User manual X-celler
Contents
1. T characteristic the charging current is kept constant and the voltage 1s free to increase symbol U is used to indicate voltage Volt and is the same as On charging with U characteristic the voltage is kept constant mostly preset by the manufacturer and the current varies W Wiis the symbol used when charging with constant power Watt Through the charging process the voltage increases and the current drops as is described in the well known formula W U x also known as P x I The symbol means switching to a subsequent step in the charging process with different parameters The a is used to symbolise automatic switching off by a timer IU characteristic W characteristic WU characteristic IUoU TIUoU is an often used characteristic in multi stage battery chargers in which the subsequent steps have been given distinctive names Boost 1 The charger starts by supplying a constant current to the battery dimensioned to 10 20 of the 20 hour capacity of the battery This is the actual charging step in which the bulk of the active material in the battery is converted Absorption U during charging the voltage rises Upon reaching the preset voltage 1 14 4 or 14 8V the charger keeps the preset voltage constant for a preset period of time During this period charging is completed and the last percents of active material are converted Float oU after completion o2. 11 4 do not necessarily have to match L5 6 Use the same cable type for ALL connections Only use good quality cable without defects or damages WARNINGS Lead THE X CELLER BATTERY CONTAINS LEAD AND SULPHURIC ACID BOTH COMPONENTS ARE DANGEROUS TOWARDS HEALTH ALWAYS WASH HANDS PROPERLY AFTER HANDLING A BATTERY OR ELECTROLYTE re Sulphuric acid SULPHURIC ACID IS A CORROSIVE PRODUCT WHEN SPILLED ON SKIN IT CAN CAUSE SEVERE BURNS IN CASE OF SKIN CONTACT IMMEDIATELY FLUSH SKIN WITH PLENTY OF WATER USE CHEMICAL SAFETY GOGGLES AND OR A FULL FACE SHIELD WHERE SPLASHING IS POSSIBLE MAINTAIN EYE WASH FOUNTAIN AND QUICK DRENCH FACILITIES IN WORK AREA WEAR IMPERVIOUS PROTECTIVE CLOTHING INCLUDING BOOTS GLOVES LAB COAT APRON OR COVERALLS AS APPROPRIATE TO PREVENT SKIN CONTACT GSO Hydrogen HYDROGEN GAS IS GENERATED UPON OVERCHARGING AND POLY PROPYLENE CASE FAILURE HYDROGEN GAS MAY BE FLAMMABLE OR EXPLOSIVE WHEN MIXED WITH AIR OXYGEN CHLORINE AVOID OPEN FLAMES SPARKS OTHER SOURCES OF IGNITION NEAR BATTERY TO AVOID RISK OF FIRE OR EXPLOSION KEEP SPARKS OR OTHER SOURCES OF IGNITION AWAY FROM BATTERY AND DO NOT ALLOW METALLIC MATERIALS TO SIMULTANEOUSLY CONTACT NEGATIVE AND POSITIVE TERMINALS OF CELLS AND BATTERIES Short circuit ALWAYS DISCONNECT THE NEGATIVE TERMINAL FIRST IF COUPLED TO THE CHASSIS AFTER DISCONNECTING THE POSITIVE TERMINAL FIRST CONTACT WITH CHASSIS MAY STILLCAUSE A SHORT
3. 225 monoblocks in a series parallel connection result in a 24 450Ah system A very important but often forgotten part in a series parallel setup is the so called compensation cable This cable mounted between the series strings takes care of voltage differences over both strings by equalisation In an ideal situation with 100 identical batteries this cable is currentless ALWAYS BE VERY CAREFULL WHEN MAKING THESE CONNECTIONS AND BE SURE THEY ARE PROPERLY FUSED AND CAN BE DISCONNECTED OVER A MAIN SWITCH A WRONG CONNECTION CAN RESULT IN A SHORT CIRCUIT AND FIRE compensation Monoblock requirements Certainly in this case requirements have to be met by the batteries used to make the system When 1 three brand new batteries are placed in a system with one older battery performance will never exceed that of the worst one in the setup Choose the number of batteries placed in parallel as small a possible Use only batteries of same make type and age Cabling The rules for cabling of a series parallel or series parallel connection are identical to those for a charger the diameter of the cable has to match the highest current in this case also the discharging current instead of charging current Calculate the diameter of the cables according to the equation HIGHEST current 0 25 x metres Ifthe result is not a standard diameter choose for the higher standard one Use cable lengths L1 L2 L3 L4 and L5 L6
4. CIRCUIT WHEN CONNECTING TO A CHARGER FIRST CONNECT THE CLAMPS TO THE TERMINALS BEFORE SWITCHING THE CHARGER ON TO PREVENT THE FORMATION OF SPARKS carbon fibre deep cycle monoblock battery 15
