Assembly and Operating instruction. 24 V Modules 48 V Modules SH24V16.0 SH48V16.0 SH24V24.0 SH48V24.0 SH24V32.0 SH48V32.0

Transcription

1 Assembly and Operating instruction Stationary valveregulated leadacid battery 24 V Modules 48 V Modules SH24V8.0 SH48V8.0 SH24V16.0 SH48V16.0 SH24V24.0 SH48V24.0 SH24V32.0 SH48V32.0

2 Content 1 Safety precautions Technical Data: Assembly instruction Installation preconditions and preparations Check of delivery Documentation Replacement of batteries Measurement of open circuit voltage Cabinets with separately delivered block batteries Operating instruction Commissioning Operation Discharge Charging for operation with controlled partial state of charge (cpsocoperation) Maintaining the full charge (float charge) Alternating currents Temperature Temperature related charge voltage Battery maintenance and control Tests Faults Storage and decommissioning Transport Discharge data Modules Module SH24V8.0, SH48V Module SH24V8.0B / SH48V8.0B Module SH24V8.0S / SH48V8.0S Module SH48V Module SH48V16.0B Module SH48V16.0S a Module SH48V16.0S b Module SH24V24.0, SH48V Module SH24V32.0, SH48V Installation note for modules Service report page 2

3 1 Safety precautions Observe these Instructions and keep them located near the battery for future reference! Modules must be installed, maintained or repaired by qualified personnel (electrically skilled person) only! Do not smoke! Do not use any naked flame or other source of ignition in close vicinity of the battery. Risk of explosion and fire! While working on batteries wear protective eyeglasses and clothing. Observe the accident prevention rules as well as EN , EN Any acid splashes on the skin or in the eyes must be immediately flushed with plenty of water. Then seek medical assistance. Spillages on clothing should be rinsed out with water. Warning: Risk of fire, explosions or burns. Do not disassemble, heat above 60 C, or incinerate. Avoid short circuits. Avoid electrostatic charges and discharges. / sparks. Electrolyte is very corrosive. In normal working conditions the contact with the electrolyte is impossible. If the block container is damaged do not touch the exposed electrolyte because it is corrosive. Block batteries are very heavy! Make sure they are installed securely! Only use suitable means of transport! Block batteries are sensitive to mechanical shock. Handle with care! Do not lift or pull blocks on the poles. Caution! Metal parts of the battery are always alive, therefore do not place items or tools on the battery. Risk of short circuit or electric arc! Use insulated tools for working on battery terminals and cables! Keep children away from batteries! Noncompliance with installation instruction, 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 (e. g. opening of valves on VRLA batteries) render the warranty void. Spent batteries have to be collected and recycled separately from normal household wastes (EWC160601). The handling of spent batteries is described in the EU Battery Directive (2006/66/EC) and their national transitions (UK: HS Regulation 1994 No.232, Ireland: Statutory Instrument No. 73/2000). Contact your supplier to agree upon the recollection and recycling of your spent batteries or contact a local and authorized Waste Management Company. page 3

4 2 Technical Data: Block battery with 6 cells, each 2 V, Type Sonnenschein@home SH12V2.0: Type Nom. Norm. capacity Nom. Dimensions Weight Terminal voltage C 1.80 Vpc energy * L W H V Ah kwh mm mm mm kg SH12V MM845 * at nom. voltage of block battery and C 10 at 20 C, the effective energy is 50 % of nominal energy Modules Sonnenschein@home Equipped with block batteries type Sonnenschein@home SH12V2.0 Module Nom. voltage V SH24V SH48V SH24V SH48V SH24V SH48V SH24V SH48V Number of block batteries Hourly ventilation air flow Q** m³ / h Nom. energy* kwh * at nom. voltage of module and C 10 at 20 C, the effective energy is 50 % of nominal energy ** Ventilation complying with DIN EN has to be ensured Dimensions, weights and permissible area load refer to para. 0. page 4

