2 VOLT GEL CELLS
Contents
1. 5 3 2 3 Ere cc izes 6 3 3 oie 6 4 OPERATION C vissii 7 4 1 Discharge stirs ss een 7 4 2 ure P 7 4 3 Pme eel Lem 7 44 CARING odia rr L S 7 4 5 QMS RAULING fe c 7 4 6 Temperature related charge voltage sssssssssesssee ene eene nnne nnne enne rn nennen enne nnns 7 4 7 i e P 7 5 Pigs 8 5 1 Battery maintenance and CONtrOl c ccccceceeeceeeeeceeeee eee eeaaeeeceeeeeeecaaeaeeeeeeescaaaaeceeeeeseceaaeceeeseeecaeaeeeeeeeseesaaeees 8 5 2 uc 8 5 3 gre EE 8 5 4 Storage and taking out of operation ecrire aa oaa ate FREE CE CoL ERR anon ERE RAEE HERR Re ERR ences 8 5 5 VANS POM T HER 8 2 Copyright 2012 Mastervolt July 2012 2 VOLT GEL CELLS EN SAFETY GUIDELINES AND MEASURES MASTERVOLT 1 SAFETY GUIDELI2. Mastervolt battery chargers are standard provided with a battery temperature sensor for automatic adjustment of the charge voltage 4 7 ELECTROLYTE The electrolyte is diluted sulphuric acid and fixed in a gel MAINTENANCE 5 MAINTENANCE 5 1 BATTERY MAINTENANCE AND CONTROL Keep the battery clean and dry to avoid leakage currents Plastic parts of the battery especially the containers must be cleaned with pure water Never use any additives acids and or scourers Check batteries and connections on a regular base Defects such as loose or corroded connections must be corrected immediately At least every 6 month measure and record e Overall voltage the batteries e Voltages of several cells e Surface temperature of several cells e Battery room temperature If the cell voltages differs from the average float charge voltage by more than 0 2V respectively 0 1V or if the surface temperature difference between cells exceeds 5 C a Mastervolt service representative should be contacted Check and record at least every year e Voltage of each cell e Surface temperature of each cell e Battery room temperature e Screw connections e Screw connections without locking devices have to be checked for tightness e Battery installation and arrangement e Ventilation 5 2 TESTS Tests have to be carried out according to IEC 60896 22 DIN 43539 part 1 Special instructions like DIN VDE 0107 and DIN VDE 0108 have to be
3. M STERVOLT USER S MANUAL GEBRUIKERSHANDLEIDING BETRIEBSANLEITING MANUEL D UTILISATION 2 VOLT GEL CELLS MVSV series ENGLISH PAGE 1 MASTERVOLT NEDERLANDS PAGINA 9 Snijdersbergweg 93 DEUTSCH SEITE 17 1105 AN Amsterdam FRANCAIS PAGE 25 The Netherlands Tel 31 20 3422100 SPECIFICATIONS PAGE 33 Fax 31 20 6971006 www mastervolt com v 1 4 July 2012 CONTENTS MASTERVOLT CONTENTS 1 SAFETY GUIDELINES AND MEASURES 0 cesescsecsccsceeseeceeeseescecessaeeneeceecesenensseceseneescnceeseecesneeesnaeeseesenacesnaessaaensees 3 2 GENERAL INFORMATP ON 22 22 tica tuae uite case ssacseanetesuecessetensecensseesectesaedesnecesntuestecesaccescnssectucssasstaceseneescee 4 2 1 WSe Of this manuali rrt iR IRE EA ae EE UR ERERRRERE E ESI aeaeaie EE r EErEE L Neun 4 2 2 Validity of this marital 2 ciii iie Re oer De eB ORE E lend Ge ae OR ORE po Lb du ito cag Po k beu EE OB Ec ea S Rea duRdRs 4 2 3 G arantee xjerele o i 4 24 Mr ree 4 2 5 PMP ONAN ETO KM OW Ems 4 3 INSTALLATION em 5 3 1 Before YOU StaMt ME E 5 3 2 lFeezubnehic e eine 5 3 2 1 Eric 5 3 2 2 b ui
4. acid batteries do not require topping up water Never open the battery Do not add acid or distilled water Pressure valves are used for sealing and cannot be opened without destruction For the installation and operation of stationary batteries EN 50 272 2 is mandatory Copyright 2012 Mastervolt July 2012 2 VOLT GEL CELLS EN INSTALLATION MASTERVOLT 3 INSTALLATION 3 4 BEFORE YOU START e Installation connection and protection must be executed in accordance with the locally applicable regulations e Check the contents of the delivery See Specifications for an overview of components that are standard included with the delivery e After unpacking check each battery for mechanical damage Do not use the product if it is damaged If in doubt contact your supplier e Check the batteries for correct polarity Terminal Indication on colour battery Meaning Red Positive Blue Negative e Check each cell separately by measuring the open circuit voltage U 2 2 07V e Control of insulation resistance New batteries gt 1MQ Used batteries gt 100 O Volt 3 2 LOCATION TO INSTALL 3 2 1 General Standards referring to installation cabinets equipment or battery rooms are EN 50 091 I 2 IEC 896 2 3 draft IEC 60896 21 4 and EN 50272 2 1 Obey the following stipulations when choosing a location to install the batteries e Keep batteries away from heat sources Allowed oper
