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Industrial Primary Batteries

High Performance Portable Power

C O N T E N T S

The CEGASA GROUP

CEGASA AIR-ALKALINE Technology

CEGASA AIR-ALKALINE battery advantages

Main applications of CEGASA AIR-ALKALINE batteries

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CEGASA AIR-ALKALINE program

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Packaging

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Operating instructions

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CEGASA quality assurance

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CEGASA worldwide

T H E C E G A S A G R O U P

Tradition & Innovation


CEGASA started its industrial activity as Primary batteries manufacturer in 1934 in a factory situated at Oate, making it one of Europes most experienced companies in the field of energy for portable uses. In the late 50s an efficient and modernised Electrolytic Manganese Dioxide (E.M.D.) manufacturing process was developed and introduced by CEGASA in its factory in Oate. Due to the continued growth in the battery sales, in 1964 a modern plant was put up in Vitoria, equipped with the most advanced technology in the manufacture of leakproof dry cells. Throughout all these years the constant evolution of R & D programs allowed Cegasa to produce batteries of the very highest quality, capable of satisfying the toughest requirements demanded by consumers and distributors all over the world. In 1980, CEGASA started its AIR-ALKALINE battery technology and manufacturing program with a new generation of High Energy Density Batteries for industrial use. By producing such a highly reliable, long lasting product suitable for any situation, we can proudly claim to be the world leaders.

Constant development, growing at full power


The CEGASA GROUP is the result of a commitment toward quality and specialisation within the world of industry. A modern dynamic GROUP which not only takes in manufacturing but also retail and distribution operations with the sole aim of offering its clients maximum satisfaction. The impressive technological and industrial skills employed by its member companies have made it possible to develop a wide range of products like Industrial Batteries, Manganese Dioxide and Torches manufactured in Oate (Spain), and latest generation Alkaline Consumer Batteries manufactured in Vitoria-Gasteiz (Spain). CEGASA INTERNATIONAL, the business heart of the CEGASA GROUP, is now primarily an export company trading its products in more than 50 countries world-wide. Cegasa International also does major work in distributing consumer products manufactured by third party companies, such as Bulbs, Household Products, Promotional Gifts and Small Electrical Household Appliances through its central warehouse in Vitoria and its 10 Regional Logistic Centres. Ever since it was set up in Oate in 1934, CEGASA has undergone an intense expansion process, which has allowed it to strengthen its present position to become an important GROUPalways progressing at full power.

CEGASA AIR-ALKALINE
technology

More powerfull, more reliable


The CEGASA AIR-ALKALINE cells may outwardly appear similar to conventional alkaline cells, but internally they have substancial differences: CEGASA AIR-ALKALINE cells use a very small amount of cathodic active material when compared to that of conventional alkaline (see Figure 1). Thus a larger amount of zinc anode can be stored in the cell and more electrical energy is available. The specially formulated manganese dioxide cathode can be continuously regenerated by oxidizing it with oxygen from the air, that penetrates through small openings in the cell and a unique cathode support system.

FIGURE 1

4 5

CELL
1 2 3 4 5 6

NEGATIVE COLLECTOR P.V.C. CONTAINER NEGATIVE MIX (Anode) DIAPHRAGM (Separator) POSITIVE MIX (Cathode) POSITIVE COLLECTOR 5

CEGASA AIR-ALKALINE
battery advantages
High and constant output voltage
The CEGASA AIR ALKALINE BATTERIES discharge at a high and constant output voltage of 1,35 V per cell throughout the entire life of the battery. That means extremely low reduction of voltage during the cell discharge. (see figure 2) The output voltage is 20% higher than other battery systems.
Cell output voltage 1,5

DISCHARGE CURVE
CEGASA AIR-ALKALINE BATTERY

1,3 AIR DEPOLARISED SALINE BATTERY

1,1

0,9

Hours

FIGURE 2

Exceptional Energy Density


Exceptional energy density compared with other technologies (see figure 3 and table 1) (377 Wh/Kg., 676 Wh/dm3).
700 600 500 400 300 200 100 0
Air Depolarised Salines Batteries Air Depolarised Wet Alkaline Other Air-Alkaline CEGASA Air-Alkaline

Watt-hour/Kg. Air Depolarised Saline Batteries Watt-hour/Kg. Watt-hour/dm3 140 150

Watt-hour/dm3 Air Depolarised Wet Alkaline 180 220 Other Air-Alkaline 260 300 CEGASA Air-Alkaline 377 676

FIGURE 3

TABLE 1

Easy to use batteries - Maintenance free


Activated by removing ventilation seal or by means of special plugs supplied with the batteries. MAINTENANCE FREE. Ready to use without adding any liquid. 6 Safe to handle, without danger of spilling any liquids. Solid state: Battery operates in any position, even in installations in motion.

