BATTERY USER MANUAL Recommended installation, charging and maintenance procedures for Rolls deep cycle Flooded,VRLA AGM & OPzV GEL batteries.
FLOODED AGM GEL RENEWABLE ENERGY MARINE MOTIVE POWER
TABLE OF CONTENTS 02 Equipment & Safe Handling Procedure 02 Inspection 03 Quick Check List 03 Disposal Procedure 04 Installation 04 Battery Orientation 04 Cable Sizing 05 Warning 05 Terminals 06 Parallel & Series Connections 09 Inspection & Initial Charge of Flooded Lead-Acid Batteries 10 Rolls Flooded Lead-Acid Battery Charging 10 Bulk Charge, Absorption Charge 11 Absorption Charge Time - Flooded 11 Float Charge, End Amp or Return Amps 12 Low Voltage Disconnect 13 Rolls Flooded Battery Charge Voltage Param
Rolls Battery has been manufacturing deep cycle lead-acid batteries since 1935. Experience and commitment to quality has helped us achieve an unmatched reputation in the industry. Our goal is to provide our customers with a premium product providing dependable performance and long-lasting cycle life. This manual provides the recommended setup, charging, Equalization and preventive maintenance procedures necessary to maximize the life of your Rolls batteries.
QUICK CHECK LIST SHIPPING/RECEIVING (MUST INSPECT PRIOR TO DRIVER RELEASE!) • All parts are included • No acid spill • No visual damage to the batteries • Verify electrolyte levels INSTALLATION • Protective equipment should be worn • All electrical components should be turned off • Acid spill cleanup material should be readily available INITIAL CHARGE • Verify electrolyte levels (add distilled water as necessary) • Measure specific gravity • Set up battery charge voltage/current limits GENERAL • Safety firs
INSTALLATION Rolls deep cycle batteries are manufactured for use in a variety of applications. In all cases, it is important that the battery is installed securely, free of contaminants and that all connections are in good contact with the terminals. For all Rolls models it is recommended that the batteries are separated 2.5cm-7.5cm (1"-3”) inches apart to allow proper airflow, cooling and ease of maintenance.
CABLE SIZING Cabling should be proportionate to the amperage of your system. The following table notes the maximum current carrying capacity based on cable gauge. Battery cables should be selected allowing a maximum voltage drop of 2% or less across the entire length of the cable. Interconnection cables (battery to battery) should also be sized at the same gauge and of equal length between connections.
Flooded LEAD-ACID TERMINALS Terminal connections should be tightened to 25 ft/lbs or 33 N.m for all Flooded Series 4000, 4500 & 5000 models. VRLA AGM & OPzV GEL TERMINALS Torque settings vary by terminal type, please refer to the chart below and/or provided specifications. Contact Rolls Battery Technical Support if your terminal type is not listed. AGM-S & AGM-R Terminals Torque N.m Button Terminal (M8) Button Terminal (M10) AP LT DT (AP and stud terminal) M6 (TP08) M8 (TP08) OPzV GEL Terminals 9.6-10.
To increase capacity and voltage, connect the batteries in series parallel as shown in Figure 2.
FLOODED LEAD-ACID BATTERIES
INSPECTION & INITIAL CHARGE OF FLOODED LEAD-ACID BATTERIES WARNING • ALWAYS WEAR THE PROPER PERSONAL PROTECTIVE EQUIPMENT (GOGGLES, GLOVES, CLOTHING) WHEN HANDLING FLOODED BATTERIES AND ELECTROLYTE. • WET BATTERIES MUST BE FULLY CHARGED BEFORE BEING DELIVERED TO THE END USER. • UNLESS INSTRUCTED BY ROLLS TECHNICAL SUPPORT, NEVER ADD ACID TO THE BATTERIES AT ANY TIME. USE DISTILLED WATER ONLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN MALFUNCTION AND WILL VOID WARRANTY.
FLOODED LEAD-ACID BATTERY CHARGING INITIAL CHARGE Although all Rolls batteries are tested and charged prior to shipping, batteries will self-discharge when stored and not in use. Upon installation, the initial charging may take 10+ hours or more depending on the size of the battery bank and charge current. Once the battery is fully charged, recheck the electrolyte level in the cell. The fluid should be 6-12mm (1/4”-1/2”) below the vent tube on each cell as shown in Figure 7.
