EnergyCell PLC Series Owner’s Manual
About OutBack Power Technologies OutBack Power Technologies is a leader in advanced energy conversion technology. OutBack products include true sine wave inverter/chargers, maximum power point tracking charge controllers, and system communication components, as well as circuit breakers, batteries, accessories, and assembled systems. Applicability These instructions apply to OutBack EnergyCell PLC series batteries only. Contact Information Address: Corporate Headquarters 17825 – 59th Avenue N.E.
Table of Contents Important Safety Instructions ............................................................... 4 Additional Resources ...................................................................................................................... 4 Introduction ..................................................................................... 5 Audience .........................................................................................................................................
Safety Instructions Important Safety Instructions READ AND SAVE THESE INSTRUCTIONS! This manual contains important safety instructions for the EnergyCell battery. These instructions are in addition to the safety instructions published for use with all OutBack products. Read all instructions and cautionary markings on the EnergyCell battery and on any accessories or additional equipment included in the installation. Failure to follow these instructions could result in severe shock or possible electrocution.
Introduction Audience This manual is intended for use by anyone required to install and operate this battery. Be sure to review this manual carefully to identify any potential safety risks before proceeding. The owner must be familiar with all the features and functions of this battery before proceeding. Failure to install or use this battery as instructed in this manual can result in damage to the battery that may not be covered under the limited warranty.
Installation and Operation Materials Required Tools (use insulated tools only) o Digital voltmeter o Socket wrench o Torque wrench calibrated in inch-pounds o Box end wrench o Battery lifting equipment (handles) and fork lift to lift pallets of batteries o Rubber gloves o Full face shield o Plastic apron o Portable eyewash o Spill kit o Fire extinguisher (class C) Accessories o Interconnect bar (included) o Terminal cover (included) o Hardware (included) o Interconnect cables a
EnergyCell Batteries Self-Discharge All EnergyCell batteries will discharge over time once charged, even in storage. Higher storage temperatures increase the rate of self-discharge. Fully charged, the natural (“rest”) voltage of all EnergyCell batteries is approximately 13.0 Vdc. A battery should have a freshening charge (see page 12) if its rest voltage is below 13.0 Vdc per battery (2.16 Vdc per cell). A battery should not be used if its rest voltage is 12.0 Vdc or lower upon delivery.
Installation and Operation The EnergyCell can be discharged and recharged (cycled) regularly to a level as low as 50% depth of discharge (DoD). This is common in a cycling application such as an off-grid system. However, for optimal life, the best practice is to avoid ever discharging below 50%. Lower DoD levels can shorten the battery life. If operated in a range with consistent charge and discharge to no more than 50% DoD, the EnergyCell PLC will typically have a life of 3,000 cycles.
EnergyCell Batteries Batteries are placed in parallel (positive to positive, negative to negative) for additive amp-hour capacity. Three batteries in parallel have three times the amp-hours of a single battery. However, batteries in parallel do not have additive voltages. A single set of batteries in parallel (as shown in this figure) have the same voltage as a single battery.
Installation and Operation DC Wiring CAUTION: Equipment Damage Never reverse the polarity of the battery cables. Always ensure correct polarity. CAUTION: Fire Hazard Always install a circuit breaker or overcurrent device on the DC positive conductor for each device connected to the batteries. CAUTION: Fire Hazard Never install extra washers or hardware between the mounting surface and the battery cable lug or interconnect. The decreased surface area can build up heat.
EnergyCell Batteries To make the DC connections: Make certain to clean all terminals and contact surfaces according to the steps on page 10. 1. If installing batteries in a rack or cabinet, always begin with the lowest shelf for stability. Place all batteries with terminals facing to the most accessible side of the rack. If terminal protectors are present, remove and save them. 2. In common configurations, the battery on one end will be the positive (+) output for that string.
Installation and Operation Commissioning The commissioning charge applies when the batteries have been in transit or in storage for 24 months or more. (This applies at a storage temperature of 25°C or 77°F. The interval is shorter at higher temperatures.) It is also needed when the battery system is intended for use at the minimum float charging voltage or when the number of cells in series is greater than 24.
EnergyCell Batteries current rates, the battery’s conversion efficiency becomes less and it may not become completely charged. The battery may permanently lose capacity over the long term. The purpose of the bulk stage is to raise the battery voltage to a relatively high level (usually referred to as either bulk voltage or absorption voltage). This number is shown as the Absorb Charging Voltage on page 12. If batteries are in series, this number is multiplied by the number of batteries in the string.
Installation and Operation Freshening Charge A maintenance or “freshening” charge should be given to batteries that have been in storage. The freshening charge must be appropriate to the battery model. All charging should be temperature-compensated (see below). With a three-stage charger, the voltages for each stage are set as noted on page 12.
EnergyCell Batteries Remote Temperature Sensor OutBack inverter/chargers and charge controllers are equipped with the Remote Temperature Sensor (RTS) which attaches to the battery and automatically adjusts the charger settings. When the RTS is used, it should be placed on the battery sidewall, as close to the center of the battery (or to the center of the bank) as possible. The charger determines the RTS compensation factor. Most OutBack chargers are preset to a compensation of 5 mV per cell.
Installation and Operation NOTES: 16 900-0227-01-00 Rev A
Troubleshooting and Maintenance Table 1 Troubleshooting Category Symptom Possible Cause Normal life cycle Replace battery bank when (or before) capacity drops to unacceptable levels. Defective cells Test and replace battery as necessary. Excessively cold battery Carefully warm up the battery. Undersized cabling Increase cable ampacity to match loads. Loose or dirty cable connections Check and clean all connections. Physical damage on terminals may require the battery to be replaced.
Maintenance Periodic Evaluation Upon replacement of a battery, all interconnect hardware should be replaced at the same time. To keep track of performance and identify batteries that may be approaching the end of their life, perform the following tests during on a quarterly basis following commissioning (see page 12). Tests must be made with a high-quality digital meter. Voltages must be measured directly on battery terminals, not on other conductors.
Specifications Table 2 Specifications EnergyCell 200PLC Cells Per Unit 6 Voltage Per Unit 12V Optimal Operating Temperature 68°F to 86°F (20°C to 30°C) Operating Temperature Range (Storage) –4° to 104° F (–20° to 40° C) Operating Temperature Range (Discharging) –40° to 149° F (–40° to 65° C) Operating Temperature Range (Charging) –5° to 140° F (–15° to 60° C) Float Charge Voltage 13.5 Vdc Absorb or Equalize Charge Voltage 14.
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