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1. 100 recyclable The following web sites and phone numbers provide additional information for recycling batteries Earth 911 USA Web site http www Earth911 com Address 14646 N Kierland Blvd Suite 100 Scottsdale AZ 85254 Phone 1 480 337 3025 direct Keep America Beautiful USA Web site http www kab org Email info kab org Address 1010 Washington Boulevard Stamford CT 06901 Phone 1 203 659 3000 Main number Fax 1 203 659 3001 National Institute of Recyclers Mexico Web site http www inare org mx Email a57841279 prodigy net mx margarita inare org mx Phone 1 55 57 85 9160 Fax 1 55 57 84 1279 900 0127 01 00 Rev A Table of Contents Table of Contents Important SATeLY INSCFUCTIONS lt ssssseccvsseccessscacdeesecsssusceccsccesussesecsasecdscownscdecesseces amp AUAI NMG Cs cceh ccc sta aeec Shadi E E Bases gee ts ese at ectea de cacti ge te ea ead aarestd Maasai cette tress 1 RECUIFECIRE SOULCCS st cseszetaashctadeciecieieesd eatae rents eeicen duets us A E TAO 3 Additional RE SOUNCES ss oicsca cesccsdscseetcceeanedebacalascsssdsededea cuca eauatuestocatescsusaeadebacwacs eauatvedetealeneasanousouueisiaes A A 3 RECy CHIN OL IRON OO enn E onusneacteteses ernie NE T EE EOE OOE NT OE ETAETA 3 Energy Cell RE Battery sssccccwonsesssescccecnsscsetscsceseeccsecsasevensssnedssesesesesssseccessssassscces D Welcome to OULBACK Power SystemMSsusssssnao cun in nn na a RON R RO ORAON AOR 5 Materai REGUE d anina
2. a Battery Terminal Surface Figure9 DC Terminals To make the DC connections 1 If installing batteries in the OutBack EnergyCell RE battery rack or a similar cabinet always begin with the lowest shelf for stability Four EnergyCell RE batteries can be placed on one shelf All batteries should be placed with terminals facing to the front Remove and save the terminal protectors 2 Clean and lightly brush all terminals and contact surfaces In normal configurations the battery on the far right will be the positive output for that string This battery should be designated 1 Proceeding to the left adjacent batteries in that string should be designated 2 3 and so on If more than one string is present designate the first string as A the second as B and so on This should be done regardless of whether the strings are on the same shelf or higher shelves Number the batteries in subsequent Strings just as was done in step 3 Install series connections using the interconnect and hardware that was supplied with each battery The interconnect should connect from the negative left side of battery 1 to the positive right side of battery 2 as shown above Tighten interconnect hardware hand tight only Continued on the next page Figure 10 Connecting Batteries 900 0127 01 00 Rev A continued 6 Repeat the process as appropriate for batteries 2 3 and any others in the string Connect the proper numb
3. indicates that the hazard may cause damage to the equipment IMPORTANT This type of notation indicates that the information provided is important to the installation operation and or maintenance of the equipment Failure to follow the recommendations in such a notation could result in voiding the equipment warranty This manual is intended for use by anyone required to install and operate this battery Be sure to review this manual carefully to identify any potential safety risks before proceeding The owner must be familiar with all the features and functions of this battery before proceeding Failure to install or use this battery as instructed in this manual can result in damage to the battery that may not be covered under the limited warranty General Safety AN A Cli 900 0127 01 00 Rev A WARNING Limitations on Use This equipment is NOT intended for use with life support equipment or other medical equipment or devices CAUTION Equipment Damage Only use battery components or accessories recommended or sold by OutBack Power Technologies or its authorized agents IMPORTANT Do not attempt to install this battery if it appears to be damaged in any way Contact the vendor if the battery was received in a damaged condition If the battery was damaged during use see the Warranty section for instructions Important Safety Instructions Personal Safety i WARNING Personal Injury gt This battery weighs i
4. of self discharge Figure 3 compares self discharge with temperatures gt When fully charged the battery s natural or rest voltage is 25 approximately 12 8 Vdc It should be given a freshening charge see page 11 if its rest voltage drops below 12 5 Vdc per battery 2 08 Vdc per cell A battery should not be used if its rest voltage is 12 0 volts or lower upon delivery Contact the vendor upon receiving a battery in this state gt If left in storage a battery must be given a freshening charge every six months when stored at 77 F 25 C The charge should be every three months if stored at 60 F 70 F 80 F 90 F 100 F 110 F 120 F 130 F temperatures of up to 92 F 33 C If stored in higher 21 C 21 C 27 C 32 C 38 C 43 C 49 C 54 C temperatures the charge should be every month Temperature gt The EnergyCell RE battery should never be permitted to Figure 3 Self Discharge Effects self discharge below 75 of its capacity This is highly detrimental and will shorten battery life This is not the same as discharging under load See page 7 20 harge isc a Monthly Self D Capacity The EnergyCell RE capacity is given in ampere hours amp hours This is a current draw which is multiplied by the duration of current flow A draw of X amperes for Y hours equals an accumulation of XY amp hours Because the battery s chemical reaction constantly releases energy it tends to replenish its own charge