5. X cellers s electrolyte may freeze and form cracks in the battery case A well charged with s g 1 280 kg l electrolyte has the lowest freezing point 70 C Winter storage During the actual storage period the X celler needs practically no attention If the battery stays connected to a trickle charger Veo 13 2 to 13 5V over the winter a check of the system every 3 months will do If a charger uses a higher Vfox 1 13 8V or if the X celler is aged then check the system every month until the behaviour of the system is known When the X celler is stored disconnected from whatever circuit and is not tricklecharged a thorough charging every 3 months is recommended regardless of the specific gravity of the electrolyte A bit of overcharging is to be preferred over a partly discharged state especially when the battery is not ready for use at the start of a new season As soon as the specific gravity has fallen below 1 240 kg l the X celler must be charged Storage conditions High temperatures accelerate unwanted side reactions in the X celler like for instance self discharge That is why the X celler has to be stored in a dry cool and ventilated place When properly charged the colder the storage conditions the better carbon fibre deep cycle monoblock battery 10 X celler and solar energy Because of it s charging characteristics the X celler is very well suited to act as a means of energy storage in sol
6. the electrolyte s specific gravity is still low 1 240 1 260kg l when the X celler is supposed to be fully charged Sulphuric acid charged back into the electrolyte does not have the chance to diffuse fully into the solution but pockets of concentrated acid are formed This behaviour is directly related to the low rates of gas evolution by low antimony alloys and the demand for low maintenance The concentrated acid trapped between the plates 15 very corrosive and if not dispersed into the solution it can harm the grids This phenomenon can be dealt with by applying An equalisation step during a short period of time the X celler is charged with constant current and unrestricted voltage In doing so hydrogen and oxygen bubbles are formed which vigorously mix the solution A charging characteristic including equalisation would be UoUIoU boost absorption float equalisation float The amount of equalisation needed depends however on the performance of the charger used and the initial state of charging of the battery Recommended equalisation currents are X celler 60 1 00 A X celler 75 1 50 A X celler 95 1 50 A X celler 105 1 75 X celler 120 2 00 X celler 185 3 00 A X celler 230 3 5A float during float a very small current 100 200mA passes through the battery Over prolonged periods of time float maintains a circulation in the electrolyte by which mixing occurs The effectiveness of float in preve
7. the storage period This does not have to be a problem for the X celler but 15 a source of annoyance because when needed it may take a long time to recharge the battery A current leakage as small as 50mA drains an X celler 95 to 100 DoD in 92 days Disconnect the X celler from the circuit by removing at least 1 connector When the negative is connected to earth reomove the negative when positive is connected to earth disconnect the positive thus preventing short circuits Cleaning Moisture and dirt on the lid of the X celler can form a conductive path between the terminals Even when disconnected the battery may then discharge quickly It is therefore important that the lid of the X celler 15 kept clean and dry before storage Cleaning with water and soap is usually sufficient Do not use organic solvents Apply some acid free Vaseline to the terminals to prevent oxydation Charging before storage After disconnecting the X celler check the electrolytre level in the cells Unlike topping up with water after the charging process during routine in storage preparation it is best to top up before charging Do not overfill however because charging increases electrolyte volume A good electrolyte level will keep self discharging at a low rate If possible rock the X celler back and forth around it s length axis to enable entrapped gasses to escape and mix the acid Charging is of great importance In a cold winter and if not properly charged the
8. Nederlandse Accumulatoren Productie BV PO Box 2427 6040 AE Roermond Montageweg 1 6045 JA Roermond The Netherlands telefoon 31 475 32 41 47 telefax 31 475 32 29 99 e mail internet http www centurion akku nl de akku met de meeste plussen User manual X celler the energy source for electric vehicles INDEX INTRODUCTION Q Dimensioning Capacity Size Q Before use Q Maintenance Q Charging The winter Charging Commissioning Exterior Contacts Electrolyte level Charging characteristics Charging current Charging voltage Temperature Tropical acid When charge the battery The charging process Equalisation cabling Disconnecting Cleaning Charging before storage Storage in winter Storage conditions carbon fibre deep cycle monoblock battery O 501 11 The solar panel The controller O Multi battery systems sesssessoessoosssosssoessosssosssoosssosssoessoeo 12 Connection in series Requirements for connection in series Connection in parallel Requirements for connection in parallel the series parallel connection Requirements for series parallel connections Cabling __ _ _ 15 carbon fibre deep cycle monoblock battery User manual X celler battery Introduction The X cell
