User Manual
Contents
1. 4 1 The CNFJ range of batteries should be charged according to the specified voltages and currents indicated in chapter 2 4 2 The CNFJ range of batteries should be discharged according to the termination voltage specified in chapter 2 and in accordance with the equipment requirements This will ensure long life of both the battery and the equipment Battery maintenance 5 1 Perform an inspection of the batteries prior to installation 5 1 1 Check for damage to ABS plastic shell 5 1 2 Check batteries open circuit voltage and calculate the per cell voltage if the voltage is less than 2 1V Cell The batteries should be charged individually to correct the balance 5 1 3 Make a battery maintenance and operation file and record all relevant information during the life of the battery 5 2 Operating maintenance 5 2 1 Monthly inspection and maintenance Content Method Inspection standard Solution The total voltage when the Battery is Equipment should be calibrated with an deviation of Total voltage charging and discharging voltage Adjust charging and discharging voltage voltage x quantity of batteries in the group 1 Ac replace defective charging and no more than 0 5 volt before x quantity of batteries in i alice I oe battery ies if individual discharging testing batteries in a group the group charging does not bring the voltage back to required level Use the voltmeter to Controller meas2. The CNFJ range is specially designed for alternative energy storage It accepts a wide range of charging currents and does not rely on high currents to start and maintain the chemical reaction making it the perfect storage battery for solar and wind generators that deliver intermitted charging at variable and interrupted currents 2 Product Features The birth of the lead crystal battery is a revolutionary technological breakthrough in the battery industry It solves most defects of lead acid and gel batteries such as serious environmental pollution low fast charging ability plate sulphuric acid sulphation short cycle life and low temperature performance ability are amongst a few A lead crystal battery combines all the advantages of long cycle life high efficiency low and high temperature resistance low internal resistance and environmental safety to make it a much more superior product 2 1 Structure characteristic 2 1 1 Special Electrolyte Composition By using a unique blending technology we are able to combine a variety of inorganic salts and organic substances to co ordinate a combined reaction to improve the reaction ability between the electrolyte and active material on the lead plates The electrolyte prevents the active material from becoming brittle and falling of the plates improving the cycle life After several charge and discharge cycles the liquid electrolyte transforms into a crystallized state leaving no free liquid electro
3. current A 0 01C 0 01 multiplied by the 10 hour rated capacity used for the discharge current A The curve graph below indicates different constant discharge currents over time of discharge at a temperature of 25 C and its effect on terminal voltage q o ll 4 p _ i 1 i t i I I I L E Dna eneuposce qe sas csapes 0 1 2 4 6 8 10 20 40 60 2 4 6 8 10 20 40 100 lt Minute e Hour gt Duration of discharge www bettabatteries com POWERED BY info bettabatteries com Betta Batteries 1 2 2 The influence of temperature on the capacity In Figure 1 you will notice the effect of temperature on the capacity of the CNFJ series lead crystal batteries To calculate the capacity of the battery when the environmental temperature is not 25 C the below formula is used Ct the actual capacity at a certain temperature t the environmental temperature at the time of discharge C K the temperature coefficient 10 hour rate coefficient is 0 006 120 7 100 Capacity 80 60 40 20 0 40 30 20 10 0 10 20 30 40 50 60 Temperature c Figure 1 CNFJ series lead crystal cell relationship between discharge capacity and temperature 1 2 3 Discharge termination voltage The termination voltage refers to the battery voltage dropping during discharge and falls to the minimum working voltage required for operatio
4. e Q TDZGO5 2010 fixed type valve control sealed lead crystal battery e BS 6290 part 4 Telcordia SR 4228 Eurobatt guide UL IEC 60896 21 22 www bettabatteries com POWERED BY info bettabatteries com Betta Batteries Chapter 2 Technical characteristics 1 Discharge characteristics Terminal voltage V cell 1 1 Battery capacity definition Batteries under certain discharge conditions will release a certain amount of current This amount od current released is called the capacity The symbol used to identify the capacity is C The commonly used unit of measure is Amp Hours Ah 1 1 1 The battery capacity The battery capacity can be defined in two parts namely rated capacity and actual capacity under different discharge conditions The actual capacity of the battery under certain discharge conditions is calculated by the current A multiplied by the discharge time h The resulting unit is Ah 1 2 Influencing factors on the battery capacity 1 2 1 Discharge rate to influence the capacity The battery discharge rate uses rated hours to determine the discharge time This time is influenced by the amount of current drawn from the battery If the discharge current increases the discharge time will decrease and also affect the rated capacity Hour rated discharge C10 10 hour rated capacity Ah C120 120hour rated capacity Ah Rate of discharge 1C 1 multiplied by the 10 hour rated capacity used for the discharge