5 3 Assembly instruction 3.1 Installation preconditions and preparations For the installation and operation of stationary batteries EN Safety requirements for secondary batteries and battery installations, Part 2: Stationary batteries is mandatory. Prior to commencing installation, ensure that the battery room is clean and dry. Pay attention to the following aspects: Load bearing capacity (refer to para. 6) and nature of the floor (transport paths and installation location). During normal use of valve regulated batteries electrolyte spillage is not to be expected. If an error occurs only few amount of some drops may leak. Do not use any source of ignition (sparking or glowing devices, electrical switches, fuses or other) in close vicinity of the battery. Observe a safety distance of at least 575 mm to the vent openings. Ventilation requirements refer to para Check of delivery Check delivery for complete and undamaged components. If necessary, clean all parts prior to installation. 3.3 Documentation Follow instructions in the documentation supplied (e.g. installation drawings for battery, refer to para. 0). 3.4 Replacement of batteries Prior to removing old batteries always ensure that all of the loads have been disconnected (loadbreak switches, fuses, insulations). This must be carried out only by personnel authorized to perform circuit operations. WARNING: Do not carry out any unauthorized circuit operation! 3.5 Measurement of open circuit voltage Carry out open circuit voltage measurements on the individual block batteries. At the same time, ensure that they are connected in the correct polarity. The opencircuit voltage of the individual block batteries should not vary themselves from the measured average value by more than ± V (guide value). If the deviation is any higher, contact the supplier. 4 Cabinets with separately delivered block batteries Assemble cabinet, place and align at the assigned location (observe the accident prevention rules). page 5

6 Cabinets installed stacked or side by side must be jointly bolted. The upper of stacked cabinets must be affixed to the wall with a wall anchor (scope of delivery). Dowel and anchor bolt do not belong to the scope of delivery. Check block batteries for perfect condition (visual check, polarity). If necessary, clean the contacting surfaces of the terminals and connectors. Allow sufficient side clearance (at least 600 mm) for installation, connecting and future maintenance and control of the block batteries. Place block batteries, using the ribbed plates supplied, in the cabinet in accordance with the installation plan (refer to para. 6), ensuring correct polarity. Align block batteries parallel to each other. Distance between block batteries shall be approx. 10 mm. Place and screw block connectors using an insulated torque wrench (for correct torque value refer to battery operating instructions). Apply the following torque for screw connectors: MM845 : 8 Nm Place the series and tier connectors supplied and screw them together, observing the given torque values. Avoid applying any mechanical force on the battery poles. All end connectors of batteries which connect batteries among each other, with the load, the disconnector or fuses, must be installed inherently shortcircuitproof. Measure total voltage (nominal voltage: sum of open circuit voltages of the individual block batteries). Sequentially number the block batteries in a visible place (not on the valves) between the positive terminal of the battery and the negative terminal of the battery. Apply polarity signs for the battery leads. Attach safety marking, type label and operating instructions in a visible place. For completing the type label refer to para. 6. Fit insulating covers for block connectors and terminals. WARNING: Prior to connecting the battery to the PV control unit, ensure that all installation work has been duly completed Do not connect any other electrical appliances to the block batteries or terminals installed in the cabinet. Observe also the assembly and operating instructions of the PV control unit the battery shall be connected to. page 6

7 5 Operating instruction In stationary valve regulated lead acid batteries of the series the electrolyte is fixed in a Gel. During the whole service life it is neither necessary nor allowed to topup water. Pressure valves are used for sealing and cannot be opened without destruction. 5.1 Commissioning Check all block batteries for mechanical damage, correct polarity and firmly seated connectors. Apply the following torque for screw connectors: MM845 : 8 Nm Fit insulating covers for block connectors and terminals Control of insulation resistance: New batteries: > 1M Ω Used batteries: > 100 Ω/Volt 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 connected. Switch on charger and start equalizing charging according to para in order to ensure the battery is fully charged. 5.2 Operation The following specification for operation and recharging must be met in order to achieve the number of specified cycles for the battery type Sonnenschein@home. GNB Industrial Power recommends asking the manufacturer or supplier to confirm that the PV control unit meets this specification. Alternatively the battery may be operated with a PV control unit deviating from the following specification, if it was released by GNB Industrial Power. For the installation and operation of stationary batteries EN is mandatory Discharge The state of charge (SOC) must not fall below 45 % of the nominal capacity C 10 during discharge Charging for operation with controlled partial state of charge (cpsocoperation) In daily cpsoc operation the state of charge must not exceed 95 % of C 10. All following voltage values refer to measurements at the battery terminals. In order to meet the following values for the charging voltages, the voltage drop on the connection between battery and charger must be kept as low as possible by using a sufficient cross section. page 7