5. put more wear on that string Instead it is recommended to use reverse return or cross corner wiring where the positive cable is connected to the first string and the negative to the last This will allow current to flow evenly among all strings This method is shown in both figures Figure8 Series Parallel String Configuration 8 900 0127 01 00 Rev A State of Charge DC Wiring 2 6 6 6 cm CAUTION Equipment Damage Never reverse the polarity of the battery cables Always ensure correct polarity CAUTION Fire Hazard Always install a circuit breaker or overcurrent device on the DC positive conductor for each device connected to the batteries CAUTION Fire Hazard Never install extra washers or hardware between the mounting surface and the battery cable lug or interconnect The decreased surface area can build up heat NOTE To avoid corrosion use plated lugs on cable Yq 20 1 2 3 0cm terminations When multiple cables are being UNC Bolt terminated use plated terminal bus bars bdlllllbbidld Lock Washer Install cable lug or interconnect nuts and washers in the order illustrated The lug or interconnect Flat Washer ANH ANG should be the first item installed It should make a z Ore solid contact with the mounting surface Do not install hardware in a different E 6 order than shown Cable Lug or Interconnect 2 6 cm
6. the battery including loss of electrolyte due to gassing The result will be permanent loss of some battery capacity and decreased battery life This is also true for battery charging that is not compensated for high temperatures Thermal runaway can result from charging at higher voltages over extended time high ambient temperatures incorrect temperature compensation see page 12 or shorted cells When the buildup of internal heat exceeds the rate of cooling the heat speeds up the internal chemical reaction The reaction releases even more heat which in turn continues to speed up the reaction Thermal runaway causes severe heat gassing lost electrolyte and cell damage It usually requires battery replacement The process can be halted by turning off the charger However if cell damage has occurred shorted cells may continue to generate heat and gas for some time Freshening Charge A maintenance or freshening charge is given to batteries that have been in storage or newly received With a three stage charger the charge should proceed as described on page 10 If a specialized VRLA charger is available it should charge the batteries at 14 4 to 14 8 Vdc continuously for 16 hours 900 0127 01 00 Rev A 11 CAUTION Equipment Damage Do not perform equalization on these batteries Equalization is a controlled overcharge used for battery maintenance As it uses high DC voltages it could result in battery damage which is not cove
7. toa minor degree Smaller loads will deplete the batteries less than larger loads because of this constant replenishment This means L that effectively the battery has more capacity under lighter loads For example if the EnergyCell 170RE is discharged at the 48 hour rate a load expected to drain 100 of its capacity in 48 hours it will be measured to have 163 9 amp hours However at the 4 hour rate a heavier load only 120 6 amp hours will be measured See Table 3 on page 14 for discharge rates and amp hours The EnergyCell RE models are named after their capacity at the 100 hour rate 170 and 200 amp hours respectively of Capacity 22 F 4 F 14 F 32 F 50 F 68 F 86 F 104 F The capacity also varies with temperature Figure 4 shows changes 30 C 20 C 10 C 0 C 10 C 20 C 30 C 40 C in capacity at various temperatures Two curves are graphed for Temperature different current rates one indicating an amperage measurement equal to 1 100 of overall battery capacity C 100 the other showing an amperage of 1 20 of capacity C 20 Figure 4 Capacity Effects 6 900 0127 01 00 Rev A State of Charge State of Charge The battery state of charge SOC can be determined by two methods One is to measure its voltage This is accurate only if the batteries are left at rest no charging or loads for 24 hours at room temperature 77 F or 25 C If these conditions are not met then voltage checks may not yield
8. usable results If they are met then on average a battery at 12 84 Vdc will be at 100 SOC 12 24 Vdc represents roughly 50 SOC The more accurate method is to use a battery monitor such as the OutBack FLEXnet DC Using a sensor known as a shunt the monitor __ __ l a observes the current through the battery It keeps a total of amp hours le lt eee pee pe p lost or gained by the battery and can give accurate SOC readings Temperature of Expected Life vI O The EnergyCell RE battery is designed for a life of many discharge charge Figure5 Battery Life cycles For optimal battery life it is recommended not to discharge below 70 SOC 30 depth of discharge on a regular basis The battery should never be discharged below 50 of its capacity as this will significantly shorten its life If operated in the recommended range the battery will typically have a life of hundreds of cycles With consistently lighter discharge the battery may have thousands of cycles This can be affected by temperature Figure 5 shows the effect of ambient temperature on battery life System Layout CAUTION Fire Hazard Failure to ventilate the battery compartment can potentially result in the buildup of hydrogen gas which is explosive gt The battery enclosure or room must be well ventilated This will protect against the accidental buildup of hydrogen gas The EnergyCell RE battery is sealed and does not normally emit noticeable amounts of
9. Cut Back POWER member of The alpha Group 5 i gt ENERGY Grid Interactive UKOR E Stid interactive Renewable Energy Renewable Erergy EnergyCell RE Front Terminal Battery Owner s Manual Ou t Ba c k i eel Yth QwDISTRIBUTOR POWER 800 967 6917 member of The alpha Group So igent www soligent net About OutBack Power Technologies OutBack Power Technologies is a leader in advanced energy conversion technology Our products include true sine wave inverter chargers maximum power point tracking charge controllers and system communication components as well as circuit breakers batteries accessories and assembled systems Contact Information Telephone 1 360 435 6030 1 360 618 4363 Technical Support 1 360 435 6019 Fax Mailing Address OutBack Power Technologies Address Sales Marketing amp Warranty North America 5917 195 Street N E 7 6115 192nd Street NE Arlington WA 98223 USA Arlington WA 98223 USA E mail Support outbackpower com Web Site www outbackpower com Disclaimer 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 U