9. The capacity has doubled When making a connection 1 parallel special attention is needed for the cabling used It is of the utmost importance that ALL the wires from terminal to the central conductor are of the same lenght A difference in length means a difference in resistance wich results in an undercharged battery on one end of the chain and an overscharged battery on the other end This comes from the fact that in a parallel connection the voltage is constant and current varies I x voltage current x resistance 12V Monoblock requirements Whenever a choice CAN be made always design a parallel system as small as possible Still a single monoblock system is to be prefered Small differences in the parallel system may cause problems that could easily be prevented by using a single battery i e one X celler 225 instead of 2 X celler 110 in parallel For the correct functioning of X celler batteries connected in parallel it is very important that performances of the connected monoblocks are equal This means the modules have to be taken into service as set of the same age and type Mixing battery types causes trouble because the smaller one 15 overcharged and the bigger 15 starved and will lose capacity The series parallel connection With a series parallel connection the advantages of the both connection types can be combined both voltage and capacity are being increased Four X celler
10. ar applications independent from grid or in off grid applications The solar panel In an autonomous photo voltaic installation in most cases the solar panels are connected in series parallel A regular 55W solar panel produces a maximum current of 3A at 17 Volt Of course there are more powerfull solar panels but the concept is the same For instance 10 solar panels can be used in parallel dependent on the controller used all positive and negative connections from the panels on the controller are made at the same point and the whole system can supply 17V 30Apeax The advantage when applied in a 2 x 5 series parallel system is that thinner cabling can be used because of reduced current 4 peak Please read the documentation that comes with the solar panel controller very carefully because wrong connections can cause severe damage to the system 12V system panels in parallel 24 system panels in series The controller The controller of a solar installation controls both charging of the batteries and depth of discharge DoD The effectiveness of the deep discharge protection is however dependent on the system chosen Often this device is nothing more than a protection against reversed polarity so that the batteries can be discharged extremely deep An item to take into account very carefully Often the controller can be adjusted for both charging and cut off voltage For setting the charging parameters follo
11. er from CENTURION AKKU 1s a ready to go battery pre filled and charged This means the battery can be used immediately and will deliver its power for prolonged periods of time Although hardly any maintenance is required there are some guidelines When followed these extend the pleasure of using the X celler to the max Dimensioning 2 Capacity The X celler is suited for multiple applications but has to be dimensioned correctly Upon choosing an X celler be aware of the fact that the useful capacity is 60 of the nominal capacity The useful capacity depends on the amount of current taken from the battery A calculation example on a discharge at the C5 and C20 rate C5 a floor scrubber drains 15A out of the battery With a 5 hour capacity of 75 Ah X celler 95 the battery can deliver 15 A for 5 hours This however means a 100 discharge and strongly reduces battery life The X celler has a safe depth of discharge of 60 wich means that the scrubber can be used for 3 hours 3 h x 15 A 75 Ah continuously without having to recharge or damaging the battery C20 a weighing unit attached to an inverter drains 55 W from the battery 55 W 12 4 6 A The capacity at the 20 hour rate of the X celler 95 is 95 Ah 134 21 21W 12 4 6A is being drained from the battery The capacity of the X celler 110 at the 20 hour rate is 95Ah wich equals a discharge current of 4 75 A for 20 hours With the 50 safety margin included the
12. f the charging process the charger switches to a lower voltage 13 5V This is a maintenance step to compensate for self discharging over prolonged periods of time When set properly the battery can stay connected to the charger Wa Wa is a charging characteristic used with simple and cheap chargers During a fixed period the battery 1s charged with constant power and the charger switches off automatically carbon fibre deep cycle monoblock battery 15 Voltage Cv pang 5 0 10 20 30 40 50 BO 100 Time hour Charging current The many different types of chargers also take a diversity of charging currents into account A high initial current during boost phase shortens charging time but at a cost in efficiency The lower the charging current the higher the efficiency so charging current and time are not in a linear relationship The X celler batteries can be charged well with a charging current between 10 and 20 of the nominal 20 hour capacity For example the 20 hour capacity of an X celler 110 is 95 Ah The recommended charging current during boost is 9 5 19A which will be 10 20 in practice Recommended charging currents for the X celler range X celler 60 75 and 95 10A X celler 95 105 and 120 20 X celler 185 and 230 30 A With given currents during boost the X celler battery can be charged properly in 8 to 10 hours It is recommended though to check the effectiveness and suitabil