8 If the charger has an input to compensate the voltage drop, e.g. by connecting a sense line connected to the battery terminal, GNB recommends using this feature Daily charge for cpsocoperation IPhase: Charging with PV system current minus load current: max. 6 x I 10, Duration: until cell voltage reaches 2.40 Vpc to 2.45 Vpc, then switch to: UPhase: Setting of the charging voltage: 2.40 Vpc to 2.45 Vpc. Duration: 120 min / 12 min Full charge If the PV system current minus load current is not sufficient to fully charge the battery, charging must be carried out with mains support. Remark: Hereby a state of charge of approx. 99 % of C 10 will be achieved. Every 14 days, or at least after a capacity throughput of 10 times of the nominal capacity C 10 : Charging characteristic: IU IPhase: average charging current I: 4 x I 10 ± 10% Duration: until cell voltage reaches 2.40 Vpc to 2.45 Vpc, then switch to: UPhase: Setting of the charging voltage: 2.40 Vpc to 2.45 Vpc. Duration: 300 min / 30 min Equalizing charge If the PV system current minus load current is not sufficient to fully charge the battery, charging must be carried out with mains support. Remark: Hereby a defined state of charge of 100 % of C 10 will be achieved. Every 90 days, or at least after a capacity throughput of 30 times of the nominal capacity C 10 : Charging characteristic: IU IPhase: average charging current I: 4 x I 10 ± 10% Duration: until cell voltage reaches 2.40 Vpc to 2.45 Vpc, then switch to: UPhase: Setting of the charging voltage: 2.40 Vpc to 2.45 Vpc. Duration: 600 min / 60 min page 8

9 5.2.3 Maintaining the full charge (float charge) Devices complying with the stipulations under DIN41773 must be used. They are to be set so that the average cell voltage is as follows (within temperature range 15 to 35 C): SH12V2.0: 2.27 Vpc ±1% Alternating currents According to the charging equipment, specification and characteristics alternating currents flow through the battery superimposing onto the direct current during charge operation. Alternating currents and their action 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. When recharging acc. to para the actual value of the alternating current is occasionally permitted to reach 10 A (RMS) / 100 Ah C 10 capacity. In a fully charged state during float charge the actual value of the alternating current must not exceed 5 A (RMS) / 100 Ah C10 capacity Temperature The recommended operation temperature range for the batteries Sonnenschein@home is 10 C to 35 C, (best 20 C ± 2 K). Higher temperatures will seriously reduce service life. The technical data are valid for the nominal temperature of 20 C. Lower temperatures reduce the available capacity and extend the charging time. The absolute maximum temperature of 55 C must not be exceeded. Permanent temperatures higher than 35 C shall be avoided Temperature related charge voltage The charging voltage shall be adjusted according to the battery temperature. For this the battery temperature has to be measured with a temperature probe, connected to the charger. The probe should be placed at a height of 1/3 of the cabinet height, respectively of the top tier. Pointed metallic probes or probes with an eyelet should be connected at the negative battery terminal. Flat probes should be placed on top or in the center of a longitudinal side of a block batterie. The battery must not be damaged by the temperature probe. Ideally the temperature related compensation shall be carried out as shown in curve A of Fig. 1 Alternatively the charging voltage can be linear temperature adjusted using a compensation factor of V/cell and K, relating to 25 C, refer to curve B of Fig. 1. Example: The charging voltage of 2.40 Vpc at 25 C corresponds to a voltage of Vpc at 30 C, respectively Vpc at 15 C. page 9

10 Charging voltage [Vpc] 2,55 2,54 2,53 2,52 2,51 2,50 2,49 2,48 2,47 2,46 2,45 2,44 2,43 2,42 2,41 2,40 2,39 2,38 2,37 2,36 2,35 2,34 2,33 2,32 2,31 2,30 B A Temperature [ C] Fig. 1 Charging voltage vs. temperature 5.3 Battery maintenance and control Keep the battery clean and dry to avoid leakage currents. Plastic parts of the battery, especially block containers, must be cleaned with pure water without additives. At least annually measure and record: Battery voltage Voltages of all block batteries in discharge operation Surface temperature of all block batteries Actual battery room temperature Average battery room temperature Amperehour (Ah) throughput Actual settings of the PV control unit at time of service Have the settings been modified? By whom? Reason for the modification? Annual visual checks: Battery installation and arrangement Ventilation page 10