10. SE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Warranty Summary OutBack Power Technologies Inc warrants that the products it manufactures will be free from defects in materials and workmanship for a period of two 2 years subject to the conditions set forth in the warranty detail found at the end of this manual OutBack Power Technologies cannot be responsible for system failure damages or injury resulting from improper installation of their products Notice of Copyright EnergyCell RE Front Terminal Battery Owner s Manual November 2011 by OutBack Power Technologies All Rights Reserved Trademarks OutBack Power is a registered trademark of OutBack Power Technologies Date and Revision November 2011 Revision A Part Number 900 0127 01 00 Rev A Important Safety Instructions Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS This manual contains important safety instructions for the EnergyCell RE battery Read all instructions and cautionary markings on the EnergyCell RE battery and on any accessories or additional equipment included in the installation Failure to follow these instructions could result in severe shock or possible electrocution Use extreme caution at all times to prevent accidents Audience WARNING Hazard to Human Life This type of notation indicates that the hazard could be harmful to human life CAUTION Hazard to Equipment This type of notation
11. ace battery bank when or before capacity Reduced operating time drops to unacceptable levels Defective cells Test and replace battery as necessary Excessively cold battery Carefully warm up the battery Performance Undersized cabling Increase cable ampacity to match loads Excessive voltage drop upon Loose or dirty cable Check and clean all connections Physical connections damage on terminals may require the battery to be replaced Replace hardware as needed Undersized battery bank Add additional batteries to match loads Defective cells Test and replace battery as necessary Thermal runaway NOTE Thermal runaway is a hazardous condition Treat the battery with caution Allow the battery to cool before approaching applying load Swollen or deformed battery NOTE A modest amount of casing rotten egg or swelling or concavity on sulfurous odor battery is hot the battery case is normal Disconnect and replace battery as necessary Address the conditions that may have led to thermal runaway see page 11 Damaged battery casing Physical abuse Replace battery as necessary External Inspection Loose or dirty cable Check and clean all connections Physical connections damage on terminals may require the battery to be replaced Replace hardware as needed Heat damage or melted grease at terminals Fully charged battery High temperature Carefully cool the battery An overheated displays low voltage battery may cont
12. aged or substandard cabling 2 900 0127 01 00 Rev A Important Safety Instructions Required Resources This product is required to be installed according to pertinent safety codes and standards If installed in the United States wiring practices must meet the requirements of the National Electrical Code NEC If installed in Canada wiring practices must meet the requirements of the Canadian Electrical Code gt National Electrical Code NEC NFPA 70 Current Edition gt Canadian Electrical Code C22 1 Current Edition gt EnergyCell RE Material Safety Data Sheet Additional Resources These references may be used when installing this equipment Depending on the nature of the installation it may be highly recommended to consult these resources National Electrical Code NEC NFPA 70 Handbook Current Edition International Building Code IBC Current Edition Photovoltaic Power Systems and the 2005 National Electrical Code Suggested Practices Institute of Electrical and Electronics Engineers IEEE guidelines IEEE 450 IEEE 484 IEEE 1184 IEEE 1187 IEEE 1188 IEEE 1189 IEEE 1491 IEEE 1578 IEEE 1635 and IEEE 1657 various guidelines for design installation maintenance monitoring and safety of battery systems VVV WV Recycling Information Cli IMPORTANT Recycle Electronics and Batteries Batteries are considered hazardous waste and must be recycled according to local jurisdiction OutBack EnergyCell batteries are
13. arge before the current has tapered down to the desired level the battery may not be 100 charged Repeated failure to perform a complete charge will result in decreased battery life If possible it is recommended to use a DC ammeter to observe and time the current as it tapers to the proper amperage The user can then manually set the charger s absorption timer accordingly Float Stage The float stage is a maintenance stage which ensures the battery remains fully charged Left with no maintenance the battery will tend to slowly lose its charge The float stage provides current to counter this self discharge As with the absorption stage float is a constant voltage stage which supplies only enough current to maintain the designated voltage The voltage requirements for float stage are much lower than for bulk and absorption The float stage should provide enough current to maintain the battery at 13 6 to 13 8 Vdc per battery in a string 2 27 to 2 30 volts per cell If batteries are in series this number should be multiplied by the number of batteries in the string Notes on Charging The current requirements for the absorption and float stages are usually minimal however this will vary with conditions with battery age and with battery bank size Larger banks tend to have higher exit current values for the absorption stage but they also have higher float current Any loads operated by the battery while charging will also impact the requ
