EnergyCell PLC Series. Owner s Manual

Transcription

1 EnergyCell PLC Series Owner s Manual

2 Abut OutBack Pwer Technlgies OutBack Pwer Technlgies is a leader in advanced energy cnversin technlgy. OutBack prducts include true sine wave inverter/chargers, maximum pwer pint tracking charge cntrllers, and system cmmunicatin cmpnents, as well as circuit breakers, batteries, accessries, and assembled systems. Applicability These instructins apply t OutBack EnergyCell PLC series batteries nly. Cntact Infrmatin Address: Website: Disclaimer Crprate Headquarters th Avenue N.E. Suite B Arlingtn, WA USA Eurpean Office Hansastrasse 8 D Schwabach, Germany UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER TECHNOLOGIES: (a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION. (b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK. OutBack Pwer Technlgies cannt be respnsible fr system failure, damages, r injury resulting frm imprper installatin f their prducts. Infrmatin included in this manual is subject t change withut ntice. Ntice f Cpyright EnergyCel PLC Series Battery Owner s Manual 2018 by OutBack Pwer Technlgies. All Rights Reserved. Trademarks OutBack Pwer and the OutBack Pwer lg are trademarks wned and used by OutBack Pwer Technlgies, Inc. The ALPHA lg and the phrase member f the Alpha Grup are trademarks wned and used by Alpha Technlgies Inc. These trademarks may be registered in the United States and ther cuntries. Date and Revisin May 2018, Revisin A Part Number Rev A

3 Table f Cntents Imprtant Safety Instructins... 4 Additinal Resurces... 4 Intrductin... 5 Audience... 5 EnergyCell PLC... 5 Materials Required... 6 Tls...6 Strage and Envirnment Requirements... 6 Temperatures...6 Self-Discharge...7 String EnergyCell PLC Batteries...7 Capacity... 7 State f Charge... 7 System Layut... 8 Battery Cnfiguratins...8 DC Wiring Cmmissining Charging Bulk Stage...12 Absrptin Stage...13 Flat Stage...13 Freshening Charge...14 Ntes n EnergyCell PLC Charging...14 Temperature Cmpensatin Remte Temperature Sensr...15 Imprper Use Trubleshting and Maintenance Peridic Evaluatin Specificatins Rev A 3

4 Safety Instructins Imprtant Safety Instructins READ AND SAVE THESE INSTRUCTIONS! This manual cntains imprtant safety instructins fr the EnergyCell battery. These instructins are in additin t the safety instructins published fr use with all OutBack prducts. Read all instructins and cautinary markings n the EnergyCell battery and n any accessries r additinal equipment included in the installatin. Failure t fllw these instructins culd result in severe shck r pssible electrcutin. Use extreme cautin at all times t prevent accidents. WARNING: Persnal Injury Sme batteries can weigh in excess f 100 lb (45 kg). Use safe lifting techniques when lifting this equipment as prescribed by the Occupatinal Safety and Health Assciatin (OSHA) r ther lcal cdes. Lifting machinery may be recmmended as necessary. Wear apprpriate prtective equipment when wrking with batteries, including eye r face prtectin, acid-resistant glves, an aprn, and ther items. Wash hands after any cntact with the lead terminals r battery electrlyte. WARNING: Explsin, Electrcutin, r Fire Hazard Ensure clearance requirements are strictly enfrced arund the batteries. Ensure the area arund the batteries is well ventilated and clean f debris. Never smke, r allw a spark r flame near, the batteries. Always use insulated tls. Avid drpping tls nt batteries r ther electrical parts. Keep plenty f fresh water and sap nearby in case battery acid cntacts skin, clthing, r eyes. Wear cmplete eye and clthing prtectin when wrking with batteries. Avid tuching bare skin r eyes while wrking near batteries. If battery acid cntacts skin r clthing, wash immediately with sap and water. If acid enters the eye, immediately fld it with running cld water fr at least 20 minutes and get medical attentin as sn as pssible. Never charge a frzen battery. Insulate batteries as apprpriate against freezing temperatures. A discharged battery will freeze mre easily than a charged ne. If a battery must be remved, always remve the grunded terminal frm the battery first. Make sure all devices are de-energized r discnnected t avid causing a spark. D nt perfrm any servicing ther than that specified in the installatin instructins unless qualified t d s and have been instructed t d s by OutBack Technical Supprt persnnel. Additinal Resurces These references may be used when installing this equipment. Depending n the nature f the installatin, it may be highly recmmended t cnsult these resurces. Institute f Electrical and Electrnics Engineers (IEEE) guidelines: IEEE 450, IEEE 484, IEEE 1184, IEEE 1187, IEEE 1188, IEEE 1189, IEEE 1491, IEEE 1578, IEEE 1635, and IEEE 1657 (varius guidelines fr design, installatin, maintenance, mnitring, and safety f battery systems) Rev A

