Classic Solar EnerSol, EnerSol T, OPzS Solar Operating Instructions
Contents
1. 7G lassic Classic Solar EnerSol EnerSol T OPzS Solar 81700705 Operating Instructions for stationary lead acid batteries Nominal data e Nominal voltage Un e Nominal capacity Cy Cy99 Or C420 e Nominal discharge current In loo OF l420 e Final discharge voltage U e Nominal temperature Ty 2 0 V x number of cells 125 C EXIDE TECHNOLOGIES INDUSTRIAL ENERGY 120 h discharge see type plate and technical data in these instructions z lioo Crop 100 h OF li20 C120 120 h see technical data in these instructions reference Do not smoke Risk of explosion and fire EN 50110 1 Electolyte is strongly corrosive suitable means of transport e Handle with care e Caution Dangerous voltage gt PPP oO items or tools on the battery e Observe these Instructions and keep them located near the battery for future e Work on the battery should only be carried out by qualified personnel Do not use any naked flame or other sources of ignition While working on batteries wear protective goggles and clothing e Observe the accident prevention rules as well as EN 50272 2 e Any acid splashes on the skin or in the eyes must be rinsed with plenty of clean water immediately Then seek medical assistance Spillages on clothing should be rinsed out with water e Explosion and fire hazard avoid short circuits e Avoid electrostatic charges and discharges sparks2. Recharge immediately following complete or partial discharge A battery is regarded as dis charged when the electrolyte density is lt 1 13 kg l at 25 C This corresponds to a discharge level of ca 80 of the nominal value An elec trolyte density of lt 1 13 kg l is a deep discharge Deep discharge reduces the lifetime of the bat tery 2 2 Charging a using an external charger All charging characteristics with their specific data described in DIN 41773 lU characteristic l const 2 U const 1 DIN 41774 W characteristic 0 05 Vpc DIN 41776 l characteristic l const 2 may be used Depending on to the charging equipment specification and characteristics alternating currents 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 causing possible damage see point 2 5 which can shorten the battery life When charging with an external charger the bat tery is disconnected from the load The tempe rature must be monitored Towards the end of the charging process the charge voltage of the battery is 2 6 V 2 75 V times the number of cells The charging process must be monitored see points 2 4 2 5 and 2 6 On reaching a fully charged state the charging process must be stopped or switched to the float charge
3. e Blocks cells are very heavy Make sure they are installed securely Only use e Block cell containers are sensitive to mechanical damage e Metal parts of the battery are always alive therefore do not place Non compliance with operating instructions and installations or repairs made with other than original accessories and spare parts or with accessories and spare parts not recommended by the battery manufacturer or repairs made without authorization and use of additives for the electrolytes alleged enhancing agents render the warranty void X Spent batteries have to be collected and recycled separately from normal household wastes EWC 160601 The handling of spent batteries is described in the EU Battery Pb Directive 2006 66 EC and their national transitions UK HS Regulation 1994 No 232 eH 1 Start Up Check all cells blocks for mechanical damage correct polarity and firmly seated connectors The following torques apply to the cell types Waste Management Company Ener Sol EnerSol T OPZS Solar A Pol M 10 M 8 8Nm 1 25 Nm 1 20 Nm 1 Put on the terminal covers if necessary Check the electrolyte level in all cells and if necessary top up to maximum level with purified water acc to DIN 43530 Part 4 Connect the battery with the correct polarity to the charger pos pole to pos terminal The charger must not be switched on during this process and the load must not be Ireland Stat