14. backpower com To ensure Warranty coverage this contact must be within the Warranty period beginning on the invoice date During this period OutBack Power Technologies will repair or replace a Product covered under this Warranty that is confirmed defective Troubleshooting One party will need to work with an OutBack Technical Support representative to perform troubleshooting This is a required step and requires a qualified technician to be present at the site of the Product with a quality DC voltmeter The OutBack representative will request voltmeter readings and other information Because Product performance is dependent on temperature in order to validate the Warranty OutBack may request documentation verifying that the Product was operated in a temperature controlled environment If OutBack determines the Product or Product part is defective and that the defect is covered under this Warranty OutBack will then and only then ship a repaired or replacement Product or Product part to the purchaser freight prepaid non expedited using a carrier of OutBack s choice where applicable The warranty period of any repaired or replacement Product or Product part is ninety 90 days from the date of shipment from OutBack or the remainder of the initial warranty term whichever is greater OutBack reserves the right to request Products to be returned to OutBack for analysis This Warranty is void for any Product that has been modified by the customer wit
15. battery fails any test it may be defective If this occurs under the conditions of the warranty see page 17 the battery will be replaced according to the terms of the warranty 24 Hour Open Circuit Test Ensure that the battery is brought to a full state of charge then remove all connections from the battery Allow the battery to rest in this state for 24 hours and test its voltage A fully charged battery should measure 12 84 Vdc temperature compensated A battery below 12 6 Vdc has lost capacity and may need to be replaced 25 Amp Capacity Test Install a DC load which draws a constant 25 Adc The load may be used on either a single battery or a full string With this load discharge the batteries until they reach 10 5 Vdc per battery 1 75 Vdc per cell and monitor the elapsed time At the same time monitor the battery temperature and record the temperature at the end of the test The elapsed time should be adjusted for temperature by the following formula M M 1 0 009 T 26 7 where M actual elapsed minutes T temperature at end of run time and M minutes corrected for temperature with a baseline of 80 F 26 7 C For the EnergyCell 170RE M should be 300 minutes For the EnergyCell 200RE M should be 347 minutes If the result is less than 70 of this number the battery or string may need to be replaced 12 900 0127 01 00 Rev A Troubleshooting Troubleshooting Table 1 Troubleshooting Normal life cycle Repl
16. enewable applications are usually charged using a three stage charging cycle bulk stage absorption stage and float stage Most OutBack chargers follow this algorithm However not all chargers are designed or programmed the same way The settings should be checked and changed to match the recommendations below if necessary Contact OutBack Technical Support before using other charger types Bulk Stage DC Volts The bulk stage is a constant current stage The 15 charger s current is maintained at a constant high level The battery voltage will rise as long as the current continues to flow Each battery 13 model has a recommended maximum current limit see Table 2 on page 14 Itis Absorption 14 12 recommended not to exceed this limit At 11 excessive current rates the battery s efficiency of M conversion becomes less and it may not become 1 2 3 completely charged Over the long term the Hours typical battery may permanently lose capacity Amperes typical The purpose of the bulk stage is to raise the battery to a high voltage usually referred to as 15 either bulk voltage or absorption voltage The acceptable range for this voltage is 14 4 to 14 8 Vdc per battery in a string 2 40 to 2 47 volts per 5 cell If batteries are in series this number is multiplied by the number of batteries in the string This stage typically restores the battery 5 i to 85 to 90 of capac
17. er of batteries in series for the nominal voltage of the load 7 If multiple series strings will be used repeat this process for strings B C and so on Install parallel connections Parallel connections are made from the positive terminal of one battery or string to the positive of the next negative connections are made similarly See Figure 7 External cables or bus bars must be provided The interconnect included with the battery cannot make parallel connections 9 Use a digital voltmeter DVM to confirm the nominal system voltage and polarity Confirm that no batteries or strings are installed in reverse polarity 10 Install cables or bus bars for DC loads Size all conductors as appropriate for the total loads See the manual for the EnergyCell RE Battery Rack if necessary 11 Before making the final battery connection ensure the main DC disconnect is turned off If this is not possible then do not make the final connection within the battery enclosure Instead make it at the load or elsewhere in the cable system so that any resulting spark does not occur in the battery enclosure 12 Once hardware is installed and batteries are properly aligned torque all connections to 110 in lb 12 4 Nm Lightly coat the surfaces with battery terminal grease and reinstall the terminal covers 13 Make the final DC connections Commission freshen the batteries with a full recharge See below also see page 11 Charging Batteries in r