Best cost-efficiency
Due to the higher energy density, the CEGASA AIR-ALKALINE batteries have the best cost of energy you can find in the market. One AIR-ALKALINE battery (4AS2/45) can replace nine (9) standard zinc carbon batteries (4R25). This means there is a high reduction in total volume to dispose of (see figure 4)

BATTERY MATERIAL DISPOSAL COMPARATIVE TABLE 100% 90 80 70 60 50 40 30 20 10


1,96 6,17 21,65 11,68 3,88 1,78 13,15 13,86 2,95 1,42 16,74 38,24

100

0
MnO2 Zinc Organic Components

Plastic

Asphalt

Steel

Heavy Metals

TOTAL

CEGASA AIR-ALKALINE (4AS2/45)

STD. ZINC CARBON (4R25)

FIGURE 4

Environmental friendly - Mercury and Cadmium free


The CEGASA AIR-ALKALINE batteries protect the environment. They are Mercury and Cadmium free with less waste disposal volume (see figure 4) Manufactured under the Quality System Certificate ISO 14001.

More reliable
Tested and approved by numerous National and International Authorities for use in safety critical appliances. Conforms to the requirements of the European and other International Standards. Manufactured under the Quality System Certificate ISO 9001

Guarantee - Higher shelf life


Two-years shelf life. Capacity loss of the stored batteries is just 5% in one year. Capacity loss of the stored batteries is just 8% in two years. 7

Main applications

CEGASA AIR-ALKALINE
batteries
Railway signalling
The world-wide Railway Authorities continue to perfect and improve their signal lighting systems for regulating the traffic and increasing safety. The CEGASA AIR-ALKALINE batteries are specially designed to power these safety critical devices. Temporary speed restrictions, track circuit signals, warning lights on trains, level crossings, traffic regulation and communication rely on high performance, autonomous and zero maintenance batteries that also have to operate in extreme conditions of temperature and humidity in static or moving installations. The CEGASA AIR-ALKALINE batteries are perfectly engineered to satisfy the above mentioned requirements and to provide: Reliability Constant and high voltage. Longer life.

Road traffic signalling


Traffic density in motorways and normal roads is continuously increasing in modern countries. To improve safety, the CEGASA AIR-ALKALINE batteries have the following advantages giving reliable energy to hazard warning lights:

Maximmun safety through high constant light. Long operating time: up to 7.000 hours. Reduced supervision and maintenance.

Navigation aids
Maritime and waterway safety is totally dependent on Navigation aids. Emergency power for lighthouses, buoy lighting, signal lights and radio beacons need an autonomous, high performance, long life and reliable power source. These requirements are more than fully satisfied by the CEGASA AIRALKALINE batteries. They are the ideal power source for these devices which cannot be frequently inspected and are subject to extreme climatic conditions.

Telecommunications
In difficult and varying environmental conditions, CEGASA AIR-ALKALINE batteries fulfill the mission of supplying emergency power for: Mountain Radio telephones. Highway emergency phones. Scientific and meteorological laboratories. Telemeters.

Electric fencers
An electric fencing system must be: Reliable. Powerful. Economical. The CEGASA AIR-ALKALINE batteries with their high and constant voltage gives to the battery operated electronic fencer systems: Constant energy output more reliable Higher energy ouput more powerful Lower consumption more economical

Parking meters and ticket machines


The new generation of parking meters and ticket machines are more compact and self powered. The new equipment reduces to the minimum the civil works for the installation and the environment impact. The CEGASA AIR-ALKALINE batteries with their high and constant voltage are a reliable power source for the new equipment. Their exceptional energy gives to the equipments manufacturers the possibility of having a very compact battery with a very high energy. 9