13. itted carbon fibre deep cycle monoblock battery Fit the X celler on a well ventilated place or make sure that the tube supplied with the X celler can ventilate into open air When fitted on a boat make sure seawater never can enter the battery as the salt causes poisonous chlorine gas to be formed and the battery loses its ability to be recharged Thoroughly clean the connectors and apply some acid free vaseline to the terminals before connecting Always connect the positive connector first as the negative is mainly connected to the chassis Accidental short circuits may be prevented this way Maintenance Exterior Keep the exterior of the X celler clean and dry Moist or dirt on the lid forms a conductive path over the terminals which causes a small short circuit the battery is able to discharge itself through this short circuit Over prolonged periods the battery could discharge too deeply and performance would decrease Contact During use of the battery it is possible that lead sulphate is formed on the X celler terminals The formation of this compound will not harm the battery but acts as an insulator between terminal and connector and causes voltage loss Whenever this white blue compound is detected clean connectors and terminals and apply some acid free vaseline to the terminals Electrolyte level Dependent on frequency of charging and the type of charger more or less water is consumed Water loss is a
14. ity of the battery charger during the first few cycles by measuring the specific gravity of the electrolyte after the charging process has been completed Before measuring shake the battery a few times to enable entrapped gasses to escape and to mix the electrolyte Voltage The maximum voltage during boost and absorption is of great interest to speed and efficiency of the charging process Where normally 14 0V is sufficient to charge the X celler to the max a higher end voltage shortens duration remarkably A standard battery charger is normally preset to cut off at 14 4V during absorption and 13 5V during float With an 000 charger 15A 14 8V 13 5V a 50 discharged X celler 110 is fully charged in 10 hours at 20 C WARNING determination of the specific gravity directly after charging will not be accurate since gas is dissolved in the electrolyte and lack of mixing results in a much lower specific gravity reading Keep the battery on float for a couple of days during first cycles or shake the battery before measuring to make sure the electrolyte is mixed either by convection or movement Before measuring disconnect the X celler from the charger A simple W charger is normally uncontrolled and voltage can in theory go endlessly high When using such a charger determine the density of the electrolyte at regular intervals first switch off the charger When a specific gravity of 1 26kg l has been reached shake the battery and determine
15. nting stratification however depends on temperature and has to be verified in the actual setup Equalisation mentioned above is only necessary in stationary applications When used is caravans campers or yachts sailed with the vibrations in and from the vehicles is sufficient to compensate for stratification Wiring The wiring between the X celler and the charger is an extremely important part of the system thin cables get hot on high currents and cause a voltage loss The voltage supplied to the battery is lower and charging takes more time The optimal diameter for the cables is current x 0 25 x metres cable For example for 25 charger with 2 metres of cable to the battery a diameter of 25 x 0 25 x 2 12 5 is needed When choosing between different standard diametres like 10 or 15 mm always take the thicker one in this case 15 mm carbon fibre deep cycle monoblock battery Winter storage In a lot of professional applications especially in the agricultural sector the battery is used for only a short period of time over the year and is stored for the rest The X celler can be prepared for this storage period fairly easy and be kept in top condition for serving another year Disconnecting Most problems after storage come from the fact that the battery stays connected in a circuit Because of the fact that hardly any circuit is completely free of current leakage for whatever reasons the battery is drained over