5. NES AND MEASURES Observe these instructions and keep them located near the battery for future reference Work on the battery should be carried out by qualified personnel only Do not smoke Do not use any naked flame or other sources of ignition Risk of explosion and fire While working on batteries wear protective eye glasses and clothing Observe the accident prevention rules as well as EN 50 272 2 VDE 0105 Part 1 Any acid splashes on the skin or in the eyes must be flushed with plenty of clean water immediately Then seek medical assistance Spillages on clothing should be rinsed out with water Explosion and fire hazard Avoid short circuits use insulated tools Do not place tools or other items on the battery Do not wear any metallic items such as watches bracelets et cetera gt e Electrolyte is very corrosive In normal working conditions contact with the electrolyte is impossible If the battery container is damaged do not touch the exposed electrolyte because it is corrosive Batteries are heavy If involved in an accident they can become a projectile Ensure adequate and secure mounting and always use suitable handling equipment for transportation Handle with care because batteries are sensitive to mechanical shock Caution Metal parts of the battery are always alive therefore do not place items or tools on the battery Keep children away from batteries Non compliance with operat
6. al operation the actual value of the alternating current is occasionally permitted to reach 10A RMS 100Ah nominal capacity In a fully charged state during float charge or standby parallel operation the actual value of the alternating current must not exceed 5A RMS 100Ah nominal capacity EN 2 VOLT GEL CELLS July 2012 Copyright 2012 Mastervolt 4 4 CHARGING CURRENTS The charging current should range between 10A to 50A 100Ah nominal capacity guide values When selecting a battery charger keep in mind that the battery charger must be capable of supplying both the current of the connected load and the battery charging current Contact your Mastervolt representative for advice if the charger current exceeds 50A 100Ah nominal capacity 4 5 TEMPERATURE The recommended operation temperature range for Mastervolt MVSV batteries is 10 C to 30 C best at 20 C 50 F to 86 F best at 68 F Higher temperatures will seriously reduce service life Lower temperatures reduce the available capacity The absolute maximum temperature is 55 C 131 F and should not exceed 45 C 113 F in service 4 6 TEMPERATURE VOLTAGE Temperature compensated charging is recommended according to the table below RELATED CHARGE Nominal voltage Temperature compensation 2V one cell 5mV PC 2 8mV F 12V 6 cells 30mV C 17 mV F 24V 12 cells 60mV C 33 mV F 48V 24 cells 120mV C 67 mV F
7. ating temperature 20 to 45 C 4 to 113 F Nominal operating temperature 10 to 30 C 50 to 86 F Recommended at 20 C 68 F The battery life is halved for every 10 C of rise in temperature Lower temperatures will reduce the available capacity e Battery installation should be made such that temperature differences between individual units do not exceed 3 C 5 F e Keep at least 1cm 0 5 inch space between the batteries Mastervolt can supply dedicated profiles for this purpose EN 2 VOLT GEL CELLS July 2012 Copyright 2012 Mastervolt e All models of the MVSV range are suitable for both horizontal and vertical mounting All cells should be mounted either vertically or horizontally e Please note that models MVSV 2000 67162000 and MVSV 2500 67202500 which were delivered before January 1 2006 are only allowed to be installed in upright vertical position See also chapter 2 2 If in doubt contact your supplier 3 2 2 Ventilation Under overcharging conditions lead acid batteries can vent an explosive mixture of hydrogen gas Therefore the batteries may not installed in airtight enclosures The ventilation of battery rooms and cabinets respectively must be carried out acc to EN 50272 2 Among others this means that under normal conditions the minimum air flow rate for ventilation of a battery location or compartment for Mastervolt MVSV gel batteries shall be calculated by the following formula up