5 Intrductin Audience This manual is intended fr use by anyne required t install and perate this battery. Be sure t review this manual carefully t identify any ptential safety risks befre prceeding. The wner must be familiar with all the features and functins f this battery befre prceeding. Failure t install r use this battery as instructed in this manual can result in damage t the battery that may nt be cvered under the limited warranty. EnergyCell PLC The EnergyCell PLC (pure-lead carbn) uses pure lead plate cnstructin cmbined with carbn additives t btain maximum cycle life, flat life, shelf life (18 mnths at 25 C), and PSC peratin. The PLC is ideally suited fr the three primary applicatins where OutBack inverters are used: Off-Grid, Grid-Tied Battery Backup, and Grid-Tied Self Cnsumptin. Lw self-discharge Oxygen recmbinatin efficiency: 97% 3D plate structure, ptimal plate design prvides better perfrmance fr high pwer utput than ther EnergyCell mdels VRLA maintenance free battery type UL94-V0 flame-retardant jar cntainer 22.0 (55.9 cm) 4.9 (12.6 cm) 12.6 (32.0 cm) Terminal Cver Carrying Handle Figure 1 EnergyCell 200PLC Rev A 5

6 Installatin and Operatin Materials Required Tls (use insulated tls nly) Digital vltmeter Scket wrench Trque wrench calibrated in inch-punds Bx end wrench Battery lifting equipment (handles) and frk lift t lift pallets f batteries Rubber glves Full face shield Plastic aprn Prtable eyewash Spill kit Fire extinguisher (class C) Accessries Intercnnect bar (included) Terminal cver (included) Hardware (included) Intercnnect cables as needed CAUTION: Fire Hazard Install prperly sized battery cabling and intercnnect cables. The cable ampacity must meet the needs f the system, including temperature, deratings, and any ther cde cncerns. Strage and Envirnment Requirements Temperatures T achieve maximum life f EnergyCell batteries, it is recmmended nt t perate them in average ambient temperatures utside the range f 68 F t 86 F (20 C t 30 C). High perating temperatures will shrten a battery s life (see page 7). D nt allw batteries t freeze, as this will damage them and culd result in leakage. D nt expse batteries t temperature variatins f mre than 5 F (3 C). This leads t vltage imbalance between multiple batteries (r between battery cells if there is a temperature differential). Batteries shuld be stred in a cl, dry lcatin. The best strage temperature is 77 F (25 C), but a range f 4 F t 104 F ( 20 C t 40 C) is acceptable Rev A