16. olyte with a hydrometer Also it is possible to extract the state of charge from the open circuit voltage NOTE the battery has to be in a depolarized condition to obtain an accurate reading Whenever specific gravity reaches 1 180 or open circuit voltage is 12 12V the X celler must be charged A deeper discharge has a negative effect on battery life carbon fibre deep cycle monoblock battery The charging process During charging of the battery discharged positive and negative active material both lead sulphate PbSO is converted into the starting materials lead dioxide PbO positive and lead Pb negative In the early stages of the charging process the specific gravity of the electrolyte is still low and so is the voltage Because charging is an endothermic process the conversion takes energy the voltage needed to charge a battery is always higher than the voltage of the battery itself As of a 70 80 level of charging enough active material has been converted to allow the battery voltage to indicate battery fully charged end of boost step Because of the fact that the voltage of the battery counteracts the voltage of the charger the remaining 20 of capacity takes more time and effort to be restored Equalisation When the X celler is used in a stationary setup and strong cyclic application there is a risk of stratification of the electrolyte After finishing the absorption fase of charging the reading of
17. ontrol is strongly recommended Directly coupled to the fact mentioned above is the influence temperature has on side reactions like positive grid corrosion grids are the lead support structures wich carry the active material and water loss The higher the temperature the higher the water loss gassing becomes more vigorous the faster corrosion and with that wear of the battery Tropical acid When operating the X celler at constantly higher temperatures the battery has to be supplied with tropical acid in wich the electrolyte has a density of 1 240 The advantage of the lower density lies in the fact that it is less corrosive towards grid lead than regular 1 280 kg l battery acid Other parameters like current voltage on charging can be kept as if operating a regular X celler When charging Any lead acid battery including the X celler has its longest life when kept in charged condition In practice this means that whenever there is an opportunity for changing the battery it 15 best to do so The shallower the discharging cycles the longer the X celler life Maximum depth of discharge in this case will be 50 state of charge 9 0 10 20 30 40 50 80 70 80 g 100 spec gravity kal 1080 1 100 1 120 1 140 1 160 1 180 1 200 1 220 1 240 1 260 1 280 voltage 1152 11 64 11 76 1188 1200 1212 1224 1236 1248 1260 12 72 The condition of the X celler can be determined by measuring the specific gravity of the electr
18. side reaction taking place in every type of lead acid battery during charging at the end of the charging process the potentials on positive and negative plates become very high due to polarisation and hydrogen and oxygen are being formed With higher temperatures the rate of water loss increases Check the electrolyte level every 3 months The level 15 too low when the plates are dry or when the magic eye 1s transparent Top up only AFTER charging and ONLY with demineralised distilled water until the level touches the indicator 60 75 95 is cm above the plate surface X celler 105 covers the white cross of the hold downs X celler 120 185 230 1 Charging The X celler from CENTURION AKKU 1s a very easy to use battery and can be charged with practically every regular charger available and with a broad range of currents The time necessary to charge the X celler however depends on the parameters of the charger used charging characteristic charging current voltage and temperature Charging characteristic There are many different kinds of battery chargers on the market The differences are in the technology used transformer or high frequency and in the charging characteristic programmed the parameters controlled during the charging process When different parameters are controlled in subsequent steps then the charger has multi stages I 115 the symbol of current Ampere When charging with
19. w the chapter charging of this manual Target has to be reaching 100 state of charging during daytime when not fully charged discharging cycles will go deeper and deeper and the X celler may fail prematurely A proper setting of a deep discharge protection 15 a cut off voltage of around 11 5V per 12V battery Over the range discharge currents C20 C100 11 5V corresponds with a depth of discharge of 50 If the controller is programmable it is best to add an equalisation step to the charging parameters to boost the X celler to 100 once a week carbon fibre deep cycle monoblock battery 11 Multi battery systems In very small solar systems like the ones used in caravans or campers a single X celler provides enough energy A more demanding application like an off grid bungalow has a higher need for power and therefore needs more batteries For a long battery life certain rules must be observed strictly especially when batteries are connected in parallel Connection in series A connection in series is been made when the power supplied to or taken from the batteries becomes very high and resistance of the wiring could be a problem Compare this to 1 e the starter system of a truck versus the system in a car consists of 1 starter battery in 12V system and a starter motor of 1 2kW The current needed to start the engine is 1200W 12 100A The engine of a truck is much heavier as is the starter motor A break away po