4. 660 575 515 0 469 55 12 0 21 5 46 9 147 208 520 31 0 9 3 OPZS Solar 765 765 670 600 0 546 6 4 14 0 25 0 54 6 168 208 520 35 4 10 8 OPZS Solar 985 985 860 770 700 8 2 17 9 32 1 70 0 147 208 695 43 9 13 0 OPzS Solar 1080 1080 940 845 773 9 0 19 6 35 2 77 3 147 208 695 47 2 12 8 OPzS Solar 1320 1320 1150 1030 937 11 0 24 0 42 9 9977 215 193 695 59 9 ileal OPzS Solar 1410 1410 1225 1105 1009 11 8 25 5 46 0 100 9 215 193 695 63 4 16 8 OPzS Solar 1650 1650 1440 1290 1174 13 8 30 0 53 8 117 4 215 235 695 73 2 21 7 OPzS Solar 1990 1990 1730 1550 1411 16 6 36 0 64 6 141 1 215 277 695 86 4 26 1 OPzS Solar 2350 2350 2090 1910 1751 19 6 43 5 79 6 irs 215 277 845 108 0 33 7 OPzS Solar 2500 2500 2215 2015 1854 20 8 46 1 84 0 185 4 215 277 845 114 0 32 7 OPzS Solar 3100 3100 2755 2520 2318 25 8 57 4 105 0 231 8 215 400 815 151 0 50 0 OPzS Solar 3350 3350 2985 2740 2524 27 9 62 2 114 2 252 4 215 400 815 158 0 48 0 OPzS Solar 3850 3850 3430 3135 2884 32 1 KES 130 6 288 4 215 490 815 184 0 60 0 OPzS Solar 4100 4100 3650 3355 3090 34 2 76 0 139 8 309 0 215 490 815 191 0 58 0 OPzS Solar 4600 4600 4100 3765 3451 38 3 85 4 156 9 345 1 215 580 815 217 0 71 0 1 The above mentioned height can differ depending on the used vents Exide Technologies GmbH Im Thiergarten 63654 B dingen Germany Tel 49 0 60 42 81 544 Fax 49 0 60 42 81 398 www industrialenergy exide com NXCSLOEPDFO0071
5. acid Final discharge 1 85 1 85 1 85 1 85 approx approx voltage Vpc mm mm mm kg kg EnerSol 50 53 we 0 44 0 52 210 1743 190 sey 2il EnerSol 65 66 65 0 55 0 65 242 175 190 17 3 2 7 EnerSol 80 80 78 0 67 0 78 278 175 190 20 7 4 7 EnerSol 100 99 97 0 83 0 97 353 175 190 26 4 7 0 EnerSol 130 132 130 1 10 1 30 349 179 290 33 0 10 9 EnerSol 175 179 175 1 49 1 75 513 223 223 47 8 14 6 EnerSol 250 256 250 Zale 2 50 518 276 242 63 0 18 6 1 The above mentioned height can differ depending on the used vents 8 1 2 Stationary lead acid cells type EnerSol T with positive and negative grid plates Nominal electrolyte density 1 26 kg l Discharge data Measurements and Weights Capacity Ah Discharge current A Length Width Height Weight Weight Discharge time max max max including acid 120 48 24 10 48 24 i h acid Final discharge 1 85 approx approx voltage V mm mm mm kg kg EnerSol T 370 367 83 198 5 445 17 3 Dal EnerSol T 460 452 101 198 5 445 21 0 6 3 EnerSol T 550 542 119 198 5 445 24 7 v9 EnerSol T 650 668 119 198 5 508 29 5 8 6 EnerSol T 760 779 EY 198 5 508 31 0 10 0 EnerSol T 880 897 137 198 5 556 38 0 11 0 EnerSol T 1000 1025 155 198 5 556 43 1 12 6 EnerSol T 1130 1154 173 198 5 556 47 7 14 1 EnerSol T 1250 1282 191 198 5 556 52 8 15 6 1 The above mentioned height can differ depending on the used vents 8 1 3 Stationary lead a
6. per K If the temperature is constantly in excess of 40 C the factor is 0 003 Vpc per K 2 9 Electrolyte The electrolyte is diluted sulphuric acid The nominal electrolyte density 0 01 kg l acc to technical data is based on 25 C when fully charged and with the maximum electrolyte level Higher temperatures reduce electrolyte density lower temperatures increase electrolyte density The appropriate correction factor is 0 0007 kg l per K Example electrolyte density of 1 23 kg l at 40 C corresponds to a density of 1 24 kg l at 25 C or an electrolyte density of 1 25 kg l at 10 C corre sponds to a density of 1 24 kg l at 25 C 3 Battery maintenance and control The electrolyte level must be checked regularly If it drops to the lower electrolyte level mark purified water must be added in accordance with DIN 43530 Part 4 maximum conductivity 30 uS cm Keep the battery clean and dry to avoid leakage currents Plastic parts of the battery especially containers must be cleaned with clean water without additives Monthly measurements and recording Battery voltage Voltage of some cells block batteries Electrolyte temperature of some cells Battery room temperature e Electrolyte density of some cells It is necessary to carry out an equalizing charge acc to 2 4 if the cell block average float charge voltages see table 2 differ more than those in table 4 below and or if the electrolyte density of the cells of a
7. so that the average cell voltage is as in table 2 and the electrolyte density should not decrease over a lengthy period if necessary the charge voltage Range Float charge voltage Vpc EnerSol 2 27 EnerSol T 2 25 OPZS Solar 2 23 Table 2 Float charge voltage must be increased acc to table 1 2 4 Equalizing charge Because it is possible to exceed the permitted load voltages appropriate measures must be taken e g switch off the load Equalizing charges are required after deep dis charges and or inadequate charges They can be carried out as follows a Using alternative form of power supply at constant voltage of max 2 4 Vpc up to 72 hours the number of hours increases with less charging current acc to table 3 b Using an external charger at constant voltage of max 2 4 Vpc up to 72 hours with l or W characteristic as in point 2 6 The electrolyte temperature must never exceed 55 C If it does stop charging or revert to float charge to allow the temperature to drop The end of the equalizing charge is reached when the electrolyte density and the cell volta ges no longer increase over a period of 2 hours 2 h criterion only applies to l and W characteris tics 2 5 Alternating currents When recharging or boost charging up to 2 4 Vpc under operation modes 2 2 the value of the alternating current is occasionally permitted to reach 10 A per 100 Ah Co In a fully charged state du