8. ay be suitable stacked and secured on pallets ADR and RID special provision 598 It is prohibited to staple pallets No dangerous traces of acid shall be found on the exteriors of the packing unit Cells whose containers leak or are damaged must be packed and transported as class 8 dangerous goods under UN no 2794 Copyright 2012 Mastervolt July 2012 2 VOLT GEL CELLS EN
9. ing instructions repairs made with other than original parts or repairs made without authorization e g opening of valves render the guarantee void Disposal of batteries company Spent batteries are harmful to health and the environment Therefore batteries may not be mixed with domestic or industrial waste but must be collected and recycled separately Contact your supplier for recollection and recycling of batteries or contact an authorized waste management EN 2 VOLT GEL CELLS July 2012 Copyright 2012 Mastervolt GENERAL INFORMATION 2 GENERAL INFORMATION 2 1 USE OF THIS MANUAL This manual serves as a guideline for the safe and effective installation operation and maintenance of the Mastervolt MVSV gel batteries further mentioned as cell s or battery batteries It is therefore obligatory that every person who works on or with the batteries must be completely familiar with the contents of this manual and that he she carefully follows the instructions contained herein Installation of and work on the batteries may be carried out only by qualified authorised and trained personnel consistent with the locally applicable standards and taking into consideration the safety guidelines and measures chapter 1 of this manual Keep this manual at a secure place The English version has 8 pages Copyright 2012 Mastervolt All rights reserved Reproduction transfer distributio
10. lowing chapter 4 2 Copyright 2012 Mastervolt July 2012 2 VOLT GEL CELLS EN OPERATION MASTERVOLT 4 OPERATION 4 4 DISCHARGE e Avoid deep discharges Regular discharges beyond 60 of the nominal capacity are not recommended as they might shorten the lifetime of the battery e Recharge the battery immediately after a discharge e Never discharge below the final discharge voltage The final discharge voltage is related to the discharge current See paragraph Final discharge voltage of the Specifications 4 2 CHARGING Recommended charging method three step battery charger with IUoUo characteristic Voltage settings 25 C 77 F Nominal voltage Float Absorption 2V one cell 2 30V 2 38V 12V 6 cells 13 8V 14 25V 24V 12 cells 27 6V 28 5V 48V 24 cells 55 2V 57 0V max 5 hrs The batteries must be charged to the full 100 regularly at least every month 4 3 ALTERNATING CURRENTS When using old style charging equipment or battery chargers of inferior quality alternating currents may flow through the battery superimposing onto the direct current during charge operation Alternating currents and the reaction from the loads may lead to an additional temperature increase of the battery and strain the electrodes with possible damages which can shorten the battery life Such damages can be avoided by using Mastervolt battery chargers When recharging up to 2 38V cell under norm
11. n or storage of part or all of the contents in this document in any form without the prior written permission of Mastervolt is prohibited 2 2 VALIDITY OF THIS MANUAL All of the specifications provisions and instructions contained in this manual apply solely to standard versions of the Mastervolt MVSV gel batteries that were delivered by Mastervolt from 1 July 2006 on MASTERVOLT 2 3 GUARANTEE SPECIFICATIONS Mastervolt guarantees that the Mastervolt MVSV gel batteries have been built according to the legally applicable standards and specifications Should work take place which is not in accordance with the guidelines instructions and specifications contained in this users manual then damage may occur and or the batteries may not fulfil its specifications All of these matters may mean that the guarantee becomes invalid The guarantee is limited to the costs of repair and or replacement of the product Costs for installation labor or shipping of the defective parts are not covered by this guarantee The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries in Amsterdam number 33279951 and are available on request 2 4 LIABILITY Mastervolt can accept no liability for e consequential damage due to use of the batteries e possible errors in the manuals and the results thereof 2 55 IMPORTANT TO KNOW Stationary valve regulated lead