ABSORPTION CHARGE TIME - FLOODED Where : T = 0.42 x C /I T = ABSORPTION CHARGE TIME C = 20 hr RATED CAPACITY (total battery bank) I = Charging Current (Amps) (recommended 10-20% of C/20 discharge rate for Flooded models) 0.42 = ( 20%/50%) + 5% (5% is added due to losses) EXAMPLE: 2 strings of 6 Volt 6 CS 25P models 20 hr AH rate = 853 AH x (2 strings) = 1706 AH I = 10% of 1706 AH = 170 Amps (10-20%, 170-340 Amps) T = 0.42 x 1706/170 = 4.2 hrs However, if maximum charger output is 120 Amps, 120 is used.
WARNING: The End Amps or Return Amps setting combined with a sulfated battery may confuse the charger, cause a state of charge reset prior to actually reaching 100% SOC. Check specific gravity regularly to confirm the battery bank reaches 100% SOC as this set point may require adjustment.
ROLLS FLOODED BATTERY CHARGE VOLTAGE PARAMETERS NOTE: Use the highlighted voltage set points when charge equipment is supplied with a temperature sensor. Set at 5mV/ºC/Cell...(+/- 120mV per ºC from a 25ºC Delta - 48V System) TABLE 2 (a): Flooded Charging Parameters: Regular Cycling - daily to 48-hour cycling (max 50% DOD) with limited charge time (solar). Example: full-time off-grid applications and Partial State of Charge (PSOC) recovery.
TEMPERATURE COMPENSATION & SENSOR INSTALLATION For charge accuracy and safety, many systems use a sensor mounted to the battery to measure cell temperature and adjust charge voltage accordingly. Temperature sensors should be installed directly on the side of a cell or battery in the center of the bank and must be securely mounted below the electrolyte level to determine accurate cell temperature. See Figure 6 Temperature Sensor below.
SPECIFIC GRAVITY The specific gravity of electrolyte in a battery is the most accurate measurement of actual state of charge. To determine if the batteries have reached full SOC, testing should be done when the charge cycle has been completed and the battery bank is resting a Float voltage. The specific gravity (SG) reading should remain constant for 3+ hours for an accurate 100% SOC reading.
BATTERY MAINTENANCE & STORAGE Batteries should be kept clean at all times. If installed or stored in a dirty location, regular cleaning should be performed. Before doing so, assure that all the vent caps are tightly fastened. Using a solution of water and baking soda (100g per litre), gently wipe the battery and terminals with a damp sponge, then rinse with water and wipe dry. A common cause of failure with Flooded battery banks is poor maintenance.
MAINTENANCE SCHEDULE For the first 12 months of usage, the following tests should be completed: MONTHLY • Measure and record resting/loaded voltage • Check electrolyte levels and top up with distilled water as necessary • Test and record specific gravity measurements in Float charge • Record ambient temperature where the batteries are installed • Inspect to ensure temperature sensor is securely attached • Inspect cell integrity for corrosion at terminal, connection, racks or cabinets • Check battery monitor
WINTER STORAGE Prior to placing Flooded batteries into winter storage, charge to 100% SOC and make certain the liquid level is approximately 13 mm (1/2”) above the top of the separators. Electrolyte in a very cold battery will be lower than normal. Allow the battery to warm to a normal ambient temperature before judging electrolyte levels. Self-discharge rate will vary by ambient temperature. Apply a refresher charge as necessary when stored for extended periods.
EQUALIZATION Individual cell readings will vary slightly in specific gravity after a charging cycle. Equalization, or a “controlled overcharge", is required to bring each battery plate to a fully charged condition. This reduces stratification and build-up of sulfation on the plates; two circumstances that shorten battery life.
PREPARATION: - Required Equipment: protective goggles, rubber gloves & rubber boots, hydrometer or refractometer, voltmeter, distilled water, baking soda or soda ash for possible overflow or spills - Standard 1/4-turn bayonet caps and Rolls R-Cap flip-top recombination caps may be left on during this procedure. Dirty or clogged caps may prevent the release of hydrogen gas. Inspect and clean caps as necessary. Hydrocaps must be removed.
Allow the battery bank to cool for 1-2 hours. Check and record the specific gravity of each cell. The gravities should be 1.265 ± 0.005 or lower. Check electrolyte levels and add distilled water as necessary. It is recommended that a specific gravity reading of one pilot cell is measured and recorded on a regular basis when it is thought that the bank is fully charged. The measurement should be compared to previous readings.