7 Self-Discharge EnergyCell Batteries All EnergyCell batteries will discharge ver time nce charged, even in strage. Higher strage temperatures increase the rate f self-discharge. Fully charged, the natural ( rest ) vltage f all EnergyCell batteries is apprximately 13.0 Vdc. A battery shuld have a freshening charge (see page 12) if its rest vltage is belw 13.0 Vdc per battery (2.16 Vdc per cell). A battery shuld nt be used if its rest vltage is 12.0 Vdc r lwer upn delivery. Cntact the vendr upn receiving a battery in this state. String EnergyCell PLC Batteries The EnergyCell PLC batteries must be given a freshening charge every 18 mnths when stred at 77 F (25 C). If stred in higher temperatures, the charge shuld be mre ften. Capacity Battery capacity is given in ampere-hurs r amp-hurs (Ah). This is a current draw which is multiplied by the duratin f current flw. A draw f X amperes fr Y hurs equals an accumulatin f XY amp-hurs. Because the battery s chemical reactin cnstantly releases energy, its amp-hur capacity is affected less by lighter lads. The battery has greater capacity under lighter lads. Fr example, if the EnergyCell PLC is discharged at the 48-hur rate t a vltage f 1.75 Vpc (a lad expected t effectively drain 100% f its capacity in 48 hurs), it will be measured t have 191 amp-hurs. Hwever, at the 4-hur rate, a heavier lad, nly 140 amp-hurs will be measured. Fr all tested discharge rates and amp-hurs, see Table 3 n page 19. The EnergyCell 200 PLC is named after its capacity at the 100-hur rate when discharged t 1.75 Vpc. State f Charge The EnergyCell SC can be determined by tw methds. One is t measure its vltage. This is accurate nly if the batteries are left at rest (n charging r lads) fr 24 hurs at rm temperature (77 F r 25 C). If these cnditins are nt met, then vltage checks may nt yield usable results. If they are met, then n average, a battery at 13.0 Vdc will be at 100% SC. A rest vltage f 12.2 Vdc represents rughly 50% SC. The mre accurate methd is t use a battery mnitr such as the OutBack FLEXnet DC. Using a sensr knwn as a shunt, the mnitr bserves the current thrugh the battery. It keeps a ttal f amp-hurs lst r gained by the battery and can give accurate SC readings. % f Expected Life F 80 F 90 F 100 F 110 F 120 F 130 F 21 C 27 C 32 C 38 C 43 C 49 C 54 C Figure 2 Temperature Battery Life Rev A 7

8 Installatin and Operatin The EnergyCell can be discharged and recharged (cycled) regularly t a level as lw as 50% depth f discharge (DD). This is cmmn in a cycling applicatin such as an ff-grid system. Hwever, fr ptimal life, the best practice is t avid ever discharging belw 50%. Lwer DD levels can shrten the battery life. If perated in a range with cnsistent charge and discharge t n mre than 50% DD, the EnergyCell PLC will typically have a life f 3,000 cycles. With cnsistently lighter discharge (10 t 30% DD with prper recharge), the battery may have significantly mre cycles. Fr the anticipated cycle life, see the OutBack data sheet fr the EnergyCell 200 PLC. (The cycle life can be affected by temperature. Figure 2 n the previus page shws the effect f ambient temperature n typical battery life.) System Layut CAUTION: Fire Hazard Failure t ventilate the battery cmpartment can result in the buildup f hydrgen gas, which is explsive. The battery enclsure r rm must be well-ventilated. This ventilatin prtects against accidental gas buildup. All EnergyCell batteries are valve-regulated and d nt nrmally emit nticeable amunts f gas. Hwever, in the event f accidental leakage, the enclsure must nt allw the leaked gas t becme cncentrated. The battery enclsure r rm must have adequate lighting. This is necessary t read terminal plarity, identify cable clr, and view the physical state f the battery as required. The battery shuld be installed with a minimum 36 (91.4 cm) clearance in frnt. This allws access fr testing, maintenance, and any ther reasns. Multiple batteries shuld have a minimum f ½ (12.7 mm) clearance n either side. Battery Cnfiguratins Lad Lad + Lad Lad + Series String (24 Vdc) Series String (48 Vdc) Batteries are placed in series (negative t psitive) fr additive vltages. Batteries in series are knwn as a string. A string f tw EnergyCell batteries has a nminal vltage f 24 Vdc and can be used fr 24-vlt lads. A string f fur has a nminal vltage f 48 Vdc. Other vltages are pssible. Hwever, batteries in series d nt have additive amp-hurs. A single string f any vltage (as shwn abve) has the same amp-hurs as a single battery. When replacing batteries, a new battery shuld nt be placed in series with ld batteries. This will cause severe stress and shrten the life f all batteries. All batteries in a string shuld be replaced at the same time. Figure 3 Series String Cnfiguratins Rev A