5. 3 1 Check for damage leakage and deformation 5 3 2 Check if there are any loose connections and tighten according to specification 5 3 3 Check if the voltage over the group is balanced 6 Remarks 6 1 Battery maintenance should be performed by professionals 6 2 Avoid constant over discharging of the batteries 6 3 When batteries are discharged the termination voltage should be set according to the discharging current requirement The over discharge protection should be set to be 0 05V lower than the termination voltage to ensure good operation and long life of the batteries and equipment After the battery is discharged it should be immediately be charged again 6 4 When abnormalities or damage is noticed the problem should be investigated immediately If the battery was the cause it should be replaced immediately to prevent further damage 6 5 When charging the battery the controllers charge voltage accuracy should be less than 1 to prolong battery service life 6 6 All display instrumentation should be regularly checked and calibrated to ensure accurate reading of measurements If the equipment can t read an error the equipment could cause damage to the batteries Chapter 4 Transportation and storage 1 During transportation please perform safe handling of batteries Due to the weight of the batteries it should be handled with care in order to not drop the batteries while loading and offloading 2 Use appropriate lifting
6. LEAD CRYSTAL BALIT TERIES Valve Regulated Lead Crystal Battery Energy Storage Cells User Manual www bettabatteries com info bettabatteries com 1 Introduction The patented lead crystal battery technology is based on intense research of the defects and operating characteristics of the lead acid and lead gel batteries We developed our own trade secret SIO2 composite electrolyte to replace the traditional sulphuric acid electrolyte commonly used in acid and gel batteries By using our own advanced patented battery manufacturing technology and combining it with the new SIO2 composite electrolyte we developed a much more superior battery replacement By using the innovative new patented composite lead crystal electrolyte technology our special formula to completely replace the traditional sulphuric acid it brought a great change to the battery product s internal and chemical structure During initial charging cycles the liquid composite electrolyte reacts with the lead plates which cause the electrolyte to crystallize The crystallized electrolyte fixes to the active material on the plates enhancing the channel for ion exchange effectively overcoming loss of moisture plate sulphation and loss of active material A superior resistance to low temperatures over charging and over discharging are results of the new chemical structure inside the lead crystal batteries This effectively multiplies the product s service and cycle life
7. ated End ae V 110 A Capacity Voltage 1120 A Capacity Voltage L WwW H Ah V Ah V 3 CNFJ 10 6 1 10 5 4 0 12 14 4 5 55 151 50 102 2 0 6 CNFJ 10 12 1 10 10 8 0 12 14 4 11 1 151 99 105 4 2 6 CNFJ 22 12 2 2 22 10 8 0 22 26 11 1 181 76 172 6 9 6 CNFJ 24 12 2 4 24 10 8 0 24 28 11 1 185 105 135 7 7 6 CNFJ 28 12 2 8 28 10 8 0 28 34 11 1 175 166 125 9 0 6 CNFJ 40 12 4 40 10 8 0 48 48 11 1 198 166 172 14 2 6 CNFJ 55 12 5 5 55 10 8 0 55 66 11 1 229 138 220 18 4 6 CNFJ 65 12 6 5 65 10 8 0 65 78 11 1 348 167 175 22 0 6 CNFJ 90 12 9 90 10 8 0 9 108 11 1 306 169 240 28 0 6 CNFJ 100 12 10 100 10 8 1 120 11 1 408 174 235 33 0 6 CNFJ 120 12 12 120 10 8 1 2 144 11 1 408 174 235 37 0 6 CNFJ 150 12 15 150 10 8 1 5 180 11 1 486 170 241 45 0 6 CNFJ 180 12 18 180 10 8 1 8 216 11 1 522 240 244 60 0 6 CNFJ 200 12 20 200 10 8 2 240 11 1 522 240 244 62 0 CNFJ 300 2 30 300 1 8 3 360 1 85 176 154 365 22 0 CNFJ 500 2 50 500 1 8 5 600 1 85 244 175 365 32 5 CNFJ 800 2 80 800 1 8 8 960 1 85 410 175 366 55 5 CNFJ 1000 2 100 1000 1 8 10 1200 1 85 475 175 365 65 CNFJ 2000 2 200 2000 1 8 20 2400 1 85 491 351 383 130 CNFJ 3000 2 300 3000 1 8 30 3600 1 85 712 353 382 192 5 Product standards Lead crystal battery products are manufactured to meet the following national and international standards and are manufactured under the ISO 9001 system e GB T22473 2008 lead acid energy storage battery e GB T19638 2 2005 fixed type valve controlled sealed battery
8. atteries Smudgy oily and loosely connected connections could cause contact problems and lead to faults on the equipment Ensure that all contacts are clean from oil and grease and that all connections are securely fastened Terminals should be torque to individual battery specifications but not exceed 15N m Excessive tightening will cause damage to the thread on or inside the battery terminal Terminal connections should be checked periodically during the life of the battery to ensure that there are no loose connections Ensure that the batteries are connected in the correct way Ensure that reverse polarity are eliminated by connecting positive to positive and negative to negative on the equipment Also ensure that the correct size of wire diameter is used according to current drawn requirement If incorrect wires are used it will heat rapidly and cause damage to both the battery and the equipment that it is connected to Correct use and maintenance 3 1 The batteries are designed for a usage environment to operate in extreme environmental temperatures ranging from 40 C 65 C Yet most installations and best recommended environmental temperatures for use are 5 C 35 C and a relative humidity of 95 The CNFJ range of batteries can be used in both float and cyclic charge applications at different environmental conditions www bettabatteries com POWERED BY info bettabatteries com Betta Batteries 4 Charge and discharge regulations
