EnergyCell PLR Series Owner’s Manual
About OutBack Power Technologies OutBack Power Technologies 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: Corporate Headquarters 17825 – 59th Avenue N.E.
Table of Contents EnergyCell Batteries ...................................................................... 5 Welcome to OutBack Power Technologies ............................................................................... 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 Technologies 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 Batteries 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 fork lift 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 (provided with front terminal batteries only) o Terminal cover (provided
Installation and Operation Self-Discharge No EnergyCell should ever be permitted to self-discharge below 70% state of charge (SoC). Such a condition is highly detrimental and will shorten battery life. (This situation is not the same as discharging to 70% SoC or lower under load. See page 8.) 2.17 100 2.16 96 2.15 91 2.14 87 2.13 83 2.12 79 2.11 2.
EnergyCell Batteries State of Charge 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 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. 90 % of Expected Life The EnergyCell SoC can be determined by two methods. One is to measure its voltage.
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 Batteries 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 Batteries To make the DC connections: Make certain to clean all terminals and contact surfaces according to the steps on page 11. 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 21 for the recommended float voltage.
EnergyCell Batteries The battery is considered to be completely full when the following conditions are met: The charge current decreases to a level of current equal to between 1% and 3% of the total battery amp-hours while maintaining the absorption voltage. At this point the charger is allowed to exit the absorption stage and enter the next stage. NOTE: Not all chargers use return amps. Many chargers absorb for a timed period (one or two hours), assuming that the current will decrease to that level.
Installation and Operation Notes on Three-Stage Charging The current requirements for absorption and float stages are usually minimal. This varies with conditions, with battery age, and with bank size. (Larger banks tend to have higher absorption exit current values, but they also have higher float current.) Any loads operated by the battery while charging will also impact the charger requirements, as the charger sustains everything. Not all chargers exit directly to the float stage.
EnergyCell Batteries Improper Use CAUTION: Equipment Damage Read all items below. Maintenance should be performed as noted on page 18. Failure to follow these instructions can result in battery damage which is not covered under the EnergyCell warranty. CAUTION: Equipment Damage Do not exceed the specified absorption voltage when charging any EnergyCell battery. Excessive voltage could result in battery damage which is not covered under the EnergyCell warranty.
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.
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Maintenance 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 13). Tests must be made with a high-quality digital meter. Voltages must be measured directly on battery terminals, not on other conductors.
EnergyCell Batteries Annual battery inspection This should include the monthly and quarterly observations, plus: o Inter-cell / inter-unit connection integrity. o Retighten terminals to specified torque values. See Table 2 on page 21 for specifications. o Record findings clearly. List the dates for all entries.
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.
EnergyCell Batteries NOTES: 22 900-0230-01-00 Rev A
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