9 EnergyCell Batteries Batteries are placed in parallel (psitive t psitive, negative t negative) fr additive amp-hur capacity. Three batteries in parallel have three times the amp-hurs f a single battery. Hwever, batteries in parallel d nt have additive vltages. A single set f batteries in parallel (as shwn in this figure) have the same vltage as a single battery. Lad Bus Parallel Lad Bus + NOTE: Use cautin when designing r building systems with mre than three EnergyCell batteries r strings in parallel. The extra cnductrs and cnnectins used in larger paralleled systems can lead t unexpected resistances and imbalances between batteries. Withut prper precautins, these factrs will reduce the system efficiency and shrten the life f all batteries. Fr systems beynd three strings, cntact an OutBack representative. Figure 4 Parallel String Cnfiguratin Batteries are placed in bth series and parallel fr bth additive vltage and amp-hur capacity. Series strings placed in parallel have the same nminal vltage as each string. They have the same amp-hur capacity f each string added tgether. Tw parallel strings f tw EnergyCell batteries in series have a nminal vltage f 24 Vdc, twice the nminal vltage. They als have duble the amp-hur capacity f a single battery. Tw parallel strings f fur batteries in series have a nminal vltage f 48 Vdc at duble the amp-hur capacity f a single battery. In a series-parallel bank, it is nt recmmended t cnnect the lad t the psitive and negative terminals f a single string. Due t cable resistance, this will tend t put mre wear n that string. Instead, it is recmmended t use reverse-return r crss-crner wiring, where the psitive cable is cnnected t the first string and the negative is cnnected t the last. This will allw current t flw evenly amng all strings. Lad Bus Lad Bus + Lad Bus Lad Bus + Figure 5 Series/Parallel String Cnfiguratins Rev A 9

10 Installatin and Operatin DC Wiring CAUTION: Equipment Damage Never reverse the plarity f the battery cables. Always ensure crrect plarity. CAUTION: Fire Hazard Always install a circuit breaker r vercurrent device n the DC psitive cnductr fr each device cnnected t the batteries. CAUTION: Fire Hazard Never install extra washers r hardware between the munting surface and the battery cable lug r intercnnect. The decreased surface area can build up heat. Terminal Hardware EnergyCell PLC battery terminals cnsist f a threaded stud which receives a nut. Terminal hardware is assembled as shwn in Figure 6. NOTE: Install the cable lugs (r intercnnects) and all ther hardware in the rder illustrated. The lug r intercnnect shuld be the first item installed. It shuld make slid cntact with the munting surface. D nt install hardware in a different rder than shwn. NOTE: T avid crrsin, use plated lugs n cable terminatins. When multiple cables are terminated, use plated terminal bus bars. Tighten the terminals t a trque value f 97.4 t in-lb (11 t 14.7 Nm). M6 Nut Flat Washer Lck Washer Cable Lug r Intercnnect Battery Terminal Stud Battery Terminal Surface Figure 6 Terminal Assemblies Cleaning Battery Terminals T minimize cntact resistance, it is imprtant that the lead terminals f the batteries be cleaned f any xidatin that may have ccurred during transprtatin and strage. It is mst cnvenient t clean them prir t placing them n the rack. Lightly brush the terminal cntact surface areas with a brass bristle brush r the equivalent. Next apply a light cating f special antixidant grease such as NO-OX-ID r NCP-2 t the surfaces. This will prtect the lead terminal frm further xidatin Rev A