9. dioxide Diluted sulphuric acid Lead Lead sulphate Water Lead sulphate Positive Plate Composite Negative Plate Positive Water Negative Active Material Electrolyte Active Material Discharge material Discharge material When discharging the positive and negative active material reacts with the acidic element of the electrolyte and becomes lead sulphate and water causing the acid density to decrease When charging the acid that concentrated in the positive discharge material during discharge cycle is released back into the electrolyte At this time the lead sulphate in the positive and negative plate transforms in to lead dioxide and a spongy type of lead which causes the acid density in the electrolyte to increase With normal lead acid batteries after charging or prior to charge completion all the charging current is used for electrolyses of the moisture in the electrolyte The positive plates release oxygen and the negative plate hydrogen gas If the gas recombination efficiency of the battery is low a large percentage of the gas will escape leaving less moisture in the battery after every charge This action causes the electrolyte content to decrease due to water loss raising the acidity in the battery and shortening the life of the battery This is known as late charge fluid loss phenomenon Lead crustal batteries besides the regular chemical reaction the composite electrolyte has various additives that participate in the electrochemica
10. e batteries can be kept on a shelf for more than one year without constant top up charging and the battery will maintain over 85 of its rated capacity The self discharge characteristics of the battery change with environmental temperatures The higher the temperature the higher the self discharge so the batteries should not be stored in an environment that is subjected to high temperature conditions for long durations of time Storage Capacity 25 C 3 months 95 6 months 90 1 year 85 www bettabatteries com info bettabatteries com POWERED BY Betta Batteries 2 Charging characteristics 2 1 2 2 2 3 2 4 2 5 Charging conditions are the key factors that affect battery life and functionality The CNFJ range of lead crystal batteries should be charged using constant voltage for both floating and cyclic charge applications The relationship between charge voltage and environmental temperature The battery benchmark temperature setting should be assumed to be 25 C Under different environmental temperature conditions a temperature compensation coefficient of 3mV C Cell should be applied to the charging equipment This equipment s voltage stability factor should be 1 or higher Equipment setting During the initial charge and discharge cycles the depth of discharge discharge current operating temperature and time of discharge should be recorded Equipment must then be recalibrated to
11. ic curve The below curve graph shows typical charge characteristics of the lead crystal batteries Charge Charging Charging capacity current voltage CA cell _ 4 Charging voltage Do 240 pill a 100 2 Tr f Charge capacity ar 100 DOD 6o 0 08 i neg PM 50 DOD 40 0 04 f 1 60 T an x _ Charging current 0 0 00 0 5 10 15 20 25 30 Time h www bettabatteries com POWERED BY info bettabatteries com Betta Batteries Chapter 3 Battery Installation 1 Installation method an sequence 1 1 1 2 1 3 1 4 1 5 After the batteries are unpacked check for any visible damage to the product Please read this manual before installation to ensure correct installation according to required application and equipment settings Ensure that the batteries remain in the shipping packaging until it arrives on the installation site When the batteries are handled please take care not to lift the batteries by means or the terminals to avoid damage to the internal seals Always lift the batteries by the supplied handles or from the bottom of the batteries in the event that the battery is not designed or supplied with the required lifting handles Before connecting the equipment to the batteries use a piece of fine grit sandpaper to sand the contact area of the terminal and the connecting lug This will ensure good contact between battery and lug and reduce the risk of oxidation When there are m
12. l reaction The additives inhabit the oxygen and hydrogen gas during the charging cycle increasing the batteries recombination rate This in turn reduces the water loss during and after charging When discharging the lead sulphate can be totally transformed back into active material prolonging the battery s use life The lead crystal group of batteries uses a new advanced type of AGM material as a separator The AGM has much higher electrical conductivity heat resistant and acid resistant abilities than standard AGM on the market The crystallized electrolyte in combination with the AGM can effectively protect the www bettabatteries com POWERED BY info bettabatteries com Betta Batteries plates and prevent the active material from falling off during use The electrolyte is completely absorbed and stored in the AGM Since the AGM is completely saturated with electrolyte then crystallized no free liquid electrolyte will be present in the battery The battery can now be used in various directional positions without leaking 4 Specifications 4 1 Product specification and model identification method 6 CN FJ 120 Rated capacity in Ah Amp hours Valve controlled sealed lead crystal storage cell Energy storage battery Number of cells 6 12 volt 3 6 volt 4 2 Model specification table ANSIA 10hr Discharge rate 120hr Discharge Rate PERA i oe Voltage Rated End R
