User`s Manual
Contents
1. 48 VOLT LAY OUT e la ole e B q A O lt Q o amp O O e o O g 0 D o D e g o amem KD o al O 3 eo a B g y IN f e g 00 e a Eo 7 A jo eo 1 4 20 STAINLESS STEEL NUT 1 4 STAINLESS STEEL LOCK WASHER N Waa 1 4 STAINLESS STEEL FLAT WASHER EY 1 4 20 X 1 LONG STAINLESS gt STEEL HEX HEAD BOLT INTERCELL CONNECTOR DETAILS N TET 566 32 5 LEAD PLATED COPPER INTERCELL FIGURES 13 Specific Gravity vs Percent Discharged Freezing Points of Battery Electrolyte Specific Gravity 77 F Centigrade Fahrenheit Gravity 1 000 1 0 32 1 050 3 3 25 1 100 tek 18 1 125 10 14 1 150 15 5 1 175 20 4 1 200 26 15 1 210 31 23 1 220 36 33 1 230 41 42 1 260 57 71 1 270 62 80 1 280 66 87 1 290 69 92 0 10 20 30 40 50 60 70 80 90 100 Discharaed2. POWERLINE PV 1 Solar Battery User s Manual Table of Contents mice ge Aa a KA aa aa a a ada 2 US Teall ON E SE Aa Adding bana 5 aec Aa a akak 6 NV OWA A P 6 SPECE gag di a O aaa AEN 8 KCC DING aaa aka Rm 8 Edialize Charge daa anaa KANA A Nda nian har A 9 Sultated Bateries oosa de ies 9 Battery SUG Sasa aaa aka 11 KAR Pl D E KN 12 FOUE Sora Goat 13 6 21701670 E 14 wiecejecio m c P t 15 Mantel alie xis a cott nl seed ox hene 16 A eui etui teta tee Au A 17 PRECAUTIONS 2 NEVER smoke or produce a spark in the battery area When performing battery maintenance wear safety glasses rubber gloves and protective clothing When using a hydrometer avoid letting the rubber tube shake as this can cause drops of electrolyte to splash onto your clothing or into your eyes Store your hydrometer in a clean dry place DO NOT OVERFILL Excessive water may spill out while battery is charging USE ONLY DISTILLED WATER Using tap or well water will void your warranty DO NOT let foreign objects enter the cells INSTALLATION ST
3. Cell Voltage Correction Factors Cell Voltage Temperature Correction To E Be Subtracted From Measured Volts Electrolyte Electrolyte Temperature F Cell Voltage Correction To Be Added To Measured Volts 49 51 0 09 52 54 0 08 55 57 0 07 58 60 0 06 61 63 0 05 64 66 0 04 67 69 0 03 70 72 0 02 73 75 0 01 Temperature Effect On Batteries Electrolyte Percent Temperature F Capacity 777 gt 100 60 95 50 91 40 87 30 81 76 787 79 81 82 84 85 87 88 90 91 93 94 96 97 99 100 102 None Needed 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 Cell Specific Gravity Temperature Correction Temp Fahrenheit Correction Factor 39 41 gt 012 42 44 45 47 48 50 51 53 54 56 57 60 61 63 64 66 67 69 70 72 73 75 76 78 79 81 82 84 85 87 88 91 92 94 011 010 009 008 007 006 005 004 003 002 001 0 001 002 003 004 005 TROUBLESHOOTING 14 PROBLEM PROBABLE CAUSE REMEDY Battery not 1 Battery is undersized 1 Replace with a larger battery performing as 2 Battery not fully charged 2 Check charger and controller expected 3 Weak or defective cells 3 Perform a load test 4 Grounds or shorts 4 Clean battery and all connections in 5 Phantom loads in system the system 6 Battery is spent 5 Find and eliminate loads 6 Replace batte
4. GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTH
5. F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP
6. battery 8 Lack of equalize charges 8 Equalize more often Unequal 1 All of the above 1 All of the above Specific 2 Recently added water 2 Gassing will mix new water Gravity Improper gravity adjustment after cell 3 Adjust specific gravity see your replacement dealer TROUBLESHOOTING 15 Rated Dimensions Short Circuit M Weigh 1 5 slt Amp Hrs LxWxH in ose m Ratings Amps 20 hr Rate Inches 12 V 104 F 6 85F 17S 845 38 25 x 6 94 x 25 666 9 600 6 85 195 950 38 25 7 69 25 738 10 800 6 85F 21S 1055 38 25 x 8 44 x 25 816 12 000 6 85F 23S 1160 38 25 x 9 19 x 25 888 13 300 6 85F 25S 1270 38 25 x 9 94 x 25 966 14 400 6 85F 27S 1375 38 25 x 10 69 x 25 1044 15 600 6 85F 29S 1482 38 25 x 11 44 x 25 1116 16 800 6 85 315 1585 38 25 12 19 x 25 1194 18 000 6 85 335 1690 38 25 X 12 94 x 25 1272 19 200 Weights 5 Warranty 10 years Cycles to 80 DOD 2100 over 10 years Battery Type Flooded Lead Acid Positive Plate Post to Cover Seal Cell Jar Material Cell Cover Material Tray Material Intercell Connectors Specific Gravity 77 F Model Breakdown Example 6 cells per Tray 85 amps per positive plate F represents Powerline 17 plates total 8 pos amp 9 neg PV 1 Solar Battery 6 85F 17S Tetrafluoroethylene Teflon Lead Antimony Burned Post to Cover Injection Molded Polypropylene Polypropyle