18. erating 74 F 23 C to 80 F 27 C Temperature Range Recommended Maximum Charging Current Limit Per String 23 AOE LAGE Float Charging Voltage 13 62 to 13 8 Vdc at 77 F 25 C Absorb Charging Voltage 14 4 to 14 8 Vdc at 77 F 25 C Self Discharge Battery can be stored at up to 6 months at 77 F 25 C before a freshening charge is required Batteries stored at temperatures greater than 77 F 25 C will require recharge sooner than batteries stored at lower temperatures P compensation rector 0 03 Vdc per battery in series 5 mV per cell per degree C Threaded copper alloy insert terminal to accept 4 20 UNC bolt 110 in lb 12 4 Nm 115 0 Ib 52 2 kg 11 1 x 22 0 x 4 9 28 3 cm x 55 9 cm x 12 6 cm 12 6 x 22 0 x 4 9 32 0 cm x 55 9 cm x 12 6 cm Ampere Hour Capacity Based On Discharge Rate Table3 Amp Hour Capacity 77 F 25 C o D X a 82 0 206 896 o 5 o OD O C2 SO o 8 S OB f OBA o R2 S OB S Y O o 2 S E 1 O S A S OA O OA 1 3 4 5 12 20 24 The EnergyCell RE battery capacity is measured in amp hours The battery capacity is not a fixed number but will vary with conditions See page 6 The figures in this table are used to measure the capacity of the EnergyCell battery based on load size Battery capacity is judged by the number of amp hours measured when a battery is discharged to a standard voltage under load This is known in the industry as terminal voltage Standard te
19. gas However in the event of accidental leakage the enclosure must not allow gas to become concentrated gt The battery enclosure or room must have adequate lighting This is necessarity to read terminal polarity identify cable color and view the physical state of the battery as required gt The battery should be installed with a minimum 36 91 4 cm clearance in front This allows access for testing maintenance or any other reasons gt If multiple batteries are installed they should have a minimum of 1 2 12 7 mm clearance on either side Battery Configurations Load Series string 24 Vdc Series string 48 Vdc Batteries are placed in series negative to positive for additive voltages Batteries in series are known as a string A string of two EnergyCell RE batteries has a nominal voltage of 24 Vdc and can be used for 24 volt loads A string of four has a nominal voltage of 48 Vdc Other voltages are possible However batteries in series do not have additive amp hours A single string of any voltage as shown above has the same amp hours as a single battery When replacing batteries a new battery should not be placed in series with a string of old batteries as this will cause severe stress and shorten the life of all batteries All batteries in a string should be replaced at the same time Figure 6 Series String Configurations 900 0127 01 00 Rev A 7 Batteries are placed in paral
20. hout authorization by OutBack A Product with a voided warranty will be treated the same as one with an expired warranty 900 0127 01 00 Rev A 17 North America 5917 195 St NE 7 Arlington WA 98223 USA 1 360 435 6030 900 0127 01 00 Rev A Cut Back POWER member of The alpha Group
21. ired Tools use insulated tools only gt Torque wrenches gt Voltmeter Accessories gt Interconnect bar gt Hardware gt Terminal cover 11 1 28 3 cm EnergyCell 200RE dimensions are listed on page 14 Figure 2 EnergyCell 170RE Battery Dimensions 900 0127 01 00 Rev A 5 Configurations Storage and Environment Requirements Temperatures gt Thebattery should not be operated in an environment where the average ambient temperature exceeds 85 F 27 C The peak temperature of the operating environment should not exceed 110 F 43 C for a period of more than 24 hours High operating temperatures will shorten a battery s life see page 7 gt The battery should never be allowed to freeze as this will damage it and could result in leakage gt The battery should not be subjected to temperature variations of more than 5 F 3 C This will lead to unbalanced voltages between multiple batteries or between cells in one battery if it is subjected to a temperature differential gt These batteries should be stored in a cool dry location They should be placed in service as soon as possible after receiving them The recommended temperature for storage is 77 F 25 C However a range of 60 F 16 C to 80 F 27 C is acceptable Self Discharge and Freshening gt The EnergyCell RE battery comes fully charged but will discharge itself over time Higher storage temperatures increase the rate
22. irements for the charger as the charger must sustain everything Not all chargers exit directly to the float stage Many will enter a quiescent or silent period during which the charger is inactive These chargers will turn on and off to provide periodic maintenance at the float level rather than continuous maintenance Some chargers are the constant float variety These are used in backup power applications where the battery is rarely discharged When a discharge occurs it is critical that the battery is recharged as soon as possible afterward When charged with a constant float charger the charger should be set to maintain the battery at 13 65 Vdc per battery in a string 2 30 volts per cell at room temperature The battery is considered to be fully charged when the cell voltage is maintained at this level and the charge current has dropped to a low level over a long period of time In constant float charging it is critical that the settings are compensated for temperature Incorrect Charging If the battery is not charged completely or if the settings are too low its total capacity will not be available during the next discharge cycle This capacity will become progressively less and less over subsequent cycles Long term undercharging will result in decreased battery life This is also true for battery charging that is not compensated for low temperatures If the charger settings are too high this will cause premature aging of