11 If the voltage of one or more block batteries during discharge is lower than 0.49 V of the average block battery voltage or if the surface temperature difference between block batteries exceeds 5 K, the service agent should be contacted. 5.4 Tests Tests have to be carried out according to DIN EN Capacity test In order to make sure the battery is fully charged prior to a capacity test (e.g. acceptance test on site), the IUcharge method according to para must be applied, using mains support. 5.5 Faults Call the service agent immediately if faults in the battery or the charging unit are found. In order to facilitate trouble shooting and remediation the following recorded data must be made available to the service agent: Data of the annual control according to para. 5.3 Commissioning date of the battery installation Settings of the PV control unit at time of commissioning A service contract with your local installation company facilitates the timely detection of errors. 5.6 Storage and decommissioning To store or decommission block batteries for a longer period of time they should be fully charged and stored in a dry and cold but frostfree room, not exposed to direct sun light. To avoid damage the following charging methods can be chosen: Option 1: Maximum storage time beginning at full charged state is 17 months at temperatures 20 C. At higher temperatures, (e.g. after 8.5 months at 30 C) equalizing charges as detailed in para will be required. Option 2: float charging acc. to para Irrespective of the aforementioned storage times recharging is required latest when the opencircuit voltage of the block batteries falls below V. 5.7 Transport Block batteries must be transported in an upright position. They must be protected against short circuits. 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 slipping, upsetting or damaging. Block 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 shall be found on the exteriors of the packing unit. Block batteries page 11

12 with leaking or damaged containers must be packed and transported as class 8 dangerous goods under UN no In case of air transport, batteries which are part of any equipment must be disconnected at their terminals, and the terminals must be protected against shortcircuits. This is in order to avoid the risk of any incidents like fire etc. 5.8 Discharge data Discharge data at different discharge times and final discharge voltage. All technical data refer to 20 C. SH12V2.0 Discharge with constant current in A at 20 C Vpc 1 h 2 h 3 h 4 h 5 h 8 h 10 h 20 h SH12V2.0 Discharge with constant power in W / Block at 20 C Vpc 1 h 2 h 3 h 4 h 5 h 8 h 10 h 20 h page 12

13 6 Modules Depending on the connection of the block batteries in the cabinet and the interconnection of the modules, the name plate has to be filled in as shown below: Module Field 1 Field 2 Field 3 SH24V SH48V SH24V SH48V SH24V SH48V SH24V SH48V SH12V2.0 Field 1 Field 2 Field 3 Example for a module SH48V8.0 SH12V page 13

14 6.1 Module SH24V8.0, SH48V Module SH24V8.0B / SH48V8.0B Weight: Area load: ca. 260 kg, incl. 4 block batteries SH12V2.0 ca. 730 kg/m² Interconnection: SH24V8.0B 7 SH48V8.0B Pos Qty EPN Name 24 V 48 V CR PS0A Inter bloc connector, rigid 45 mm², L = 72 mm EC ZSKA End connector 25 mm², L = 900 mm EC ZSKA End connector 25 mm², L = 1200 mm CBP Rib plate 229 x 200 x Connection unit for flexible cable up to 95 mm² page 14

15 6.1.2 Module SH24V8.0S / SH48V8.0S Weight: Area load: ca. 275 kg, incl. 4 block batteries SH12V2.0 ca kg/m² 8 Interconnection SH24V8.0S 5 Pos Qty EPN Name 3 2 CR PS0A Inter bloc connector, rigid, 45 mm², L = 72 mm 4 2 EC ZSKA End connector 25 mm², L = 900 mm 5 2 EC ZSKA End connector 25 mm², L = 1200 mm 6 4 CBP Rib plate 229 x 200 x Connection unit for flexible cable up to 95 mm² Interconnection SH48V8.0S 8 Pos Qty EPN Name 3 2 CR PS0A Inter bloc connector, rigid, 45 mm², L = 72 mm 4 1 CC ZSKA Etagenverbinder 25 mm², L = 1100 mm 5 1 EC ZSKA End connector 25 mm², L = 600 mm 6 1 EC ZSKA End connector 25 mm², L = 900 mm 7 4 CBP Rib plate 229 x 200 x Connection unit for flexible cable up to 95 mm² page 15