12. observed MASTERVOLT 5 3 FAULTS Call a Mastervolt service representative immediately if faults in the battery or the battery charger are found Recorded data as described in chapter 5 1 must be made available to the service representative It is recommended that a service contract is taken out with your agent 5 4 STORAGE AND TAKING OUT OF OPERATION To store or decommission cells for a longer period of time they should be fully charged and stored in a dry and cold but frost free room away from direct sun light The rate of self discharge is approximately 2 per month 20 C 68 F Elevated environmental temperatures increase the self discharge rate of the batteries Therefore batteries need supplementary charge according to the table below to keep its capacity Maximum charging interval Every 24 months Every 12 months Every 6 months Every 3 months Storage temperature lt 20 C lt 68 F 20 to 30 C 68 to 86 F 30 to 40 C 86 to 104 F 40 to 50 C 104 to 122 F 5 5 TRANSPORT The batteries must be transported in an upright position Never lift the batteries at the terminals Use soft slings to avoid damage Do no stand below the batteries Batteries without any visible damage are not defined as dangerous goods under the regulations for transport of dangerous goods by road ADR or by railway RID They must be protected against short circuits slipping upsetting or damaging Cells m
13. s not recommended A system made of insulating material should be used e Racks and cabinets shall have a distance of at least 100 mm to the wall for a better placement of connections and better access for cleaning MASTERVOLT 3 3 CONNECTION e To avoid corrosion of the battery poles Mastervolt recommends to lubricate the inserts and connections moderately using a small quantity of silicone grease Vaseline The use of a petroleum based lubricant is not recommended e Use properly sized and reliable cables cable lugs and battery terminals Tighten all connections firmly The following torque values apply for screw connectors M8 20x1 Nm 175 10 InLbs e Rubber covers shall be fitted to both ends of the connector cables pole covers before installation e Batteries in series or parallel must be of the same brand type capacity and state of charge Do not mix old and new batteries If a battery temperature sensor is used it should be located on top or on one side of the cell which is located in the centre of the battery bank Connect the battery with the correct polarity to the charger positive pole to positive terminal Note that the position of the battery poles may differ from previous installed batteries The charger may not be switched on during this process and the load must not be connected Connect the minus cable last of all Check if all connections are firmly seated Then switch on charger and start charging fol
14. to 40 C operating temperature Q 0 05 x n x Caos x 10 m h With n number of cells Cnom Nominal capacity see Specifications With natural ventilation air convection the minimum inlet and outlet area A is calculated as follows Air convection speed 0 1 m s A 28 x Q cm INSTALLATION Example Given 24V battery bank consisting of 12 pieces Mastervolt MVSV 800 gel batteries Crom 998 Ah Calculation of fresh air necessary Q 0 05 x n X Crom x 10 m h 0 05 x 12 x 998 Ah x 10 m h 0 5988 m h A 28 x Q cm 28 x 0 5988 cm approx 16 8 cm Potential sources of ignition must have a safety distance to the pressure valves of the batteries as specified in EN 50272 2 3 2 3 Use of battery racks When batteries are installed horizontally use of a battery rack is obligatory Obey the following recommendations Each cell should be supported separately by the rack over its full length Never stack a battery on another e Check that the battery racks are stable and horizontal For the shelf assemblies with 4 levels of 2 rows or 5 levels of 3 rows the assembly should be anchored with on the floor e Precautions must be taken if batteries are being installed in metallic cabinets or on racks Keep an air safety distance of at least 10 mm 0 5 inch between insulated cables and electrically conductive parts or use additional insulation e The use of metal clamps on the cells i
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