VRLA AGM BATTERIES
ROLLS VRLA AGM BATTERY CHARGING INSTRUCTIONS To maximize the life of your Rolls VRLA AGM battery, it is important that it is properly charged. Over or undercharging a VRLA AGM battery will result in shortened cycle life. The best protection from improper charging is to use a quality charger and routinely checking that the charge current and manufacturer-recommended voltage settings are properly maintained.
VRLA AGM ABSORPTION CHARGE TIME Where : T = 0.38 x C /I T = ABSORPTION CHARGE TIME C = 20 hr RATED CAPACITY (total battery bank) I = Charging Current (Amps) (recommended 20% of C/20 discharge rate) 0.38 = ( 20%/50%) + 5% (5% is added due to losses) EXAMPLE: 2 strings of 6 Volt S6-460AGM models 20 hr AH rate = 415 AH x (2 strings) = 830 AH I = 20% of 830 AH = 166 Amps T = 0.38 x 830/166 = 1.9 hrs NOTE: If charger output is 120 Amps max, 120 is used. T = 0.38 x 830/120 = 2.
VRLA AGM CHARGE EFFICIENCY/CHARGE FACTOR Charge efficiency is a measure of the energy you may take out of a charged battery divided by the energy required to charge it. Charge efficiency will depend on a number of factors including the rate of charging or discharging. VRLA AGM batteries have an average charge efficiency of ~85%. This should be reduced 1% per year after the third (3) year of operation.
OPzV GEL BATTERIES
ROLLS OPzV GEL BATTERY INSTALLATION & CHARGING Designed and well-suited for regular cycling as well as float and backup applications, Rolls sealed OPzV GEL batteries have a low internal resistance than Flooded deep cycle models allowing quick recharge and a low self-discharge rate (2% per month). Rolls OPzV GEL batteries perform well in installations requiring frequent cycling even under extreme operating conditions and offer more than 20 year cycle life in float applications at 25ºC (77ºF).
OPzV GEL CHARGER INSPECTION The charger cabling should be insulated and free of breaks or cuts. The cable connectors should be clean and properly mated with the battery terminals to ensure a snug connection. The charger’s AC cord should be free of breaks or cuts and the wall plug should be clean. OPzV GEL CHARGING GUIDELINES To maintain good health, VRLA AGM batteries should be brought to a full charge on each cycle or, at minimum, once every 6-7 days.
OPzV GEL ABSORPTION CHARGE TIME Where : T = 0.38 x C /I T = ABSORPTION CHARGE TIME C = 20 hr RATED CAPACITY (total battery bank) I = Charging Current (Amps) (recommended 20% of C/20 discharge rate) 0.38 = ( 20%/50%) + 5% (5% is added due to losses) EXAMPLE: NOTE: 1 string of 2-Volt S2-1380GEL models 20 hr AH rate = 1571 AH I = 20% of 1571 AH = 314 Amps T = 0.38 x 1571/314 = 1.9 hrs If charger output is 288 Amps max (ex 3 x 96 Amp controllers), 288 is used. T = 0.38 x 1571/288 = 2.
RENEWABLE ENERGY APPLICATIONS
RENEWABLE ENERGY APPLICATIONS Most deep cycle batteries used in the Renewable Energy Industry were originally designed and manufactured for use in commercial and industrial applications where consistent charge cycles are carried out from six to twelve hours until the batteries reach a full state of charge.
CYCLE LIFE VS. DEPTH OF DISCHARGE – ROLLS BATTERY ENGINEERING SERIES 5000 WITH ADVANCED NAM Off-grid Renewable Energy systems are typically sized to operate between 20% and 50% DOD. Deep cycle batteries should be used to a maximum 50% DOD as this offers a balance between capacity vs. cycle life, also taking into consideration the cost of replacement.
BATTERY SELECTION FOR OFF-GRID SYSTEMS Choosing the appropriate battery for the application is key to long battery life and performance. Once the load is calculated, a battery bank should be selected to meet the system design as well as installation requirements. Flooded lead-acid models using lead-antimony plates require frequent cycling to maintain capacity and prevent sulfation buildup.
DISCHARGE RATES Discharge and recharge rates should be considered when selecting and sizing a battery bank. Battery manufacturers publish multiple discharge rates for each battery model, which range from 100 hrs to 1 hr. These are often referenced for various type of applications. The most common in Renewable Energy applications is the 20 hr rate as this closely matches a 1 day period.
GRID-CONNECTED BACKUP There are two distinct uses for a grid-connected battery bank. The first, and the most common is a power backup system. The purpose is to provide temporary power in the instance of grid loss. This is simular to a UPS system, but is typically on a much larger scale with higher storage capacity. The second is a grid-tied system with battery backup.