16 6.2 Module SH48V Module SH48V16.0B Weight: Area load: ca. 520 kg, incl. 8 block batteries SH12V2.0 ca kg/m² Interconnection SH48V16.0B 7 Pos Qty EPN Name 3 6 CR PS0A Inter bloc connector, rigid 45 mm², L = 72 mm 4 2 EC ZSKA End connector 25 mm², L = 1200 mm 5 2 EC ZSKA End connector 25 mm², L = 1600 mm 6 12 CBP Rib plate 229 x 200 x Connection unit for flexible cable up to 95 mm² Interconnection SH24V16.0B: available on request page 16

17 6.2.2 Module SH48V16.0S a Weight: Area load: ca. 550 kg, incl. 8 Block batteries SH12V2.0 ca kg/m² 3 6 Interconnection SH48V16.0Sa Pos Qty EPN Name 3 4 CR PS0A Inter bloc connector, rigid 45 mm², L = 72 mm 4 2 EC ZSKA End connector 25 mm², L = 1100 mm 5 2 EC ZSKA End connector 25 mm², L = 1600 mm 6 2 EC ZSKA End connector 25 mm², L = 1800 mm 7 8 CBP Rib plate 229 x 200 x Connection unit for flexible cable up to 95 mm² Wall anchor Interconnection SH24V16.0Sa: available on request page 17

18 6.2.3 Module SH48V16.0S b Weight: Area load: ca. 550 kg, incl. 8 Block batteries SH12V2.0 ca kg/m² Interconnection SH48V16.0Sb Pos Qty EPN Name 3 4 CR PS0A Inter bloc connector, rigid 45 mm², L = 72 mm 4 2 EC ZSKA End connector 25 mm², L = 1100 mm 5 4 EC ZSKA End connector 25 mm², L = 1600 mm 6 8 CBP Rib plate 229 x 200 x Connection unit for flexible cable up to 95 mm² Interconnection SH24V16.0Sb: available on request page 18

19 6.3 Module SH24V24.0, SH48V24.0 Drawings und interconnection available on request. 6.4 Module SH24V32.0, SH48V32.0 Drawings und interconnection available on request. page 19

20 ventilation opening Installation of modules Attention must be paid to the weights and permissible area load at installation site Observe a safety distance for sparking or glowing devices (max. surface temperature 300 C) of at least 500 mm to Sonnenschein@home modules! Minimum opening for air inlet and outlet for natural ventilation resp. minimum ventilation air flow rate for rooms with technical (forced) ventilation 8 kwh modul appr. 50 cm² / x ~7 cm resp. 1.6 m³/h 16 kwh modul appr. 100 cm² / x ~10 cm resp. 3.2 m³/h 24 kwh modul appr. 150 cm² / x ~12 cm resp. 4.8 m³/h 32 kwh modul appr. 200 cm² / x ~15 cm resp. 6.4 m³/h The air inlet and outlet shall be located at the best possible location to create best conditions for exchange of air, i.e. openings on opposite walls, minimum separation distance of 2 m when openings on the same wall 6.5 Installation note for modules page 20

21 7 Service report a) Total battery voltage:... V b) Voltage and surface temperature of each block battery in discharge operation Discharge current / power at time of recording... A / kwh (delete as applicable) Block Voltage V Temperature C Block Voltage V Temperature C c) Battery room temperature:... C d) Average battery temperature... C (read from PV control unit) e) Amperehour (Ah) throughput... C (read from PV control unit) f) Settings of the PV control unit at time of commissioning (read from PV control unit) g) Modifications of the settings of the PV control unit at time of service (read from PV control unit) By whom? Reason for the modification? Date Signature page 21

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24 NXSSHOEPDF01013 Subject to change State October 2013 GNB INDUSTRIAL POWER Exide Technologies GmbH Im Thiergarten D Büdingen Tel.: 49 (0) / Fax: 49 (0) / gnb.com