23. ity if the charge rate does i hay g not exceed the maximum shown on page 14 einen yeaa 10 Absorption Stage Figure11 Three Stage Charging The absorption stage is a constant voltage stage It is established upon reaching the desired voltage in the bulk Stage This causes the charger to begin limiting the current flow to only what is necessary to maintain this voltage A large amount of current is required to raise the voltage to the absorption level but less current is required to maintain it there This requirement will tend to decrease as long as the absorption level is maintained resulting in a tapering current flow The amount of absorption current will vary with conditions but will typically decrease to a very low number This tops off the tank leaving the battery at 100 of capacity 10 900 0127 01 00 Rev A The battery is considered to be completely full when the following conditions are met The charge current must taper down to an amperage equal to between 1 and 2 of the total battery amp hours while still maintaining the absorption voltage At this point the charger is allowed to exit absorption to the next stage Not all chargers measure their absorption stage in amperes Many chargers maintain absorption for a timed period often two hours under the assumption that the current will taper to the desired level during this time However if the charger exits absorption and ends the ch
24. lel positive to positive negative to negative for additive amp hour capacity Three batteries in parallel have three times the amp hours of a single battery However batteries in parallel do not have Load Bus Load Bus additive voltages A single set of batteries in parallel as shown below have the same voltage as a single battery Series parallel strings It is not recommended to place more than three batteries or three strings in parallel Imbalances between batteries will reduce the efficiency and shorten the life of all batteries Load Bus Parallel batteries Load Bus Figure 7 Parallel and Series Parallel String Configurations Batteries are placed in both series and parallel for both additive voltage and amp hour capacity Series strings placed in parallel have the same nominal voltage as each string They have the same amp hour capacity of each string added together Two parallel strings of two EnergyCell RE batteries in series have a nominal voltage of 24 Vdc twice the nominal voltage See the illustration on the right side of Figure 7 They also have double the amp hour capacity of a single battery Two parallel strings of four batteries in series see Figure 8 havea nominal voltage of 48 Vdc at double the amp hour capacity of a single battery In a series parallel bank it is not recommended to connect the load to the positive and negative terminals of a single string Due to cable resistance this will tend to
25. n excess of 115 Ibs 52 kg Use safe lifting techniques when lifting this equipment as prescribed by the Occupational Safety and Health Association OSHA or other local codes Lifting machinery may be recommended as necessary gt Wear appropriate protective equipment when working with batteries including eye or face protection acid resistant gloves an apron and other items gt Use safety equipment as prescribed by the Occupational Safety and Health Association or other local codes when working on this or related equipment Examples include steel toed safety boots safety hard hats and other items gt Use appropriate safety practices when working with electrical equipment remove all jewelry use insulated tools wear cotton clothing etc gt Never work alone when installing or servicing this equipment Have someone nearby that can assist if necessary gt Wash hands after any contact with the lead terminals or battery electrolyte Battery Safety i WARNING Explosion Electrocution or Fire Hazard gt Ensure the cables are properly sized based on the requirements of devices which use these batteries Failure to size the cables properly can result in a fire hazard Ensure clearance requirements are strictly enforced around the batteries Ensure the area around the batteries is well ventilated and clean of debris Never smoke or allow a spark or flame near the batteries VV V WV Always use insulated tools Avoid dr
26. nnn a A 5 TOOIS USE ony Insured tools ar a alias ince tea demtadareidnee oo os heeds 5 FROCOSS ONCS ois ico ccs ci ssa cP tacit i eal asp de ad T Oe ae ade alee s 5 Storage and Environment REQUIFEMENMS cccsecssscssscscscsscscssssssssesescsescscscsssssssseseesesescscsesesesssseseseseseaescsesssssseesess 6 MF STM VST UU I S a T causaaesacesceetsacpesvanes cece acasces saudsencesennsuan tensa sys seas cendonte ys E sos ts esa eee 6 SelT DISe Marge and PLES SN NING aousi E E E E etree tame AN 6 CA CVI AT EAE AE E A ES N A A E E E E cana 6 ECO CAN G Cai T O re ren aera 7 SVS UCIT yo Uea in teat ar hens E E T E E T E E omietacaued 7 Battery COMP QUT aUl INS eane r T EA O T ARA 7 B ERT E S PEE TE E O TE E E TE E A E E payee E E A E A E A E E 9 CHargiN O zena TERT T RUA A TEA 10 BUIK Stage meae E E A E satiate RARE RMR 10 ADSON UAC a a a a Secu Mauda E A A ttatessu tense ladaceactet aera ates 10 FIO AU Stage nanna a A A NRE 11 Notes ON ChargiNO nsee A EE e a TR 11 lemperature COM PEN Sal OM oeiee ia a EE E A AO 12 Periodic Evaluation and MaiNteNaNce sscsssssssssssssssssssssccsescssssssssssssssesesesessscsssescsesssssssessesesesesssescsesssesseseseseseaes 12 2A HOU OPENA CUIT OS U noniin e a aE ANENE INE tease ONON OLEN OONA 12 25A MO Capacity VCS inean A ET A 12 TOURE ROONG estes anme EE EET NE Rectan E ATOE 13 SPECIEI 6 ON S On E EN TETA TOTON R 14 Ampere Hour Capacity Based On Discharge Rate sssessesssessesseessessessseoseosecssee
27. opping tools onto batteries or other electrical parts Yy Keep plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes gt Wear complete eye and clothing protection when working with batteries Avoid touching bare skin or eyes while working near batteries gt If battery acid contacts skin or clothing wash immediately with soap and water If acid enters the eye immediately flood it with running cold water for at least 20 minutes and get medical attention as soon as possible gt Never charge a frozen battery gt Insulate batteries as appropriate against freezing temperatures A discharged battery will freeze more easily than a charged one gt Ifa battery must be removed always remove the grounded terminal from the battery first Make sure all devices are de energized or disconnected to avoid causing a spark gt Do not perform any servicing other than that specified in the installation instructions unless qualified to do so and have been instructed to do so by OutBack Technical Support personnel gt When connecting cables from the inverter to the battery terminals ensure the proper polarity is observed Connecting the cables incorrectly can damage or destroy the equipment and void the warranty gt Use only the recommended cable sizes or greater for AC and DC conductors in compliance with local codes Ensure all conductors are in good condition Do not operate the system with dam
