0.001 x Crt x Ihydrogen x n dm³/h (litre/h) Variable Ihydrogen = Ifloat/Boostx(1-Rv) Description Value Current producing gas during overcharge when charged with constant voltage Ifloat = current for the float charge under fully charged condition at 1.4 V to 1.43 V at + 20 °C 1 mA/Ah IBoost = current for the boost charge under fully charged condition at 1.5 V to 1.55 V at + 20 °C 10 mA/Ah Rv = recombination degree, proportion of hydrogen that is recombined into water 0.3 Ihydrogen = Icommissioning Current for commissioning at constant current charge at 0,2 C5 A 200 mA/Ah n Number of cells 20 Crt Rated capacity 255 C5 Ah At float At boost Commissioning H2 Emission (dm³/h) 1.50 15.0 428 H2+O2 Emission (dm³/h) 2.25 22.5 643 Heat dissipation The heat dissipation during float is normally used for dimensioning the cooling system. The cells will also generate heat during discharge and recharge but the generated heat will be absorbed by the plates and the electrolyte and will slowly dissipate to the surrounding air. Heat dissipation per system (W) At float 1.43V Per cell At boost 1.45V Per cell At discharge av.current of N/A av.voltage of 1.24V Per cell 2.2 22.7 N/A ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 6/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 IEC 62485-2 / EN 50272-2 ventilation requirement / heat dissipation Battery 20 x HB255P Safety distance according to IEC 62485-2 chaper 7.7 Variable Igas = Ifloat/Boost x fg x fs Description Value Current producing gas during overcharge when charged with constant voltage Ifloat = current for the float charge under fully charged condition at 1.4 1 mA/Ah V to 1.43 V at + 20 °C Crt Safety distance (mm) NOTE device. IBoost = current for the boost charge under fully charged condition at 1.5 V to 1.55 V at + 20 °C 10 mA/Ah fg = gas emission factor, proportion of current at fully charged state producing hydrogen 1 fs = safety factor taking into account faulty cells and an ageing 5 Rated capacity 255 C5 Ah At float At boost 312 672 The required safety distance d can be achieved by the use of a partition wall between battery and sparking ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 7/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 Environmental footprint Battery 20 x HB255P Global Warming Potential (GWP) As explained in the IPPC (Intergovernmental Panel on Climate Change (2001)), the Global Warming Potential (GWP) is a measurement of greenhouse gas emissions, such as CO2 and methane. These emissions are causing an increase in the absorption of radiation emitted by the earth, magnifying the natural greenhouse effect. It is expressed in kg CO2 equivalent and measures the Environmental Footprint of a product. Life Cycle Assessment (LCA) As part of its environmental commitment, Alcad gives priority to recycled raw materials over virgin raw materials, reduces its plants’ air and water releases year after year, minimizes water usage, reduces fossil energy consumption and associated CO2 emissions, and ensures that its customers have recycling solutions for their spent batteries. To reach this target, Alcad is using Life Cycle Assessment (LCA) which is a standardized scientific method for the systematic analysis of all mass and energy flows as well as environmental impacts attributed to a product system, from raw material acquisition to end-of-life management. To provide the best environmental information to its customers Alcad has been performing since 2010 comparative LCA of several battery technologies used for back-up solution. A third party is also involved to perform a critical review of the data and ensure that the highest level of compliance with the ISO 14040/44 standards is met. Data used in this comparative LCA were updated in 2017 and the previous LCA study was enlarged to more battery types. By interpolation of these verified LCA calculations, the Global Warming Potential of different Ni-Cd and Lead-acid batteries used for back-up applications and sized through Basics is evaluated and displayed given that the user indicates the expected life time of the battery. ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Page 8/13 Monday, June 23, 2025 Estimated life of Lead-Acid batteries Estimated life for Lead-Acid batteries is based upon the half-life formula L0=life time in years at the temperature T0 T1=temperature increase required to reduced life time with 50% T= System design temperature is taken from the inputted value “Nominal temperature” The constants used for VR Lead-Acid is well known facts that is found in several VR Lead-Acid manufacturers documentation[i]. L0 = 10 years, T0 = 25 °C, T1 = 8.3 °C, T= Tnom Number of cells and capacity comparison between NiCd and VR Lead-Acid batteries Number of cells differs between NiCd and VR Lead-Acid batteries with the nominal voltage difference. The conversion factor is 1.2V/2.0V = 0.6. Number of VR Lead-Acid cells is assumed to be made of 6 (12V blocks). The capacity comparison between NiCd and VR Lead-Acid cells is assumed to be equal. ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Page 9/13 Monday, June 23, 2025 Values/Calculations Variable Description 20 x HB255P 12 x VRLA 255 Cnom Rated capacity (Ah) 255 255 N Number of cells 20 12 Ns Number of strings 1 1 Tnom Nominal temperature (°C) 25 25 L Expected battery system life 10 10 Lest Estimated life of one battery in the design temperature (years) 20 10.0 L/Lest Number of batteries needed during life 1 1 GWP, (global Equivalent Kg of CO2 for one warning potential) battery -712 448 / 1.0 = 448 GWP * L/Lest -712 * 448 Equivalent Kg of CO2 during estimated life of the battery system Comparison -259% * Negative result means the environmental credits from the battery recycling surpasses the GWP impact from the other phases of the LCA (mainly manufacturing and use) Global Warming Potential (GWP) Equivalent Kg of CO2 Conclusion/statement The GWP of the proposed Ni-Cd battery shows a 259% decrease compared to the GWP of the comparable VR Lead-Acid. Disclaimer The results described in this document are based on the analysis of available information. They are for personal use and guidance only. They do not constitute any contractual representation and are not binding. i Power Through – http://www.power-thru.com/documents/The%20Truth%20About%20Batteries%20-%20POWERTHRU%20White%20Paper.pdf ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Page 10/13 Monday, June 23, 2025 HB255P - Cell data sheet Classification Wiring principle Brand Cell type Cell P/N Capacity at 5 hours rate IEC Designation According to IEC 60623 Crosswise Alcad HB255P 310051581 255 Ah KH255P Physical data Overall height 411 mm Cell height 410 mm Width 195 mm Length 159 mm Weight per cell 21.7 Kg No. of terminals/polarity Terminal material Vent type 2 Steel Handle Yes Negative Type of plates Pocket E13 E22 5.2 liters Max/Min Vent oil quantity 50 mm 50 cm3 120 mm² End-lug (and external cable) 120 mm² Construction Container material Separator type Connection torque Terminal size Polypropylene Grid 30.0 +/- 3.0 Nm M10 SW 16 mm Plates Positive Type of plates Pocket Electrolyte Electrolyte type: Renewal Electrolyte type: Initial Electrolyte per cell: Liquid Connection Cable area of internal connection cables ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 11/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 HB255P - Cell data sheet Charging Float voltage Single-level voltage 1.4 V/Cell 1.43 V/Cell High rate voltage (recommended) 1.45 V/Cell Resistance/Short circuit Internal resistance 0.17 mOhm Short circuit