7. skip the remaining steps WARNING Do not let the lid fall onto the cells as this could cause shorting from terminal to terminal CAUTION These cells can be extremely heavy a come along or block and tackle may be needed to do the lifting Do not try lifting these cells by yourself Serious injury could occur INSTALLATION Continued 4 WARNING NOTE STEP 6 STEP 7 STEP 8 STEP 9 WARNING The weight inside the plastic cells will cause the sides to bulge when removed from the tray This is normal however use caution when handling the cells Any pressure on the sides will cause the cells to breathe and can release small droplets of electrolyte in the area of the cap Placing a rag over the vent cap will reduce this hazard As you remove the cells from the tray you may notice the electrolyte level is very low DO NOT add water to the cells this condition is normal As soon as the battery is reassembled charge the battery at 2 of its rated capacity After approximately 2 hours the electrolyte level will return to normal If the electrolyte level does not rise as expected contact your dealer Neutralize the sides of the cells and the steel tray Rinse and dry thoroughly Move the steel tray to the desired location Install the cells back into the tray using the diagram on page 12 to ensure the cells are correctly installed The cells must be completely seated in the tray to properly ins
8. EP 1 Acquire the following safety items Safety glasses or face shield Acid resistant apron Insulated 7 16 wrench Insulated ratchet with 7 16 socket 1 gal neutralizing agent 1 baking soda to gal water mix this solution thoroughly Rubber gloves NOTE Wrapping your tools with several layers of electrical tape will reduce the hazard of shorting from cell to cell You should also remove any jewelry that may be at risk of shorting INSTALLATION Continued 3 STEP 2 Inspect the battery and tray for evidence of damage if damage has occurred file a claim with the carrier immediately If you see liquid on the top of the cells pour some neutralizing agent into a small container and apply with a clean paint brush Be extra careful not to get any of this agent into the cell Apply this agent to the terminals as well as the cell tops then rinse with clear water and wipe dry CAUTION If you should get battery acid in your eyes flush with clear water for 15 minutes and seek medical attention DO NOT use the neutralizing agent in your eyes STEP 3 Remove the tray lid by tapping one hinge back into the lid hinge or remove the internal hex head bolts STEP 4 Remove the buss bars STEP 5 Connect the cell lifting strap into the holes of the terminals and lift the cells out of the tray If the clevis on the cell lifting strap will not slide over the terminal slightly spread the clevis NOTE If you move the battery fully assembled
9. GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L
10. LY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L MONTHLY CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E F F G G H H K K K K L L CELL SP GR Cell Voltage CELL SP GR Cell Voltage A A B B C C D D E E
11. l voltage and the specific gravity of a cell that is on open circuit no charging or discharging These open circuit voltage readings are useful in determining uniformity A fully charged battery on open circuit with a specific gravity of 1 260 1 280 will read 2 10 volts per cell to 2 12 volts per cell at 77 F This spread of 02 vpc is considered normal for a new battery As the battery ages the spread will increase to about 03 vpc DOD Depth of Discharge buo Specific Gravity 0 Full Charged 12 78 25 56 51 12 1 275 1 285 50 Half Discharged 12 24 48 1 205 80 Considered Dead 10 5 21 42 1 175 100 Over Discharged 9 3 18 6 37 2 1 140 voltage readings see Pg 13 You must take the electrolyte temperature into consideration when using VOLTAGE Continued 7 FULLY CHARGED VOLTAGE READINGS On charge voltage readings are most informative and are good indicators of battery condition These readings should be taken when the battery is approaching full charge with 296 of the battery capacity flowing into the battery New batteries when fully charged and 296 of the battery capacity flowing into the battery will have cell voltages between 2 55 2 65 vpc Older batteries with the same circumstances will have voltages about 2 45 2 55 vpc Multiplying the battery capacity times 02 will give you 296 of capacity Example 6 85F 17S 845 x 02 16 9 a