11 EnergyCell Batteries T make the DC cnnectins: Make certain t clean all terminals and cntact surfaces accrding t the steps n page If installing batteries in a rack r cabinet, always begin with the lwest shelf fr stability. Place all batteries with terminals facing t the mst accessible side f the rack. If terminal prtectrs are present, remve and save them. 2. In cmmn cnfiguratins, the battery n ne end will be the psitive (+) utput fr that string. This battery shuld be designated [1]. Prceeding t the ther end, adjacent batteries in that string shuld be designated [2], [3], and s n. Intercnnecting Bar 3. If mre than ne string is present, designate the first string as A, the secnd as B, and s n. This shuld be dne regardless f whether the strings are n the same shelf r higher shelves. Number the batteries in subsequent strings just as in step Install series cnnectins. If an intercnnecting bar was supplied, it shuld cnnect frm the negative (left) side f battery [1] t the psitive (right) side f battery [2] as shwn abve (see arrw). Tp-terminal batteries require shrt intercnnecting cables t be prvided. Tighten intercnnect hardware hand tight nly. 5. Repeat the prcess as apprpriate fr batteries [2], [3], and any thers in the string. Cnnect the prper number f batteries in series fr the nminal vltage f the lad. 6. If multiple series strings will be used, repeat this prcess fr strings B, C, and s n. 7. Install parallel cnnectins. Parallel cnnectins are made frm the psitive terminal f ne battery r string t the psitive f the next; negative cnnectins are made similarly. (See Figure 4 n page 9.) External cables r bus bars must be prvided. Intercnnecting bars cannt make parallel cnnectins. 8. Use a digital vltmeter (DVM) t cnfirm the nminal system vltage and plarity. Cnfirm that n batteries r strings are installed in reverse plarity. 9. Install cables r bus bars fr DC lads. Size all cnductrs as apprpriate fr the ttal lads. See the manual fr the battery rack r cabinet if necessary. 10. Befre making the final battery cnnectin, ensure the main DC discnnect is turned ff. If this is nt pssible, then d nt make the final cnnectin within the battery enclsure. Instead, make it at the lad r elsewhere in the cable system s that any resulting spark des nt ccur in the battery enclsure. 11. Once hardware is installed and batteries are prperly aligned, trque all cnnectins t the apprpriate value fr the battery mdel. (See the requirements n page 19.) Lightly cat the surfaces with battery terminal grease. Reinstall the terminal cvers if present. Figure 7 Cnnecting Batteries IMPORTANT: Befre using the battery bank, cmmissin the batteries as described n the next page Rev A 11

12 Installatin and Operatin Cmmissining The cmmissining charge applies when the batteries have been in transit r in strage fr 24 mnths r mre. (This applies at a strage temperature f 25 C r 77 F. The interval is shrter at higher temperatures.) It is als needed when the battery system is intended fr use at the minimum flat charging vltage r when the number f cells in series is greater than 24. Under any f these cnditins, it is recmmended the battery system be given a freshening charge at 2.35 vlts average per cell fr 24 hurs. This will assure higher initial perfrmance and will reduce the time perid required fr the cells t achieve prper vltage balance between the individual units. T apply a freshening charge: Cnfirm the freshening (equalizatin) vltage frm the charger/rectifier is set t a value equal t the Absrb Charging Vltage shwn belw. Clse the circuit frm the charger t the battery and cnfirm that the battery accepts current. Mnitr the battery peridically and nte that the peratin is prceeding nrmally. Make certain that the current acceptance is declining and that the batteries are nt verheating (within ±5 F r ±2.8 C f each ther and the ambient temperature). Make certain that the individual battery vltages n equalizatin charge are 14.1 ± 0.50 Vdc. Terminate the freshening charge in the case f any extrardinary situatin r after 24 hurs. Initial Flat Charging Fllwing the freshening charge the battery system shuld be placed n flat charge at a value equal t the Flat Charging Vltage shwn in the fllwing sectin. See page 13 fr a descriptin f flat charging. Prir t placing n flat charge, assure the charger is set t the prper utput vltage. After the battery system has been n flat fr apprximately 24 hurs, the flat current acceptance shuld be greater than zer, but n mre than apprximately Adc per rated ampere-hur capacity f the battery string. Charging EnergyCell PLC batteries are usually charged using a three-stage charging cycle: bulk stage, absrptin stage, and flat stage. Mst OutBack chargers fllw this algrithm. Hwever, nt all chargers are designed r prgrammed the same way. The settings shuld be checked and changed t match the recmmendatins belw if necessary. Charging Vltages Absrb Charging Vltage: 14.1 Vdc Equalize Charging Vltage: 14.1 Vdc (same as Absrb vltage but used under different cnditins) Flat Charging Vltage: 13.5 Vdc Bulk Stage The bulk stage is a cnstant-current stage. The charge current is maintained at a cnstant high level. The battery vltage will rise as lng as the current flws. This battery has a recmmended maximum current limit f 50 Adc which shuld nt be exceeded. At excessive Rev A

