Alpais provides status-based electrolyte level and electrolyte leakage sensor
integration for vented industrial batteries, including applicable Ni-Cd and
flooded lead-acid battery configurations.
The solution uses a dedicated Battery Module configuration with sensor inputs.
Alarm status from the connected sensors is collected through the
Alpais Battery Monitoring System architecture
and displayed in Alpais Software.
What This Solution Covers
- Low-electrolyte level alarm monitoring
- Electrolyte leakage alarm monitoring at battery or cell level
- Dedicated Battery Module inputs for the selected sensors
- Status-based OK / Alarm display in Alpais Software
- Alarm history and email notification for registered users
- Application to compatible vented Ni-Cd and flooded lead-acid batteries
Terminology Note
On this page, cell leakage means physical electrolyte leakage
detected around an individual battery or cell. It does not mean electrical
leakage current, insulation resistance measurement or DC ground-fault
detection. Electrical ground-fault monitoring is covered separately on the
DC Ground Fault Detection
page.
Battery Electrolyte Level Monitoring
A compatible electrolyte level sensor provides a status signal when the
electrolyte falls below the sensor's configured detection point. Alpais
receives this status and presents it as a level alarm in the monitoring
interface.
The sensor does not replace the battery manufacturer's inspection, topping-up
or maintenance procedure. Sensor suitability depends on the battery design,
electrolyte type, cell geometry, installation method and manufacturer
requirements.
Electrolyte Leakage Monitoring
A compatible leakage sensor can be installed to detect electrolyte in the
selected area around the battery or cell. When the sensor changes state,
Alpais records and displays the resulting leakage alarm.
Leakage-sensor placement depends on the battery terminal structure, case
design, rack arrangement and the areas where electrolyte could collect.
The sensor configuration must therefore be evaluated for each battery model
and project.
Sensor Options
- Low-electrolyte level sensor
- Electrolyte leakage sensor
- Dedicated Battery Module with sensor inputs
Final compatibility must be confirmed from the sensor and battery
documentation before installation.
Dedicated Battery Module Configuration
The standard Alpais Battery Module provides the connections required for
battery measurement and module-to-module communication. For electrolyte level
and leakage sensing projects, a dedicated Battery Module version is used with
additional sensor inputs.
The sensor inputs collect status information from the connected devices and
transfer it through the standard BATMOD, STRMOD and CONMOD communication
structure. The exact module version and connector arrangement must be confirmed
for the ordered project configuration.
Typical Application on the Battery
A project configuration may include the following components, subject to the
battery design and selected sensors:
- One dedicated Battery Module per monitored battery or cell
- Standard battery measurement connection
- One electrolyte level sensor where compatible with the battery design
- One electrolyte leakage sensor or sensor set according to the required coverage
Quantities and sensor locations are project-specific. A configuration used
for one battery model should not be treated as universal for all Ni-Cd or
flooded lead-acid batteries.
Monitoring, Alarms and Notifications
The electrolyte level and leakage inputs are status-based. Alpais normally
displays an OK or Alarm condition rather than a continuously measured
electrolyte height or leakage volume.
Depending on the configured software version, the statuses can be displayed
as Level and Leakage in the general battery
list. When an alarm condition occurs, the event can be recorded and included
in email notifications for registered users.
Additional alarm, history and reporting functions are described on the
Alpais Battery Monitoring Software
page.
Battery Types and Project Compatibility
The solution is intended for compatible vented batteries where electrolyte
level or physical leakage can be monitored using the selected sensors. Typical
applications may include industrial Ni-Cd batteries and flooded lead-acid
batteries.
Compatibility must be checked against the battery manufacturer's instructions,
terminal configuration, cell material, electrolyte chemistry, operating
temperature, enclosure arrangement and maintenance procedure.
Information Required for Project Evaluation
Project evaluation should include the battery manufacturer and model, battery
chemistry, cell quantity, terminal layout, case dimensions, electrolyte access
point, rack arrangement, sensor model, sensor output type and required alarm
workflow.
Need Electrolyte Level or Leakage Monitoring?
Share the battery model, chemistry, terminal arrangement and sensor
requirements with Alpais for compatibility and project evaluation.