12. mps VARIATIONS IN ON CHARGE VOLTAGE f all cells of a battery show similar full charge voltages they are equally healthy The uniformity and value of the individual cell voltage readings vary with the overall condition of the battery A battery with an on charge voltage of 2 45 to 2 50 volts per cell has more uniformly healthy cells than a battery having an on charge voltage spread of 2 40 to 2 50 volts per cell The battery s age and service duty must be considered in the interpretation of the on charge voltage readings An example would be an older battery which has on charge cell voltage readings of 2 45 volts to 2 65 volts The reason may very well be that the inside cells operate at higher than average temperatures causing higher local action which would result in lower voltage Regular equalize charging will compensate for the higher self loss of the inside cell Any wide spread in on charge voltage that could not be attributed to the battery s service life or age is a sign that something is wrong and attention is necessary Some cause of abnormally wide spread or charge voltages are Abnormal temperature differential Internal shorts Acid loss causing over discharge Insufficient charging Insufficient equalize charging po eue General Settings for Trace Inverter Charger 12 Volt 24 Volt 48 Volt Bulk 14 8 Equalize 15 15 5 Float 13 5 These voltage settings are ball park settings that will work for most systems If you find
13. ne Epoxy Coated Steel Lead Plated Copper Rated 700 Amps 1 285 1 275 Fully Charged 1 160 80 Discharged Photo is a 12 85F 13 battery MAINTENANCE 16 WEEKLY 1 Record hydrometer reading of pilot cell the cell with the lowest specific gravity when you first received the battery Once a year select a different cell to be the pilot cell Check the water level add as needed Record Amp Hrs consumed Inspect connections for corrosion clean as needed OW MONTHLY 1 Record hydrometer readings of all cells after the battery is fully charged 2 Check water level add as needed a If the average readings are less than 1 275 1 285 check all charging sources and adjust as needed b If one or two cells read 20 points more or ess than the average circle those readings and check for improvement at next monthly reading If the low cells do not improve the cells are in need of an equalize charge specific gravity adjustment or internal inspection Record Amp Hrs consumed Record battery temperature Clean battery with a damp cloth If battery tops are wet with acid use neutralizing agent with a clean paint brush dry thoroughly 6 Equalize the battery see Page 5 7 Inspect connections for corrosion clean as needed YEARLY 1 Torque all terminal bolts RECORDS 17 ENTERING DATA IN THE WEEKLY FORMS It is essential that you label each cell for these rec
14. ng an equalize charge It can take up to several days for the fresh water to mix with the rest of the acid This fresh water could freeze before mixing with the electrolyte WARNING Do NOT over fill Do NOT use tap or well water They can contain small amounts or nickel iron manganese copper chlorine nitrates etc These and other minerals can seriously affect battery life HYDROMETER 6 Insert the rubber tip into the cell but not into the electrolyte Squeeze the bulb and lower the rubber tip into the electrolyte and release the pressure from the bulb The barrel will fill up and the float will rise It is very important for the float to be freely suspended in the electrolyte Gently move the hydrometer back and forth until the float is not in contact with the barrel where the numbers on the float intersect with the top of the electrolyte this is the specific gravity See the following section for interpreting your hydrometer readings With the rubber tip in the cell but not submersed into the electrolyte squeeze the bulb and drain the electrolyte back into the cell Wipe dry any spilled electrolyte WARNING Always wear protective clothing and eye face protection when working around batteries If you should get acid in your eyes or on your skin flush with clear water for 15 minutes and see a physician Do not use neutralizing agent in your eyes VOLTAGE OPEN CIRCUIT READINGS There is a definite relationship between the cel