13 EnergyCell Batteries current rates, the battery s cnversin efficiency becmes less and it may nt becme cmpletely charged. The battery may permanently lse capacity ver the lng term. The purpse f the bulk stage is t raise the battery vltage t a relatively high level (usually referred t as either bulk vltage r absrptin vltage). This number is shwn as the Absrb Charging Vltage n page 12. If batteries are in series, this number is multiplied by the number f batteries in the string. This stage typically restres the battery t 85% t 90% SC, if the charge rate des nt exceed the 50 Adc maximum. Absrptin Stage Absrptin is a cnstant-vltage stage. It is established upn reaching the Absrb vltage setting. The charger limits the current flw t nly what is necessary t maintain this vltage. A high current is required t raise the vltage t the absrptin level, but less is required t maintain it there. As lng as the absrptin level is maintained, the requirement tends t decrease, causing a tapering current. The amunt f absrptin current will vary with cnditins, but will typically decrease t a very lw number. This tps ff the tank, leaving the battery at 100% SC. The battery is cnsidered t be full when the fllwing cnditins are met: The charge current must taper dwn t a level between 1% and 2% f the ttal battery amp-hurs (while maintaining the absrptin vltage). The charger can then exit absrptin t the next stage. Nt all chargers measure this in amperes. Many chargers hld the absrptin fr a timed perid (ften tw hurs), assuming that the current will taper dwn by then. Hwever, if the charge ends befre the current tapers t the desired level, the battery may nt reach 100% SC. Repeated failure t charge the batteries t 100% will result in decreased battery life. If pssible, use a DC ammeter t bserve and time the current as it tapers dwn. The absrptin timer can then be set accrdingly. Flat Stage DC Vlts Amperes (typical) Hurs (typical) Hurs (typical) The flat stage is a maintenance stage which ensures the battery remains fully charged. Left with n maintenance, the battery will tend t slwly lse its charge. The flat stage prvides current t cunter this self-discharge. As with the absrptin stage, flat is a cnstant-vltage stage which supplies nly enugh current t maintain the designated vltage. The vltage requirements fr flat stage are much lwer than fr bulk and absrptin. This number is shwn as the Flat Charging Vltage n page 12. The flat stage shuld prvide enugh current t maintain the apprpriate vltage. If batteries are in series, this number shuld be multiplied by the number f batteries in the string. Bulk Bulk Figure 8 Absrptin Absrpti Flat Flat Three-Stage Charging Rev A 13

14 Installatin and Operatin Freshening Charge A maintenance r freshening charge shuld be given t batteries that have been in strage. The freshening charge must be apprpriate t the battery mdel. All charging shuld be temperature-cmpensated (see belw). With a three-stage charger, the vltages fr each stage are set as nted n page 12. Ntes n EnergyCell PLC Charging The current requirements fr the absrptin and flat stages are usually minimal; hwever, this will vary with cnditins, with battery age, and with battery bank size. (Larger banks tend t have higher exit current values fr the absrptin stage, but they als have higher flat current.) Any lads perated by the battery while charging will als impact the requirements fr the charger, as the charger must sustain everything. Nt all chargers exit directly t the flat stage. Many will enter a quiescent r silent perid during which the charger is inactive. These chargers will turn n and ff t prvide peridic maintenance at the flat level, rather than cntinuus maintenance. Cnstant-Flat Charging Cnstant-flat charging may be used with the EnergyCell PLC in backup pwer applicatins where the battery bank is rarely discharged. When a discharge ccurs, it is critical t recharge the bank as sn as pssible afterward. When charged with a cnstant-flat charger, the charger shuld be set t maintain the batteries at 13.5 Vdc per battery in a string (2.25 Vpc) at rm temperature. The batteries are cnsidered t be fully charged when the cell vltage is maintained at this level and the charge current has drpped t a lw level ver a lng perid f time. In cnstant-flat charging, it is critical t cmpensate the settings fr temperature. Temperature Cmpensatin Battery perfrmance will change when the temperature varies abve r belw rm temperature (77 F r 25 C). Temperature cmpensatin adjusts the charging t crrect fr these changes. When a battery is cler than rm temperature, its internal resistance ges up, the vltage changes mre quickly, and the charger reaches its vltage set pints mre easily. Hwever, it will nt deliver all the required current and the battery will tend t be undercharged. Cnversely, when the battery is warmer than rm temperature, its internal resistance ges dwn, the vltage changes mre slwly, and the charger des nt reach its vltages as easily. It will cntinue t deliver energy until the set pints are reached, but this tends t be far mre than required. The battery will be vercharged. (See Imprper Use.) T cmpensate fr these changes, a charger used with the EnergyCell battery must have its vltages raised by a specified amunt fr every degree belw rm temperature. They must be similarly lwered fr every degree abve rm temperature. This factr is multiplied if additinal batteries are in series. Failure t cmpensate fr significant temperature changes will result in undercharging r vercharging which will shrten battery life. EnergyCell PLC Required Cmpensatin The factr is 5 mv per cell (0.03 Vdc r 30 mv per battery) per degree C abve r belw rm temperature (77 F r 25 C) when the battery is regularly cycled. The factr is 3 mv per cell (0.018 Vdc r 18 mv per battery) per degree C in cnstant-flat applicatins Rev A