CEGASA AIR-ALKALINE
program
Battery Model Family AS10 8AS10 4AS10 2AS10 AS10-8 AS10-6 AS10-4 AS10-2 AS10 Family AS8 6AS8-350 4AS8-3 2AS8 AS8/100-5 AS8-2 AS8 Family AS6 2ALR40/100 ALR40/200 ALR40/100 3 1,5 1,5 100 200 100 260 260 130 55 110 55 220 440 220 440 880 440 41 82 41 2 2 2 9 6 3 1,5 1,5 1,5 350 700 350 500 700 350 2730 3640 910 650 910 455 200 300 200 500 400 200 800 1200 800 2000 1600 800 1600 2400 1600 4000 3200 1600 150 225 150 375 300 150 2 2 2 2 2 12 6 3 1,5 1,5 1,5 1,5 1,5 600 600 600 4800 3600 2400 1200 600 6240 3120 1560 6240 4680 3120 1560 780 250 250 250 2000 1500 1000 500 250 1000 1000 1000 8000 6000 4000 2000 1000 2000 2000 2000 16000 12000 8000 4000 2000 185 185 185 1500 1125 750 375 185 1 1 1 1 1 1 1 1 O.C.V. Voltage (V) Capacity (Ah) Energy (Wh) Maximum Continuous Drain (mA) Max. Intermittent Maximum Max. Hourly Drain (<1 min) Pulse Drain Capacity (mA) (<1 sec) (mA) (mAh) Terminals

TYPICAL DISCHARGE CURVE


Volts 1,5 1,4 1,3 1,2 1,1 1 0,9
0 1000 2000 3000 4000 5000 6000 Hours
ALR40-200 (30 ohm, 14 hours/day) AS8-2 (10 ohm, 14 hours/day) AS8/100-5 (6ohm, 14 hours/day) AS10-2 (6 ohm, 14 hours/day)

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10

TERMINALS

M4

27 W 1/4

10 M4

10

16

N 1

N 2

Capacity vs. Temperature


100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 50 100 150 200 250 300 350 400 450 500

AS10-2
% Rated capacity
20C 0C -10C -20C

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 50 100 150

AS8-2
20C 0C -10C -20C

% Rated capacity

200

250

300

350

400

mA

mA

AS8/100-5
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 50 100 150 200 250 300 350 400 450 500

ALR40-200
% Rated capacity
20C 0C -10C -20C

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 10 20 30 40 50 60 70 80 90 100 110

% Rated capacity

20C 0C -10C -20C

mA

mA

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CEGASA AIR-ALKALINE
program
Battery Model Family AS3 8AS3/60-2 8AS3/60 6AS3/165 6AS3/150A 6AS3/150B 6AS3/120 A 6AS3/120 B 6AS3/90 A 6AS3/90 B 6AS3/65 A 6AS3/65 B 6AS3/45 5AS3/90 5AS3/65 Family AS2 4AS2P/80 4AS2P/40 4AS2/45 4AS2/25 6 6 6 6 80 40 45 25 420 208 234 130 45 45 45 45 180 180 180 180 360 360 360 360 34 34 34 34 6 6 3 3 12 12 9 9 9 9 9 9 9 9 9 9 7,5 7,5 120 60 165 150 150 120 120 90 90 65 65 45 90 65 1248 624 1300 1100 1100 940 940 750 750 507 507 350 585 500 100 50 50 50 50 50 50 50 50 50 50 50 50 50 400 200 200 200 200 200 200 200 200 200 200 200 200 200 800 400 400 400 400 400 400 400 400 400 400 400 400 400 75 38 38 38 38 38 38 38 38 38 38 38 38 38 2-4-5 4 4 4 4 4 4 4 4 4 4 4 2 2 O.C.V. Voltage (V) Capacity (Ah) Energy (Wh) Maximum Continuous Drain (mA) Max. Intermittent Maximum Max. Hourly Drain (<1 min) Pulse Drain Capacity (mA) (<1 sec) (mA) (mAh) Terminals

TYPICAL DISCHARGE CURVE


Volts 9 8,1 7,2 6,3 5,4 4,5 3,6
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Hours

4AS2/45 (250 ohm, 14 hours/day)

6AS3/120 (240 ohm, 24 hours/day)

6AS3/150 (240 ohm, 24 hours/day)

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Capacity vs. Temperature


4AS2/45
100%
~4
20C 0C -10C -20C

% Rated capacity

TERMINALS
14 8

For 3,0

90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 5 10 15 20 25 30 35 40 45

12

22 For 4,0

N 3

N 4

~5

mA

6AS3/120
100%

TERMINALS
% Rated capacity

90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 5 10 15 20 25 30 35 40 45 50

20C 0C -10C -20C

N 5

mA

6AS3/150 N 6
% Rated capacity
100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 5 10 15 20 25 30 35 40 45 50
20C 0C -10C -20C

TERMINALS

mA

Tailor made batteries


If you do not find a suitable battery model in our Batteries Program, our Design and Development Department is open to study other battery configurations according to your requirements.