20. weighing unit can be used for 4 75A for 20h This means that including the 50 safe margin the battery can supply its energy to this setup for 10 5 hours uninterruptedly Size The CENTURION AKKU X celler range consists of batteries in 7 different capacities and sizes Always try to utilize the available space to the max it is better to use an overrated battery because There will always be sufficient power in reserve also in unexpected or emergency situations heavier battery is discharged less deeply when used with the same user profile than a battery with less capacity and so it will experience less strain wich results in a longer life of the X celler Before use Charging It is advised to charge the X celler before taking it into commission to let the X celler provide the full potential it has been manufctured for Even when not used 1 e during storage a lead battery discharges itself slowly and loses a part of the capacity that might be necessary at one point Commissioning X celler is manufactured with a robust configuration in a strong box of polypropylene When moving try to prevent the X celler from bumping into sharp objects wich may cause any leakages When using hoist don t attach it to the handles as these are for manual moving only Put the batteries on a pallet and hoist the pallet Prevent too sudden moves as when the tilting angle exceeds 55 acid may be spilled when flame retarders are not f
21. wer of 14kW is not unusual In a 12 14 4kW setup this would mean the battery has to deliver 1200A This 15 not only an extremely high current for one battery but it would also require large diameter wiring To reduce the wiring diameters in solar applications connection in series is usual The scheme below shows the wiring of a 48 Volt system with 4 X celler batteries connected in series Compared to a 12V installation of the same power range the current is only 25 which means wiring diameter and cost can be reduced In private applications 24 Volt systems are commonly used Their layout comprising two X celler batteries 15 comparable to the 48 system shown Monoblock requirements For the correct functioning of X celler batteries connected in series it is very important that performances of the connected monoblocks are equal This means the modules have to be taken into service as a set of the same age and type Mixing battery types causes trouble because the smaller one is overcharged and the bigger one is starved and will lose capacity Parallel connection A connection in parallel 15 made when the number of solar panels in a system or the need for power exceeds the performance of a single battery A parallel connection doesn t increase the voltage like a connection in series but increases the capacity Two X celler 225 batteries connected in parallel act as if the set were a single 450Ah C100 monoblock
22. whether a gravity of 1 28 has been reached If so charging time has been determined carbon fibre deep cycle monoblock battery Temperature Temperature has a strong influence on the charging process the efficiency of the charging process and side reactions as water loss and deviation from the measured or read specific gravity of the electrolyte depend on temperature Temperature C Measured s g kg x Corrected s g kg x at 20 C 6 1 290 1 280 13 1 285 1 280 20 1 280 1 280 27 1 275 1 280 34 1 270 1 280 table above shows that the specific gravity s g diverts from the actual value at 20 C by 0 5 points every 7 C 0 005 When a specific gravity of 1 280 is measured at a temperature of 27 C the battery is actually being overcharged because the temperature corrected value is 1 285 kg l This fact needs to be taken into account seriously because overcharging can damage the battery Next to that temperature influences the charging process in a way that for every degree of deviation from 20 C a correction should be made The more advanced multi stage chargers come with a temperature sensor that can be mounted on terminal or case Temperature control takes care of decreasing above 20 C or increasing below 20 C the charging voltage with 18 24mV C for a 12V setup In practice temperature control 15 not necessary 1 the range 10 C 30 C Outside these boundaries temperature c
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