15. ords to aid in the operation of your battery This form is designed to enter general battery information on a weekly basis and will at a glance show any abnormalities in the battery s health Select a pilot cell this should be the cell with the lowest specific gravity after you do your initial charge after installation It is suggested that the pilot be rotated annually to a different cell in the battery Step 1 Enter the date Step 2 Enter the pilot cells voltage Step 3 Enter the specific gravity of the pilot cell Step 4 Check your A H meter and enter the amp hrs reading Step 5 Enter the cell temperature Step 6 Enter a W if water has been added in the previous week Enter an E if the battery has been equalized in the previous week Enter a if the battery was cleaned in the previous week ENTERING DATA IN THE MONTHLY FORMS Once a month enter the specific gravity and cell volt ages of all cells in the appropriate columns If your battery has more than 12 cells you can identify these cells as AA BB CC etc DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP GR A H USED CELL TEMP DATE CELL VOLTAGE SP
16. ple task is required for your warranty and will be of great assistance in determining the health of your battery Record keeping is the single most important tool in good battery maintenance As the battery ages you can see trends spot possible problems before they become permanent and make any adjustments to your charging systems Without records it is almost impossible to know how your system is functioning While instrumentation in Renewable Energy has made leaps and bounds they are only another tool in the proper operation of your battery By using the records and instrumentation together your battery system can provide you with years of trouble free service EQUALIZE CHARGE 9 The term equalize simply means a controlled overcharge This procedure is used to adjust the difference between cells that develop due to temperature variations within the battery manufacturing and cycling of the battery The equalize charge will also help scrub off sulfate particles that tend to build up on the battery s positive plate When to equalize If a cell has a 020 difference in specific gravity or at least once a month How to equalize Generally you continue the bulk charge for an additional 3 hours after the battery has become full The equalize charge rate should be approximately 2 of the battery capacity This will tend to raise the battery voltage 1 1 5 volts above the bulk setting Ensure that any sensitive loads can accept this higher
17. ry Battery 1 Improper equipment settings 1 Adjust charging equipment overheats on 2 Malfunction of charging equipment 2 Verify charging equipment output charge 3 Battery too deeply discharged 3 Limit discharge to 80 DOD 4 High resistance connection 4 Check for hot connections 5 Low electrolyte level 5 Water battery to correct level and 6 Battery room too warm allow to cool and recharge 7 Weak or defective cells 6 Provide cooler battery room 8 Battery is spent 7 Repair or replace battery 8 Replace battery Battery 1 Excessive load 1 Reduce loads Need larger battery overheats on 2 Battery not full recharged 2 Let battery cool Do a load test discharge 3 Battery over discharged 3 Limit discharge to 80 DOD 4 Battery room too warm 4 Provide cooler battery room Low 1 Lack of watering 1 More care required electrolyte 2 Frequent overcharging 2 Adjust check charging system level 3 Spilled electrolyte 3 Add water equalize and adjust 4 Cracked or broken jars specific gravity contact dealer 4 Replace jars Unequal cell 1 Overdischarging 1 Give equalize charge voltages 2 Acid loss due to over watering or 2 Give equalize charge and adjust spillage specific gravity 3 Corroded or dirty tops 3 Neutralize and clean tops 4 Grounds in battery 4 Clean battery 5 Impurities in electrolyte 5 Use only distilled water 6 Battery used infrequently 6 Deep discharge and equalize 7 Weak or defective cells 7 Repair or replace
18. s x 50 hrs 100 of the 6 hr capacity Discharge the battery to 1 75 volts per cell 10 5 for 12 volt systems or 21 volts for 24 volt systems making sure not to allow any cells to go into reversal Cell reversal can be identified by very high cell voltage 3 4 volts while on charge or very low cell voltage 1 volt or less while being discharged Recharge until the specific gravity is the same for 3 hours Repeat the process until the specific gravity remains constant If the battery gives 80 or more you have succeeded if not replace the battery 11 BATTERY CHARACTERISTICS CELL VOLTS 8 8 3 TEMPERATURE 8 CHARGE SPEC GRAVITY AMP HOURS RETURNED 8 18 18 8 13 3 wah e DIAGRAMS 12 STANDARD LAY OUT FOR SOLAR BATTERY 12 VOLT LAY OUT VOLTAGE OR AMPERAGE CAN BE INCREASED BY LINKING BATI 2 TWO TERIES TOGET Ia a gie ifi X UE NEGATIVE MAIN POSITIVE HER WITH BATTERY CABLE RALLELED 12 VOLT LAY OUT soe Qo Y gio E dU Ul 24 VOLT LAY OUT eG gig a OA KD O A Q la e o