28. ostal Code or Zip Code ew p C SYSTEM PURCHASE Pesanan O e se o pew 900 0127 01 00 Rev A 15 Product Registration INSTALLATION INFORMATION System Install Commission Date System Array Size System Array Nominal Voltage Type of PV Modules Other Renewable Energy Type and Size System Battery Bank Size Amp Hours Does this system include an auxiliary AC generator If yes please specify brand and model of generator INSTALLER INFORMATION Contractor Number Installer Name Installer Address Installer City State Postal or Zip Code Country Installer Telephone E mail Please check ALL factors affecting purchase decision Product Reputation Back up Capability Reputation of OutBack Power Technologies Value Looks Other OUOUOUOU 16 900 0127 01 00 Rev A Warranty 2 Year Limited Warranty for EnergyCell RE Products OutBack Power Technologies Inc OutBack provides a two year 2 limited warranty Warranty against defects in materials and workmanship for its EnergyCell RE products Product The term of this Warranty begins on the Product s initial purchase date or initial ship date whichever is later This must be indicated on the invoice bill of sale and or registration submitted to OutBack This Warranty applies to the original Product purchaser and is transferable only if the Product remains installed in the original use location This Warranty applies solely to Product
29. red under the EnergyCell RE warranty Temperature Compensation Battery performance will change when the temperature varies above or below room temperature 77 F or 25 C Temperature compensation is a process that adjusts battery charging to correct for these changes When a battery is cooler its internal resistance goes up and the voltage changes more quickly This makes it easier for the charger to reach its voltage set points However while accomplishing this process it will not deliver all the current that the battery requires As a result the battery will tend to be undercharged See Incorrect Charging on page 11 Conversely when a battery is warmer its internal resistance goes down and the voltage changes more slowly This makes it harder for the charger to reach its voltage set points It will continue to deliver energy over time until the charging set points are reached However this tends to be far more than the battery requires meaning it will tend to be overcharged See Incorrect Charging on page 11 To compensate for these changes a charger that is used with the EnergyCell RE battery must have its voltage settings raised by a specified amount for every degree below 77 F 25 C It must be lowered by a similar amount for every degree above this temperature The temperature compensation factor is 0 03 Vdc 30 mV per battery or 5 mV per battery cell for every degree C above or below this temperature This factor also is m
30. ribute to thermal runaway Fully charged battery Low temperature Carefully warm up the battery displays high voltage Voltage Individual battery charging Shorted cell Test and replace battery as necessary A testing voltage will not exceed shorted cell may contribute to thermal 13 3 Vdc high float current runaway failure to support load Individual battery float Open cell Test and replace battery as necessary voltage exceeds 14 5 Vdc failure to support load Charging current to series Open connection or open Check and clean all connections If battery string is zero failure to battery cell in string appears to have an open cell test and replace support load as needed Replace hardware as needed Current Charging current to series Batteries require additional Normal behavior no action necessary testing string remains high over time time to charge Charging current to series Shorted cell may contribute Test and replace battery as necessary string remains high with no to thermal runaway corresponding rise in voltage 900 0127 01 00 Rev A 13 Specifications Table2 EnergyCell RE Front Terminal Battery Specifications Battery Category Valve regulated lead acid VRLA Battery Technology Absorbed glass mat AGM Cells Per Unit a lt n Voltage Per Unit nominal Operating Temperature Range Discharge 40 F 40 C to 160 F 71 C with temperature compensation Charge 10 F 23 C to 140 F 60 C Optimal Op
31. rminal voltage is 10 5 volts per 12 volt battery or 1 75 volts per cell The amp hours measured upon reaching terminal voltage also depend on the size of the load A load capable of discharging the battery in one hour is far larger than a load which takes 3 4 or 5 hours 8 hour loads 12 hour loads etc are progressively smaller in size As described on page 6 the battery has less capacity under larger loads and more capacity under smaller loads Under a 1 hour load the EnergyCell 170RE has only 89 1 amp hours Under a much lighter 100 hour load the same battery has 170 amp hours almost twice that amount The EnergyCell 200RE is measured similarly 14 900 0127 01 00 Rev A Product Registration The purchase of an OutBack Power Technologies product is an important investment Registering the products will help us maintain the standard of excellence expected in terms of performance quality and reliability Please take a moment to register and provide us with some important information Registration can be done as follows gt Goto the following website http www outbackpower com resources warranty or gt Fill out the information on this form pages15 and 16 and return a paper copy using a postal service to the following address OutBack Power Technologies Attn Warranty Registration 5917 195 Street N E 7 Arlington WA 98223 USA Be sure to keep a copy for your records SYSTEM OWNER a e City State P
