EnergyCell PLR Series Owner’s Manual
About OutBack Power OutBack Power is a leader in advanced energy conversion technology. OutBack 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. Applicability These instructions apply to OutBack EnergyCell PLR series batteries only. Contact Information Address: 17825 – 59th Avenue N.E. Suite B Arlington, WA 98223 USA Website: www.
Table of Contents EnergyCell Batteries ...................................................................... 5 Welcome to OutBack Power ..................................................................................................... 5 Audience ................................................................................................................................... 5 EnergyCell PLR Front Terminal Battery ....................................................................................
Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS! This manual contains important safety instructions for the EnergyCell PLR battery. These instructions are in addition to the safety instructions published for use with all OutBack products. Read all instructions and cautionary markings on the EnergyCell 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.
EnergyCell Batteries Welcome to OutBack Power Thank you for purchasing the OutBack EnergyCell battery. EnergyCell is a series of absorbed glass-mat (AGM) batteries with a valve-regulated lead-acid (VRLA) design. They are designed to provide long, reliable service with minimal maintenance. Several versions are available, including front-terminal and top-terminal designs. All have high recharge efficiency and a compact footprint for higher energy density.
EnergyCell PLR Materials Required Tools (use insulated tools only) o Digital voltmeter o Socket wrench, insulated o Torque wrench calibrated in inch-pounds o Box end wrench, insulated o Battery lifting equipment (handles) and forklift to lift pallets of batteries o Rubber gloves o Full face shield o Plastic apron o Portable eyewash o Spill kit o Fire extinguisher (class C) Accessories o Interconnect bar o Terminal cover o Hardware kit o Interconnect cables as needed CAUTION: F
Installation and Operation NOTES: 900-0230-01-00 Rev B 7
EnergyCell PLR Storage and Environment Requirements Temperatures o To achieve maximum life of EnergyCell PLR batteries, it is recommended not to operate them in average ambient temperatures exceeding 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 9). o Do not allow batteries to freeze, as this will damage them and could result in leakage.
Installation and Operation Capacity Because the battery’s chemical reaction constantly releases energy, its level of depletion is not always obvious. Smaller loads will deplete the batteries less than larger loads, so the battery has more capacity under lighter loads. 120 % of Rated Capacity Battery 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.
EnergyCell PLR The more accurate method of SoC measurement is to use a battery monitor such as the OutBack FLEXnet DC. Using a sensor known as a shunt, the monitor observes the current through the battery. It keeps a total of amp-hours lost or gained by the battery and can give accurate SoC readings. 8,000 % of Expected Life The EnergyCell PLR can be discharged and recharged (cycled) regularly to a level as low as 50% depth of discharge (DoD).
Installation and Operation Battery Configurations Load – Load + Load – Series String (24 Vdc) Load + 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 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.
EnergyCell PLR 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 batteries in series have a nominal voltage of 24 Vdc, twice the nominal voltage. They also have double the amp-hour capacity of a single battery.
Installation and Operation DC Wiring CAUTION: Equipment Damage Never reverse the polarity of the battery cables. Always ensure correct battery 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.
EnergyCell PLR To make the DC connections: Make certain to clean all terminals and contact surfaces according to the steps on page 13. 1. If installing batteries in a rack or cabinet, always begin with the lowest shelf for stability. Place all batteries with terminals facing to the most accessible side of the rack. If terminal protectors are present, remove and save them. 2. In common configurations, the battery on one end will be the positive (+) output for that string.
Installation and Operation Commissioning The commissioning charge applies when the batteries have been in storage or transit for an extended period. It should be applied before conducting a capacity discharge or fully loaded duty cycle test. In float applications the commissioning charge consists of 7 continuous days of float charge with no battery load. See Table 3 on page 23 for the recommended float voltage.
EnergyCell PLR Absorption Stage Absorption is a constant-voltage stage. It is established upon reaching the voltage target at the end of the bulk stage. The charger maintains this voltage as the charging current decreases until the batteries are full. A large current is needed to raise the voltage to absorption level. Less is required to maintain it there. This requirement tends to decrease as long as the absorption level is maintained.
Installation and Operation Constant-Float Charging “Constant-float” charging may be used with the EnergyCell PLR in backup power applications where the battery bank is rarely discharged. When a battery discharge occurs, it is critical to recharge the bank as soon as possible afterward. The voltage range is listed in Table 3 on page 23.
EnergyCell PLR Remote Temperature Sensor 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. When the RTS is used, it should be placed on the battery sidewall, as close to the center of the battery (or to the center of the bank) as possible. The charger determines the RTS compensation factor. Most OutBack chargers are preset to a compensation of 5 mV per cell.
Troubleshooting and Maintenance Table 1 Troubleshooting Category Symptom Possible Cause Normal life cycle Replace battery bank when (or before) capacity drops to unacceptable levels. Defective cells Test and replace battery as necessary. Excessively cold battery Carefully warm up the battery. Undersized cabling Increase cable ampacity to match loads. Loose or dirty cable connections Check and clean all connections. Physical damage on terminals may require the battery to be replaced.
EnergyCell PLR Periodic Evaluation Upon replacement of a battery (or string), all interconnect hardware should be replaced at the same time. To keep track of performance and identify batteries that may be approaching the end of their life, perform the following tests during on a quarterly basis following commissioning (see page 15). Tests must be made with a high-quality digital meter. Voltages must be measured directly on battery terminals, not on other conductors.
Maintenance Quarterly Battery Inspection This should include the monthly observations, plus: o End of charge voltage of every cell and battery terminal voltage measured at battery. o End of discharge voltage of every cell and battery terminal voltage measured at battery. o Temperature of electrolyte in representative cell(s), typically one cell/tier distributed throughout the battery. o Record findings clearly. List the dates for all entries.
EnergyCell PLR Battery Voltage Records Date: Date: Date: Battery 1 Battery 2 Battery 3 Battery 4 Battery 5 Battery 6 Battery 7 Battery 8 Battery 9 Battery 10 Battery 11 Battery 12 Battery 13 Battery 14 Battery 15 Battery 16 Battery 17 Battery 18 Battery 19 Battery 20 Battery 21 Battery 22 Battery 23 Battery 24 22 900-0230-01-00 Rev B
Specifications Table 2 EnergyCell PLR Specifications Item Specification Battery Category Valve-regulated, lead-acid (VRLA) Battery Technology Absorbed glass-mat (AGM) Cells Per Unit 6 Voltage Per Unit (nominal) 12 Vdc Cycle Life (50% DoD, 1.75 Vpc) 1500 cycles Operating Temperature Range (with temperature compensation) –40°F (–40°C) to 113°F (45°C) Optimal Operating Temperature Range 68°F (20°C) to 77°F (25°C) Store up to 18 months at 77°F (25°C) before a freshening charge is required.
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