8. 0 Druckhaus Bechstein Printed in Germany Subject to change without prior notice 81700705 0 5 T 09
9. battery string deviates from the average value more than 0 01 kg l Tolerance 2 V Cell 6 V Block 12 V Block 0 10V 0 17V 0 24V 0 05 V 0 09 V 0 12V Table 4 Annual measurements and recording e Voltage of all cells block batteries e Electrolyte temperature of all cells e Electrolyte density of all cells Annual visual check e Screw connections e Screw connections without locking devices have to be checked for tightness e Battery installation and arrangement e Ventilation the battery room 4 Tests Tests have to be carried out according to IEC 60896 11 and DIN 43539 Part1 Special instructions like VDE 0107 and EN 50172 have to be observed 5 Faults Call the service agents immediately if faults in the battery or charging unit are found Recorded data as described in point 3 simplify the trouble shooting and fault clearance A service contract for example with Exide Technologies facilitates detecting faults in time 6 Storage and taking out of operation To store or decommission cells blocs for a lon ger period of time they should be fully charged and stored in a dry and cold but frost free room away from direct sunlight To avoid damage the following charging methods can be chosen 1 Equalizing charges every three months as described under point 2 4 At average ambient temperatures of more than the nominal temperature shorter inter vals can be necessary 2 Float charging as under poi
10. cid bloc batteries type OPzS Solar bloc batteries and single cells with positive tubular plates and negative grid plates Nominal electrolyte density 1 24 kg l Bloc battery Discharge data Measurements and Weights Capacity Ah Discharge current A Length Width Height Weight Weight Discharge time max max max including acid 120 48 24 10 120 48 24 10 h acid Final discharge approx approx voltage MV 1 85 1 80 1 80 1 80 1 85 1 80 1 80 1 80 mm imm imm kol Iko 12V OPZS Solar 70 82 7 78 4 69 4 51 5 0 7 1 6 2 9 52 275 208 385 35 15 12V OPzS Solar 140 139 0 141 0 118 0 103 0 1 2 2 9 4 9 10 3 275 208 385 45 14 12V OPzS Solar 210 210 0 200 0 177 0 154 0 1 8 4 2 7 0 15 5 383 208 385 64 19 6V OPzS Solar 280 294 0 296 0 250 0 206 0 2 5 6 2 10 5 20 6 275 208 385 41 13 6V OPZS Solar 350 364 0 374 0 311 0 257 0 3 0 7 8 13 0 25 8 383 208 385 56 20 6V OPZS Solar 420 417 0 420 0 354 0 309 0 3 5 8 8 14 8 30 9 383 208 385 63 20 Single cell OPZS Solar 190 190 165 145 0 132 0 1 6 3 4 6 0 12 105 208 405 13 7 52 OPZS Solar 245 245 215 190 0 173 0 2 0 4 5 7 9 17 3 105 208 405 15 2 5 0 OPZS Solar 305 305 270 240 0 220 0 25 5 6 10 0 22 0 105 208 405 16 6 4 6 OPZS Solar 380 380 330 300 0 273 0 3 2 6 9 12 5 27 3 126 208 405 20 0 5 8 OPzS Solar 450 450 395 355 0 325 0 3 8 8 2 14 8 325 147 208 405 23 3 6 9 OPZS Solar 550 550 480 430 0 391 4 6 10 0 17 9 39 1 126 208 520 26 7 8 1 OPZS Solar 660
11. nt 2 3 7 Transport To prevent any leakage of electrolyte the cells block batteries must be transported in an upright position Cells block batteries without any visible damage are not defined as hazardous goods under the regulations for transport of hazardous goods by road ADR or by rail RID They must be protected against short circuits slipping upsetting or damaging Bloc batteries may be suitably stacked and secured on pallets ADR and RID special provision 598 It is prohibited to stack pallets No dangerous traces of acid may be found on the exteriors of the packing units Cells bloc batteries whose cases leak or are damaged must be packed and transported as class 8 hazardous goods under UN no 2794 8 Technical data The nominal voltage the number of cells the nominal capacity C499 Or C429 Cy and the bat tery type are described on the type plates See table 8 1 1 8 1 3 other capacities at different discharge currents with the corresponding discharge times 8 1 Measurements weights and capacities C at different discharge times t and final discharge voltage U 8 1 1 Stationary lead acid bloc batteries type EnerSol with positive and negative grid plates Nominal electrolyte density 1 28 kg l Discharge data Measurements and weights Capacity Ah Discharge current A Length Width Height Weight Weight Discharge time max max max including acid 120 100 120 100 A h