Private Labelling
CEGASA is also specialised in the field of private label batteries. This distinction allows us to offer our clients the best in battery technology, along with flexible conditions and an excellent service adapting to the specific characteristic of each request.

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PACKAGING
pallet information

BATTERY Model Weight (Kg) Family AS10 8AS10 4AS10 2AS10 AS10-8 AS10-6 AS10-4 AS10-2 AS10 Family AS8 6AS8-350 4AS8-3 2AS8 AS8/100-5 AS8-2 AS8 Family AS6 2ALR40/100 ALR40/200 ALR40/100 Family AS3 8AS3/60-2 8AS3/60 6AS3/165 6AS3/150A 6AS3/150B 6AS3/120A 6AS3/120B 6AS3/90A 6AS3/90B 6AS3/65A 6AS3/65B 6AS3/45 5AS3/90 5AS3/65 Family AS2 4AS2/45 4AS2P/80 4AS2P/40 4AS2/25 0,73 1,5 0,8 0,55 4 2,3 3,1 3,1 2,8 2,8 2,6 2,3 2,2 1,94 1,85 1,5 2,1 1,8 0,8 0,8 0,55 7,5 10,2 2,5 2,4 2,5 1,5 16,5 8,24 4,12 16,5 12,36 8,24 4,12 2,2

BATTERY DIMENSIONS Length Width Height (mm) (mm) (mm) 216 216 108 216 334 216 108 108 216 108 108 216 116 108 108 108 226 226 220 226 234 226 220 220

BOX Batteries per box 1 2 4 1 2 2 4 4

PALLET INFORMATION Number of Gross Dimensions batteries Weight (mm) 60 120 240 60 60 120 240 320 1075 1075 1075 1075 815 1075 1075 758 1200 x 1000 x 870 1200 x 1000 x 870 1200 x 1000 x 870 1200 x 1000 x 870 1200 x 1000 x 900 1200 x 1000 x 870 1200 x 1000 x 870 1200 x 1000 x 1110

95 170 85 85 85 85

265 170 85 85 85 85

212 210 209 209 209 209

4 2 12 12 12 12

160 90 396 396 396 660

1250 953 1065 985 1065 1065

1200 x 1000 x 1050 1200 x 1000 x 810 1200 x 1000 x 810 1200 x 1000 x 810 1200 x 1000 x 810 1200 x 1000 x 1250

64,5 64,5 64,5

163 163 163

10 10 10

900 900 1400

769 769 834

1200 x 800 x 1038 1200 x 800 x 1038 1200x1000x1186

147 166 190 190 166 190 166 190 166 190 166 166
180 180

136 112 126 126 112 126 112 126 112 126 112 112 -

122 114 160 160 114 160 114 160 114 160 114 114 171 171

4 4 4 4 4 4 4 4 4 4 4 4 4 4

288 396 168 168 352 320 352 320 240 256 440 440 168 168

1197 1002 567 538 968 977 967 788 568 550 872 846 388 337

1200 x 1000 x 930 1200 x 1000 x 1239 1200 x 800 x 1020 1200 x 800 x 1010 1200 x 1000 x 1118 1200 x 1000 x 1526 1200 x 1000 x 1118 1200 x 1000 x 1526 1200 x 800 x 876 1200 x 800 x 1450 1200 x 1000 x 1360 1200 x 1000 x 1360 1200 x 800 x 1480 1200 x 800 x 1550

66 110 110 66

66 64,5 64,5 66

110 197 197 110

12 12 12 12

1536 720 720 1680

1190 1080 655 988

1200x1000 x 1142 1200 x 1000 x 1458 1200 x 1000 x 1458 1200 x 800 x 1390

OPERATING INSTRUCTIONS

Operating temperature range


The CEGASA AIR-ALKALINE batteries can be used over a wide range of ambient temperature: -20oC. to + 50oC. However, for optimum results the recommended range is -10oC to + 40oC. Similar to other dry batteries, the capacity falls quickly for high drain rates when operating below -10oC. Then it is recommended to connect batteries in parallel in order to decrease the discharge level.

Influence of humidity
When humidity is between 25% and 85%, it has no influence on the batterys operation. When humidity is lower than 25% or higher than 85%, the battery has a capacity loss.

Storage
The CEGASA AIR-ALKALINE batteries are supplied in air-tight boxes, with the ventilation holes closed with a tape. They can be stored for two years without significant loss in the batterys capacity in standard conditions of temperature and humidity.