15 EnergyCell Batteries Remte Temperature Sensr OutBack inverter/chargers and charge cntrllers are equipped with the Remte Temperature Sensr (RTS) which attaches t the battery and autmatically adjusts the charger settings. When the RTS is used, it shuld be placed n the battery sidewall, as clse t the center f the battery (r t the center f the bank) as pssible. The charger determines the RTS cmpensatin factr. Mst OutBack chargers are preset t a cmpensatin f 5 mv per cell. If an RTS is nt present, if a different charger is in use, r if a different cmpensatin factr is required, it may be necessary t adjust the charger settings manually. The RTS shuld be checked peridically. Failure t cmpensate crrectly may result in wrng vltages. Imprper Use CAUTION: Equipment Damage Read all items belw. Maintenance shuld be perfrmed as nted n page 18. Failure t fllw these instructins can result in battery damage which is nt cvered under the EnergyCell warranty. CAUTION: Equipment Damage D nt exceed the specified absrptin vltage when charging any EnergyCell battery. Excessive vltage culd result in battery damage which is nt cvered under the EnergyCell warranty. Fr any EnergyCell battery, if the charger settings are t high, this will cause premature aging f the battery, including lss f electrlyte due t gassing. The result will be permanent lss f sme battery capacity and decreased battery life. This is als true fr battery charging that is nt cmpensated fr high temperatures. Thermal runaway can result frm high ambient temperatures, charging at higher vltages ver extended time, incrrect temperature cmpensatin, r shrted cells. When the buildup f internal heat exceeds the rate f cling, the battery s chemical reactin accelerates. The reactin releases even mre heat, which in turn cntinues t speed up the reactin. Thermal runaway causes severe heat, gassing, lst electrlyte, and cell damage. It usually requires battery replacement. The prcess can be halted by turning ff the charger. Hwever, if cell damage has ccurred, shrted cells may cntinue t generate heat and gas fr sme time. If an EnergyCell battery is nt charged cmpletely (r if the settings are t lw), it will nt reach 100% SC. Its ttal capacity will nt be available during the next discharge cycle. This capacity will becme prgressively less and less ver subsequent cycles. Lng-term undercharging will result in decreased battery life. This is als true fr battery charging that is nt cmpensated fr lw temperatures Rev A 15

16 Installatin and Operatin NOTES: Rev A

17 Trubleshting and Maintenance Table 1 Trubleshting Categry Symptm Pssible Cause Remedy Reduced perating time Nrmal life cycle Replace battery bank when (r befre) capacity drps t unacceptable levels. Defective cells Test and replace battery as necessary. Excessively cld battery Carefully warm up the battery. Perfrmance Undersized cabling Increase cable ampacity t match lads. Excessive vltage drp upn applying lad Lse r dirty cable cnnectins Check and clean all cnnectins. Physical damage n terminals may require the battery t be replaced. Replace hardware as necessary. Undersized battery bank Add additinal batteries t match lads. Defective cells Test and replace battery as necessary. External Inspectin Swllen r defrmed battery casing; rtten-egg r sulfurus dr; battery is ht Thermal runaway NOTE: A mdest amunt f swelling (r cncavity) n the battery case is nrmal. NOTE: Thermal runaway is a hazardus cnditin. Treat the battery with cautin. Allw the battery t cl befre appraching. Discnnect and replace battery as necessary. Address the cnditins that may have led t thermal runaway (see page 15). Damaged battery casing Physical abuse Replace battery as necessary. Heat damage r melted grease at terminals Lse r dirty cable cnnectins Check and clean all cnnectins. Physical damage n terminals may require the battery t be replaced. Replace hardware as necessary. Fully-charged battery displays lw vltage High temperature Carefully cl the battery. An verheated battery may cntribute t thermal runaway. Fully-charged battery displays high vltage Lw temperature Carefully warm up the battery. Vltage testing Individual battery charging vltage will nt exceed 13.3 Vdc; high flat current; failure t supprt lad Shrted cell Test and replace battery as necessary. A shrted cell may cntribute t thermal runaway. Individual battery flat vltage exceeds 14.5 Vdc; failure t supprt lad Open cell Test and replace battery as necessary. Charging current t series string is zer; failure t supprt lad Open cnnectin r pen battery cell in string Check and clean all cnnectins. If battery appears t have an pen cell, test and replace as needed. Replace hardware as necessary. Current testing Charging current t series string remains high ver time Batteries require additinal time t charge Nrmal behavir; n actin necessary. Charging current t series string remains high with n crrespnding rise in vltage Shrted cell Test and replace battery as necessary. A shrted cell may cntribute t thermal runaway Rev A 17