13. lyte in the battery This opens a wide range of installation applications since the risk of electrolyte leakage is eliminated This reaction also improves the products safety making it less harmful to installers and users alike 2 1 2 Special Manufacturing Process Using pressure filling technology in combination with patented gravity filling containers to fill the batteries with electrolyte and the patented terminal connecting equipment these improvements ensure a much more even distribution of electrolyte in each cell further enhancing the performance of the batteries and increasing the efficiency www bettabatteries com POWERED BY info bettabatteries com Betta Batteries 2 2 Performance Characteristics 2 2 1 Long service life Twice as long as regular lead acid and gel batteries 2 2 2 Deep discharge ability Can be discharged to 0 volt and be recovered under normal charging conditions to 100 capacity within 2 cycles 2 2 3 Extreme environmental temperature resistance Can be cycled in 40 C to 65 C conditions and used as normal It performs especially well in the low temperature ranges 2 2 4 Environmentally friendlier Classified as non dangerous non explosive and non radioactive goods by various governmental institutions Working Principle The main electrochemical reaction during the charge and discharge process of the lead crystal battery Discharge PbO 2H2SO Pb PbSO H20 PbSO gt Charge Lead
14. n The termination voltage and the discharge current are closely related Generally during high current discharge the termination voltage of the battery should be set lower During long term operation at small discharge currents the battery will form a thin layer of sulphation on the plates increasing their size This could cause deformation af the active material and cause it to fall off the plates To prevent this and also to protect the battery during small current operations the termination voltage should be set higher Over discharging below the termination voltage should be avoided since the over discharging could only gain a small amount of additional capacity but drastically reduce the battery s service life www bettabatteries com POWERED BY info bettabatteries com Betta Batteries The below table indicates recommended termination voltages at different rates of discharge for the CNFJ range 1 2 4 Discharge current A Discharge termination voltage V Cell Below 0 05C or non constant discharge me Equal close to 0 05C 1 85 Equal close to 0 1C 1 8 Equal close to 0 2C 1 75 0 2C 0 5C 1 7 0 5C 1C 1 6 1C 3C 1 5 Above 3C 1 3 Self discharging of the lead crystal batteries Lead crystal batteries with the use of our unique crystal composite electrolyte and alloy grid plate technology efficiently reduces the battery self discharge consumption At a constant 25 C environment th
15. oltage parameters Controller Charge and discharge current Use the ammeter to measurement the controllers output current highest charge current and over discharge protection Check if the results meet the required specifications Adjust the controller current parameters Visual inspection of the batteries appearance Check if there are visible leaking of electrolyte If there is the battery should be replaced Check if the battery is free from dust and pollutants If there is pollutant or dust clean with a moist cloth Check if there is water present in the battery container enclosure and if the terminals and cables are dusty or corroded Find the source of water and repair clean or repair corroded cables if possible replace www bettabatteries com info bettabatteries com POWERED BY Betta Batteries 5 2 3 Annual maintenance and inspection Annual inspection should include six monthly maintenance check and also perform the following procedures and inspections Inspection Content Method Solution standard Ensure good See installation According to connection of the requirements the battery Terminal i nuts and bolts on the and tighten to specification connections battery terminals and individual tighten and and cables connections on battery torque nuts and equipment specification bolts 5 3 Maintenance while inspecting the battery 5