12. ory Instrument No 73 2000 Contact your supplier to agree upon the recollection and recycling of your spent batteries or contact a local and authorized connected Switch on charger and start charging following acc to 2 2 If there is only an alternative source of energy available then the battery must be charged until the cell voltage is the same in all cells and the electrolyte density has reached the nominal value see technical data The loads must be switched off during charging The insulation resi stance measured at the disconnected loads and charger should be 100 Q per volt nominal vol tage 2 Operation For the installation and operation of stationary batteries EN 50 272 2 is mandatory The battery should always be operated using a charge controller and deep discharge protection Battery type Number of cells blocks Assembly by Exide Technologies order no date Commissioned by date Security signs attached by date The battery must be installed so that it is not in direct sunlight and in a way which prevents ambiance dependent temperature differences of gt 3 K arising The spacing between the cells or blocs should be 10 mm and at least 5 mm in rack mounting 2 1 Discharge Discharge must not be continued below the vol tage recommended for the discharge time Deeper discharges must not be carried out Discharge should not exceed the nominal capa city Unless otherwise indicated by the manu facturer
13. ring float charge or standby parallel operation the value of the alter nating current must not exceed 5 A per 100 Ah Co 2 6 Charging currents When charging with the IU characteristic the charging current should be 10 A to 35 A 100 Ah C49 reference values Exceeding this voltage of 2 4 Vpc increases water decomposition Charging in cyclical appli cation generates more heat For that reason the charging currents shown in the following table 3 must not be exceeded Charging Max charging Charging procedure current voltage A 100 Ah Co Vpc lU characteristic 35 2 40 characteristic 5 2 60 2 75 a at 2 40 W characteristic 35 at 2 65 Table 3 Maximal charging currents with different characteristics 2 7 Temperature The recommended operating temperature range for lead acid batteries is 10 C to 30 C All tech nical data apply to the nominal temperature 25 C The ideal operating temperature is 25 C 5 K OPZS Solar 20 C Higher temperatures will seriously reduce servi ce life Lower temperatures reduce the available capacity The absolute maximum temperature is 55 C 2 8 Temperature related charge voltage A temperature related adjustment of the charge voltage within the operating temperature of 10 C to 30 C is not necessary If the operating tem perature is constantly outside this range the charge voltage has to be adjusted The temperature correction factor is 0 004 Vpc
14. voltage as in table 1 For charge current see point 2 6 b with alternative power supply When using power supply units with solar modu les or wind generators the battery charger is not able to supply the maximum load current at all times The load current intermittently exceeds the nominal current of the battery charger During this period the battery supplies power This results in the battery not being fully charged at all times Therefore depending on the load the charge voltage must be set at 2 23 V 2 35 V x number of cells This has to be carried out in accordance with the manufacturers instructions Recommended charge voltage for cyclical appli cation Depending on the depth of discharge and the load the charge voltage is adjusted according to the specified values on table 1 Range Charge voltage Vpc EnerSol 2 32 2 40 EnerSol T 2 30 2 40 OPZS Solar 2 28 2 40 Table 1 Recommended charge voltage for cyclical application The charge voltage has to be adjusted to reach the nominal value 0 01 kg l see technical data once a month If this is not the case it is neces sary to increase the recommended charge voltage stepwise by approximately 20 mVpc to a maxi mum of 2 40 Vpc according to table 1 or carry out an equalizing charge acc to 2 4 every month 2 3 Maintaining full charge float charging The devices used must comply with the stipula tions under DIN 41773 They are to be set
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