18 Maintenance Peridic Evaluatin Upn replacement f a battery, all intercnnect hardware shuld be replaced at the same time. T keep track f perfrmance and identify batteries that may be appraching the end f their life, perfrm the fllwing tests during n a quarterly basis fllwing cmmissining (see page 12). Tests must be made with a high-quality digital meter. Vltages must be measured directly n battery terminals, nt n ther cnductrs. All cnnectins must be cleaned, re-tightened, and re-trqued befre testing. If a battery fails any test, it may be defective. If this ccurs under the cnditins f the warranty, the battery will be replaced accrding t the warranty terms. Bring the batteries t a full state f charge befre perfrming the fllwing test. Mnthly Battery Inspectin General appearance and cleanliness f battery, battery rack and battery area. Inspect fr cntaminatin by dust. Inspect fr lse r crrded cnnectins. If necessary, islate the string/battery and clean with a damp sft clth. D nt use slvents r scuring pwders t clean the batteries. Cracks in cell cntainers r leakage f electrlyte. Any evidence f crrsin at cell terminals, cnnectrs r racks. Ambient temperature and cnditin f ventilatin equipment. Current and vltage during charge cycle. Measure individual battery vltages at the battery terminal. The measurements shuld be within 5% f the average. Vltage at end f charge cycle. Measure individual battery vltages at the battery terminal. The measurements shuld be within 5% f the average. End f discharge vltage measured at the battery. Measure individual battery vltages at the battery terminal. The measurements shuld be within 5% f the average. Recrd findings clearly. List the dates fr all entries. Quarterly Battery Inspectin This shuld include the mnthly bservatins, plus: End f charge vltage f every cell and battery terminal vltage measured at battery. End f discharge vltage f every cell and battery terminal vltage measured at battery. Electrlyte temperature in representative cell(s), typically ne cell/tier distributed thrughut battery. Recrd findings clearly. List the dates fr all entries. Annual battery inspectin This shuld include the mnthly and quarterly bservatins, plus: Inter-cell / inter-unit cnnectin integrity. Retighten terminals t specified trque values. See page 19 fr specificatins. Recrd findings clearly. List the dates fr all entries Rev A

19 Specificatins Table 2 Specificatins EnergyCell 200PLC Cells Per Unit 6 Vltage Per Unit Optimal Operating Temperature Operating Temperature Range (Strage) Operating Temperature Range (Discharging) Operating Temperature Range (Charging) Flat Charge Vltage Absrb r Equalize Charge Vltage Maximum Charge Current Charging Temperature Cmpensatin Factr Relative Humidity Terminal Terminal Trque 2 Weight Dimensin L x W x H Warranty 12V 68 F t 86 F (20 C t 30 C) 4 t 104 F ( 20 t 40 C) 40 t 149 F ( 40 t 65 C) 5 t 140 F ( 15 t 60 C) 13.5 Vdc 14.1 Vdc 50 Adc ±5 mv / C / cell 0% t ~95%, nn-cndensing T t in-lb (11 t 14.7 Nm) ~130 lb (~59 kg) ( mm) 6 years (glbal), full replacement Table 3 Ampere-Hur Capacity t 1.75 Vlts Per Cell at 25 C Discharge in Hurs: EnergyCell 200PLC Rev A 19

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