WARRANTY GLOSSARY & FAQ'S
WARRANTY We build one mean battery and we back them with comprehensive warranties that lead the industry in length of coverage. We’re confident that our batteries will perform time after time, year after year. However, should a problem arise, you may be assured that you're covered better than any other battery warranty in the business.
ROLLS BATTERY WARRANTY PROCEDURE Please refer to product warranty for the specific model as terms and conditions may vary. For warranty requests and inquiries, please submit your request via support ticket (www.rollsbattery.com/support) or by email to support@rollsbattery.com. DAMAGED BATTERY YES Damaged batteries DO NOT qualify for Rolls Battery product warranty NO Check individual cell voltages < 2.1 VPC Charge battery at 0.1/C/20 for 10 hours Cells < 1.250 Charge battery at 0.
LEAD-ACID BATTERY GLOSSARY ABSORBED (OR ABSORPTIVE) GLASS MAT A type of sealed lead-acid batteries. The electrolyte is absorbed in a matrix of glass fibers which holds the electrolyte next to the plate and immobilizes it, preventing spills. AGM batteries tend to offer good power characteristics, low internal resistance and high charge efficiency. AMP, AMPERE Unit of electrical current. Abbreviated “A”. AMP-HOUR, AMPERE-HOUR Unit of electrical energy, one Amp of current flowing for one hour. Abbreviated AH.
HYDROMETER A tool for testing the specific gravity of a fluid such as the electrolyte in a Flooded battery. Hydrometers use a squeeze-bulb to suck up a sample of the fluid and a float indicates the specific gravity of the electrolyte. REFRACTOMETER A tool for testing the specific gravity of a fluid such as the electrolyte in a Flooded battery. Refractometers are hand-held devices which provide a visual reading of specific gravity using a sample of the electrolyte placed on a glass slide.
TROUBLESHOOTING & FREQUENTLY ASKED QUESTIONS The following is a list of common scenarios, questions and concerns relating to system setup, battery charging and maintenance procedures. Please refer to these as general guidelines. For assistance with your specific system setup, please contact your Installer. NOTE: specific gravity readings should be taken at full charge after the batteries have cooled and are resting in a Float voltage charge for 1-2 hours.
• Confirm End Amps is programmed to 2-3% of C/20 (Series 4000) or 2-5% (Series 4500 & 5000 with Advanced NAM). • Decrease Bulk/Absorption/Boost Voltage in .2v to .4v volts increments. •D ecrease Absorption Time by 15 to 30 minutes increments as necessary. Clean and inspect all cabling and connections. Physically disconnect cable, inspect for terminal concaving (Over torqued), grease and re-torque connections.
• Battery(s) temperatures are very high. • If at or near 51˚C (125˚F) shut off charge and allow batteries to cool. • If a single battery or cell in a string is hot, this may indicate a cell failure or short. Verify specific gravity for all cells and take voltage readings from each battery and perform a load test to identity any cell failures and verify proper cell operation. • Battery cases are bulging on the sides.
• Battery cover has cracked, shattered and/or dislodged from the case • (Not affecting positive and negative terminals or connections). • Ignition of hydrogen gas may have caused the battery cover to crack or explode. • This sometimes occurs during a charge where a loose connection at the terminal sparked, igniting hydrogen gas from the cell. • This may be the result of low electrolyte levels causing high cell temperature and increased hydrogen gas.
• Charging current to the battery bank (Amp output) is low. •C harging current will decrease as the batteries become fully charged. If charge current is low the battery bank may have reached the end of the charge cycle. Verify that the charger is nearing the end of Absorption time or in Float voltage phase. Low current is normal this stage of charging. • T he battery bank self-regulates charge current.
CONTACTS Surrette Battery Company Ltd. PO Box 2020, 1 Station Road Springhill, Nova Scotia, Canada B0M 1X0 PHONE: 1 902 597 3767 (local) 1 800 681 9914 (toll free) FAX: 1 902 597 8447 (local) 1 800 681 9915 (toll free) CUSTOMER SERVICE: 1 902 597 4005 customerservice@rollsbattery.com SALES: 1 902 597 3767 (local) 1 800 681 9914 (toll free) sales@rollsbattery.com TECHNICAL SERVICE: 1 902 597 3767 (phone) 1 800 681 9914 (toll free) support@rollsbattery.com TECHNICAL SUPPORT TICKET: support.rollsbattery.
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