Installation
The CEGASA AIR-ARKALINE batteries are supplied ready for use. There is no need to add any liquid. Before connecting the battery, the tapes that cover the ventilation holes must be removed. The batteries require a continuous supply of air to obtain correct operation. They can not be used in completely air-tight installations. There is no need for periodic inspections nor maintenance during the operation life. The removal of discharged batteries and the connection of new ones is a very easy operation that does not require qualified personnel.
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CEGASA QUALITY
assurance

The High standards that we constantly achieve have been recognised by the award of Quality Management System. Cegasa has held an ISO 9001 certificate since 1999. Our manufacturing sister company has also been certified to ISO 14001, as their Environmental Management System meets stringent environmental standards.

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CEGASA WORLDWIDE
CEGASA INTERNATIONAL markets its products in more than 50 countries of the 5 continents thanks to its extensive sales network of subsidiaries and representatives.

Subsidiaries
CEGASA INTERNACIONAL (DEUTSCHLAND) GmbH Diezer Strasse, 52 D-65624 Altendiez, Deutschland Tfno.: +49 (0) 6432 988 749 Fax: +49 (0) 6432 988 750 info.deutschland@cegasagroup.com CEGASA-COMRCIO DE PILHAS, LDA. Campo Grande 35 12 D 1700-187 Lisboa, Portugal Tfno.: +351 217 978 097 Fax: +351 217 978 099 info.portugal@cegasagroup.com CEGASA ITALIA S.R.L. Via Ungheri, 25A 40012 Calderara di Reno, Bologna Italia Tfno: +39 051 646 6328 Fax: +39 051 082 1241 Info.italia@cegasagroup.com GAROA S.A.R.L. Espace Olano 137 Avenue de Jalday 64500 Saint Jean de Luz, France Tfno.: +33 05 59 26 64 80 Fax: +33 05 59 26 46 04 info.france@cegasagroup.com CEGASA U.K Ltd. 36a The Colonnades, Albert Dock Liverpool L3 4AA, UK. Tfno.: +44 (0) 151 709 84 00 Fax: +44 (0) 151 709 06 64 info.uk@cegasagroup.com CEGASA HONK KONG CEGASA Hong Kong Limited Unit 2303-05, 23/F, 113 Argyle Street, Mongkok, Kowloon, Hong Kong Tfno.: +852 252 93 452 Fax: +852 311 20 439 CELAIR CORP. 1455 Oakbrook DR, NW, Suite 200 Norcross, Georgia 30093 USA Tfno.: +1 770 449 8998 Fax: +1 770 449 8781 info.usa@cegasagroup.com CEGASA MEXICO Boulevard Avila Camacho n 36 Piso 10 1035 Col. Lomas de Chapultec 1100 Mexico DF, Mexico Tfno.: +52 (55) 917 11636 Fax: +52 (55) 917 11699 info_mexico@cegasamotionenergy.com CEGASA RUSIA 127474, Russia, Moscow, Dmitrovskoe sh., 60, office 313 Tfno: +7 495 617 1586 info@cegasamotionenergy.com

CEGASA CHINA CEGASA Hong Kong Limited Shenzhen Representative Office 13ABC, Times Plaza, No. 1 Tai Zi Road, Shekou Nanshan District Shenzhen, P.R.C., 518067 Tfno: +86 (755) 2681 2115 Fax: +86 (755) 2681 2113

HEAD-OFFICE CEGASA INT. S.A. Artapadura, 11 01013 VITORIA-GASTEIZ (SPAIN) Tfno.: +34-945129510 Fax: +34-945129514 info@grupocegasa.com

CEGASA BRASIL CEGASA SISTEMAS DE ENERGA E TRAFEGO DO BRASIL LTDA. Av. Dr. Cardoso de Melo, 1470 cj. 504 Barrio: Vila Olimpia 04548 004 Sao Paulo Tfno.: +55 11 3842-9200 Fax: +55 11 3842-911 info.brasil@cegasagroup.com

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www.grupocegasa.com www.cegasamotionenergy.com info@cegasamotionenergy.com

D a ta i n th is doc um e nt a r e s u b je c t t o c h a n g e w it h ou t n ot ic e .

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A division of Artapadura 11 01013 Vitoria-Gasteiz Spain Tel. +34 945 129 510 Fax. +34 945 129 567 info@cegasamotionenergy.com - www.cegasamotionenergy.com