current 7583 A Performance data Current discharge After prolonged float charge of fully charged cells. Available amperes at +20°C +/- 5°C (+68°F +/- 9°F) V/Cell 10h 8h 5h 3h 2h 1.5h 1h 30m 20m 15m 10m 5m 1m 30s 5s 1s 1 25.6 31.9 51.0 84.2 125 164 240 436 586 672 794 963 1,209 1,364 1,658 1,763 1.05 25.3 31.7 50.3 82.8 122 161 232 414 503 572 672 782 1,014 1,145 1,381 1,439 1.1 24.7 30.8 49.2 80.6 118 155 220 336 394 443 499 602 808 920 1,094 1,150 1.14 24.0 30.0 47.2 77.2 109 138 181 265 316 355 402 491 644 739 869 900 1.16 23.3 29.1 46.1 74.2 100 123 147 220 262 291 323 404 547 617 723 765 Engine starting performance For a fully charged cell by a constant current charge according to IEC 60623 standard at +20°C +/- 5°C (+68°F +/- 9°F), 30 seconds discharge down to 0,85 V Available amperes 2,226 A Power discharge Available power (W), after prolonged float charged of fully charged cells at +20°C +/- 5°C (+68°F +/- 9°F) V/Cell 10h 8h 5h 3h 2h 1.5h 1h 30m 20m 15m 10m 5m 1m 30s 5s 1s 1 30.9 38.6 61.0 100 147 186 261 453 600 682 800 963 1,209 1,364 1,658 1,763 1.05 30.6 38.3 60.1 98.1 145 184 259 446 536 607 710 822 1,065 1,202 1,450 1,512 1.1 29.8 37.3 58.8 95.5 140 179 250 376 438 491 551 662 889 1,012 1,204 1,266 1.14 29.0 36.3 56.4 91.5 128 161 210 305 362 405 459 560 735 842 991 1,026 1.16 28.2 35.2 55.1 87.9 118 144 172 256 305 338 375 468 635 716 839 888 Engine starting performance For a fully charged cell by a constant current charge according to IEC 60623 standard at +20°C +/- 5°C (+68°F +/- 9°F), 30 seconds discharge down to 0,85 V Available amperes 2,226 A ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 12/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025 Monday, June 23, 2025 HB255P - Cell data sheet Kt Factor Current discharge After prolonged float charge of fully charged cells. Kt factor at +20°C +/- 5°C (+68°F +/- 9°F) V/Cell 10h 8h 5h 3h 2h 1.5h 1h 30m 20m 15m 10m 5m 1m 30s 5s 1s 1 10.0 7.98 5.00 3.03 2.04 1.55 1.06 0.58 0.44 0.38 0.32 0.26 0.21 0.19 0.15 0.14 1.05 10.1 8.05 5.07 3.08 2.08 1.59 1.10 0.62 0.51 0.45 0.38 0.33 0.25 0.22 0.18 0.18 1.1 10.3 8.27 5.19 3.17 2.15 1.65 1.16 0.76 0.65 0.58 0.51 0.42 0.32 0.28 0.23 0.22 1.14 10.6 8.50 5.40 3.30 2.35 1.85 1.41 0.96 0.81 0.72 0.64 0.52 0.40 0.35 0.29 0.28 1.16 11.0 8.77 5.53 3.44 2.56 2.07 1.74 1.16 0.97 0.88 0.79 0.63 0.47 0.41 0.35 0.33 Engine starting performance For a fully charged cell by a constant current charge according to IEC 60623 standard at +20°C +/- 5°C (+68°F +/- 9°F), 30 seconds discharge down to 0,85 V Available amperes 2,226 A Power discharge Kt factor power, after prolonged float charged of fully charged cells at +20°C +/- 5°C (+68°F +/- 9°F) V/Cell 10h 8h 5h 3h 2h 1.5h 1h 30m 20m 15m 10m 5m 1m 30s 5s 1s 1 8.25 6.60 4.18 2.56 1.73 1.37 0.98 0.56 0.43 0.37 0.32 0.26 0.21 0.19 0.15 0.14 1.05 8.32 6.66 4.24 2.60 1.76 1.39 0.99 0.57 0.48 0.42 0.36 0.31 0.24 0.21 0.18 0.17 1.1 8.54 6.83 4.34 2.67 1.83 1.42 1.02 0.68 0.58 0.52 0.46 0.38 0.29 0.25 0.21 0.20 1.14 8.78 7.02 4.52 2.79 1.99 1.58 1.22 0.84 0.70 0.63 0.56 0.46 0.35 0.30 0.26 0.25 1.16 9.06 7.25 4.63 2.90 2.17 1.77 1.49 1.00 0.84 0.75 0.68 0.54 0.40 0.36 0.30 0.29 Engine starting performance Kt factor power, after prolonged float charged of fully charged cells at +20°C +/- 5°C (+68°F +/- 9°F) Available amperes 2,226 A ALCAD confidential and proprietary. The data herein given are for information purposes only and are not binding on ALCAD. They may be modified without prior notice. Please contact an ALCAD representative in order to obtain confirmation of the above data. Visit our website at www.alcad.com Page 13/13 380752 27f65118-562d-4def-bab0-fcf020f516b2 Version: 3.5, Last updated on 01/2024, Referential data 6/23/2025
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