16. techniques while handling batteries Never lift the batteries by means of the terminals or ventilation valves 3 Note that the batteries are charged and could cause electrical shock to personnel and damage to the battery and equipment if the terminals are short circuited 4 The batteries should be stored in a clean dry and well ventilated place where the ambient temperature is between 5 C 30 C Batteries should be rotated to ensure on shelf storage is approximately 6 months Longer storage of up to 24 months is possible and would not cause damage to the batteries but it would need to be charged prior to installation www bettabatteries com POWERED BY 12 info bettabatteries com Betta Batteries 5 Avoid contact with organic solvents and corrosive liquids Also prevent metal impurities from falling in to the battery Keep batteries free from mechanical shock and heavy pressures 7 Half used batteries can be stored for future use It should be charged prior to storage then stored according to safe storage practise Appendix When selecting the appropriate battery for a project the following parameters should be considered and the below formula used to calculate the quantity and size of battery needed System output and maximum power continuous rainy day storage quantity of solar panels wind generators or both and the total system current To determine the battery capacity use the following formula C K1 x W V x Tx d 1 0 8 C Ba
17. the recorded parameters as to ensure longer life of both the batteries and the equipment After complete discharge the battery should periodically be fully charged and discharged for at least two complete cycles to ensure full recovery of the battery s capacity The abovementioned results should be recorded and again adjustment should be made to the equipment if necessary Float charging applications For applications that is constantly connected to the electrical grid and where the batteries are in constant charging state and only discharged when there is a break in or loss of grid supply the charging equipment should be set to the float charging mode The equipment should be set and monitored so that strict control can be maintained over charging to ensure a constant charging voltage and current Recommended floating charge voltage should be between 2 25 2 3V Cell and the floating current should be between 0 005 0 01A In long term float charging applications a six month balanced charge and discharge should be performed as part of battery maintenance where the balanced cycles should be no more than 8 12 hours in duration During the initial charge and discharge cycles on new installations the charge current should be limited to 0 1C 0 25CA not to exceed 0 3CA and the temperature not more than 35 C During this stage of operation if an increase of temperature is noticed the charge current should be reduced Charging characterist
18. ttery capacity in Ah K1 safety coefficient normally set as 1 2 W system output power in watt W V system operating voltage in volt V T daily operating time in hours h d continuous rainy days www bettabatteries com POWERED BY 13 info bettabatteries com Betta Batteries
19. ultiple batteries connected together in a group series or parallel ensure that the voltage of the batteries in the group match prior to connecting Ensure the connections on the batteries are secure and the configuration is according to the voltage required to operate the equipment Before connecting the load charge the batteries to a state of full charge to ensure all the batteries are on the same level At this point it is safe to connect the batteries Matters that need attention during installation 2 4 2 2 2 3 2 4 2 5 Ensure that all heating and cooling ducts are directed away from the batteries The installation site should be kept clean dry and well ventilated at all times Avoid installing the batteries in direct sunlight away from a heat source organic solvents and corrosive gas to ensure longer battery life and to prevent accidents All the lead crystal batteries are fully charged prior to shipping to activate the crystallization of the electrolyte in the batteries Care should be taken when handling the batteries during transport and prior or during installation to prevent short circuit and reverse connection in order to avoid damage to the equipment and harm to people Because of high voltage and the risk of electrical shock the batteries should be handled with great care during transportation and when being installed Electrically insulated equipment and clothing should be used worn when working with or connecting b
20. urement the controllers Check if the results meet Adjust the controller Charge and output voltage highest charge the required discharge voltage voltage and over discharge protection voltage specifications voltage parameters Controller Charge and discharge current Use the ammeter to measurement the controllers output current highest charge current and over discharge protection Check if the results meet the required specifications Adjust the controller current parameters www bettabatteries com info bettabatteries com POWERED BY Betta Batteries 5 2 2 Six monthly maintenance and inspection Content Method Inspection standard Solution The total voltage when the Battery is charging and Equipment should be calibrated with an deviation of no more than 0 5 volt before Total voltage charging and discharging voltage x quantity of batteries in Adjust voltage charging and discharging voltage x quantity of batteries in the group replace defective battery ies if discharging testing batteries in a group the group Aci individual charging does not bring the voltage back to required level Use the voltmeter to Controller measurement the controllers Check if the results meet i i Adjust the controller Charge and output voltage highest charge the required discharge voltage voltage and over discharge protection voltage specifications v
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