32. s installed and operated in the United States Canada or other country which is approved by Outback in writing The Warranty does not apply to any Product or Product part that has been modified or damaged by the following Installation or removal Normal wear and tear Accident abuse or neglect Shipping or transportation Lightning fire floods or acts of God Incidents not foreseeable by OutBack Operation with temperature variation more than 5 F 2 78 C between cells Routine or daily discharge of more than 40 of capacity Charging discharging or commissioning contrary to instructions Incidental or consequential damage caused by other system components Alteration disassembly or service provided by an unauthorized facility Any other battery make model in the same battery bank as the Product VVVVV V VVVVV V If the Product delivers at least 60 of its rated capacity during the Warranty period and is not judged defective by OutBack in any other way no breach of this Warranty will be deemed to have occurred OutBack s liability for any defective Product or any Product part shall be limited to the repair or replacement of the Product at OutBack s discretion OutBack does not warrant or guarantee workmanship performed by any person or firm installing its Products This Warranty does not cover the costs of installation removal shipping or reinstallation of Products or parts of Products Warranty support will not be provided for a Prod
33. ssessesseessesseoseroseoseesseoseeseessessesseesseosesseesses 14 PFOGUCE REGIS atO scsveseseadecdsssedcuvetsoccusesvdecvassetecdesswesccescetecsenaccescesendeccessce O Wa rra nty 0000000 OOOO OOHOOHOOHOHHOHHOHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHHOHHOHHHHHOHHOHHHHHHHHHHHHHHHHHHHH0H88HO888 1 7 2 Year Limited Warranty for EnergyCell RE Products ccssssssssssssssscsssessssssesscsssecscssssssssesessssessssssescseeessseeees 17 How 1o Arrange for Warranty SEVICE esner erruna a A A 17 GTO UD LSS OLIN G anan a A A E E N 17 4 900 0127 01 00 Rev A EnergyCell RE Battery Welcome to OutBack Power Systems Thank you for purchasing the EnergyCell RE battery This product is a valve regulated lead acid VRLA battery This type of battery incorporates an absorbent glass mat and pasted lead calcium tin plates It is intended for use in backup off grid and renewable energy RE applications The EnergyCell RE is designed to provide long reliable service with minimal maintenance Intended for use with all OutBack inverters charge controllers and other devices that require the use of deep cycle batteries High density pasted plates for high cycle life Lead calcium tin alloy plates for long life in both cycling and float applications High recharge efficiency Compact footprint for higher energy density Thermally welded case to cover bond to eliminate leakage 100 recyclable UL recognized component Figure 1 EnergyCell RE Battery Materials Requ
34. uct for which the Warranty period has expired THIS LIMITED WARRANTY IS THE EXCLUSIVE WARRANTY APPLICABLE TO OUTBACK PRODUCTS OUTBACK EXPRESSLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIED WARRANTIES OF ITS PRODUCTS INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OUTBACK ALSO EXPRESSLY LIMITS ITS LIABILITY IN THE EVENT OF A PRODUCT DEFECT TO REPAIR OR REPLACEMENT IN ACCORDANCE WITH THE TERMS OF THIS LIMITED WARRANTY AND EXCLUDES ALL LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION ANY LIABILITY FOR PRODUCTS NOT BEING AVAILABLE FOR USE OR LOST REVENUES OR PROFITS EVEN IF IT IS MADE AWARE OF SUCH POTENTIAL DAMAGES IF YOU ARE A CONSUMER THAT PURCHASED THIS PRODUCT IN A MEMBER STATE OF THE EUROPEAN UNION YOU MAY HAVE ADDITIONAL STATUTORY RIGHTS UNDER DIRECTIVE 1999 44 EC THESE RIGHTS MAY VARY FROM EU MEMBER STATE TO EU MEMBER STATE SOME STATES OR JURISDICTIONS MAY NOT ALLOW THE EXCLUSION OR LIMITATION OF WARRANTIES OR DAMAGES SO THE ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY TO YOU How to Arrange for Warranty Service In the event of a failure Warranty service is provided by the installer dealer or distributor Defective Product will be replaced under Warranty In the event that the installer dealer or distributor cannot provide support or needs more information contact OutBack Technical Support at 1 360 435 6030 or direct at 1 360 618 4363 or support out
35. ultiplied if additional batteries are in series Failure to compensate for significant temperature changes will result in undercharging or overcharging which will shorten battery life OutBack inverter chargers and charge controllers are equipped with the Remote Temperature Sensor RTS which attaches to the battery and automatically adjusts the charger settings by this amount If the RTS is in use no further action needs to be taken If an RTS is not present or a different charger is in use it may be necessary to adjust the charger settings manually When the RTS is used it should be placed on the sidewall of the battery as close to the center of the battery or to the center of the bank as possible The RTS should be checked periodically Failure to compensate correctly may result in wrong voltages See Incorrect Charging on page 11 Periodic Evaluation and Maintenance Upon replacement of a battery or string all interconnect hardware should be replaced at the same time To keep track of battery performance and identify batteries that may be approaching the end of their life it is recommended to perform the following tests upon initial installation and then on a quarterly basis afterward The battery must be fully charged Tests must be made with a high quality digital meter Voltages must be measured directly on battery terminals not on other conductors All connections must be cleaned re tightened and re torqued before testing If a
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