SunXtender Technical Manual

Document No. 6-0100 Rev. H
Page 14 of 43
CHAPTER 5 - COMMISSIONING AND SERVICING INSTRUCTIONS
5.1 Storage
Sun Xtender® batteries are charged at the factory before shipment to the distributor. For
warranty coverage, batteries need to be properly boost charged while in storage and installed
within 12 months of the original factory ship date. Batteries should be stored in the coolest
environment available, preferably not exceeding 20°C (68°F). The higher the temperature, the
faster the battery will self-discharge and require boost charging. See Appendix C for data on
storage time versus temperature.
While in storage, batteries should be boost charged every 90 days or when the open circuit
voltage (OCV) drops to 2.08 volts per cell (12.5 volts for a 12-volt battery). This OCV
corresponds to approximately 75% state of charge. Boost charge batteries using a constant
voltage charger set at 2.45 volts per cell (14.7 volts for a 12-volt battery) at a temperature of
20°C (68°F). If the temperature is above 20°C (68°F), compensate the charge voltage by
subtracting 0.04V/cell for every 10°C difference (0.24V for a 12-volt battery). If the temperature
is below 20°C (68°F), compensate the charge voltage by adding 0.04V/cell for every 10°C
difference. The boost charge should be applied until the charging current falls below 0.5 percent
of the battery’s 24 hour rated capacity (0.5 amps for a 100 Ah battery). The time it takes for
boost charging can be estimated from the following equation, based on the battery state of
charge (SOC), rated capacity, and rated output of the charger:
Time to Reach Full Charge = [(1-SOC/100) x Rated Capacity (Ah) ÷ Rated Output of Charger
(Amp)] + 2 hours.
For example, when boosting a 258 Ah battery at 75% SOC using a 15A charger, the charging
time can be estimated as follows:
Time to Reach Full Charge = [(1-75/100) x 258 Ah ÷ 15A]+ 2 hours = 6.3 hours.
5.2 Installation
Sun Xtender® AGM batteries are designed to be installed upright (terminal facing upwards). For
installation in non-upright orientations, contact Concorde for assistance.
Be sure there is adequate ventilation in the area where the batteries are to be installed. Refer to
Section 7.1 for specific safety hazards associated with the emission of hydrogen gas. The space
surrounding adjacent batteries should be at least 0.25 inch to permit airflow around each
battery.
Batteries may be connected in series (voltage adds, capacity stays the same), in parallel
(capacity adds, voltage stays the same), or a combination of series and parallel (both voltage
and capacity add). Each of these connection options are illustrated in Figures 5-1 through 5-3,
respectively. Be sure to torque the terminal bolts to the values given in Section 4.2.
Always use batteries of the same size and condition in multi-battery installations. Connect
batteries using cabling that is sized for the maximum load of the system. The voltage drop on
the cables during charging should not exceed 0.2 volts at full output. Protect the battery
terminals from shorting during installation. When replacing batteries, it is best to replace the
entire set of batteries so they remain balanced.