19. tall the cell interconnects All plastic spacers MUST be reinstalled when the battery is assembled Referring to the diagrams on page 12 or 13 install the nuts and bolts in the exact pattern as shown If your installation requires the inverter connections to be on the opposite side of what is shown turn the book over and proceed Torque all bolts to 115 135 inch lbs Never allow tools or other conductive objects to make contact with two or more battery terminals INSTALLATION Continued 5 STEP 10 Install the lid by taping the hinge pin back into the can hole When you install the lid you have a choice of where the hinges are located Some lid hinges use an internal hex head bolt use an Allen wrench to remove and replace the lid ADDING WATER Fill to from the bottom of the cap throat A flashlight will make adding water much easier A certain amount of water loss is normal in all batteries and must be replaced at regular intervals with distilled or deionized water Over filling is one of the most common errors made during battery maintenance and will cause gradual lowering of the specific gravity and a subsequent loss of capacity corrosion to the can and intercell connectors Add water after the battery is done charging and after taking hydrometer readings If the battery is subjected to freezing temperatures it is a good idea to add water when the battery is reaching approximately charged or 1 hour before endi
20. voltage SULFATED BATTERIES All lead acid batteries sulfate when discharged The active material must convert to lead sulfate in order for the cells to produce energy The term sulfated battery means that the battery has developed abnormal sulfate and has its capacity reduced as a result The most common cause of sulfation are Under charging or neglect of equalize charge Standing in a partially or completed discharged condition Low electrolyte level Adding acid High specific gravity High temperature WARNING not let your battery stand a discharged state for more than 24 hours or when temperatures are below freezing SULFATED BATTERIES Continued 10 Cells of a sulfated battery give a low specific gravity and voltage reading and the battery will not become fully charged after a regular equalize charge Before assuming that the battery is sulfated rule out the possibility that low specific gravity may be due to acid loss If the sulfation has not progressed too far it may be possible to return the battery to a serviceable condition by paying careful attention to the following 1 2 3 Neutralize wash and dry the battery Add water to the proper level Charge the battery at 2 of its capacity using the 6 hr rate until 100 of the battery s capacity has been restored Example 6 85F 23S 1160 A H x 77 893 A H at the 6 hr rate 893 A H x 02 17 86 amps 17 86 amp
21. your specific gravity is not reaching 1 275 1 285 raise these settings by 1 volt increments until the specific gravity readings indicate a fully charged battery If the battery uses an excessive amount of water or is overheating lower the settings by 1 volt increments until the overcharge is removed SPECIFIC GRAVITY 8 The standard fully charged specific gravity for the HAWKER PV 1 Solar Battery is 1 275 1 285 at 77 F see Fig 4 and Fig 5 on page 14 and the 100 discharged gravity is 1 140 Since the acid content of the electrolyte decreases linearly as the cell is discharged the decrease in gravity is directly proportionate to the amount in ampere hrs taken out The specific gravity at any point in the discharge indicates the depth of discharge and can be translated into ampere hrs taken out Knowing that the fully charged gravity is 1 280 and the final specific gravity is 1 140 we can find our state of discharge EXAMPLE Assume the specific gravity is 1 180 that is 100 points below the fully charged specific gravity of 1 280 With a difference of 140 points from 100 charged to 100 discharged we can divide 100 140 71 discharged Use this formula to help keep your Amp Hr meter synchronized with your battery See Fig 1 on Page 14 WARNING All lead acid batteries are considered discharged when 80 of the capacity has been removed NEVER remove more than 80 of the battery capacity RECORD KEEPING This sim
Download Pdf Manuals
Related Search