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EnerSys reserve power

SBS EON Installation,


operations & Maintenance
training
Outline

• Safety
• Storage
• Installation
• Commissioning
• Temperature Operation and Effect
• Parameters & Settings
• Maintenance - checks, cleaning etc.
• Use of Ohmic measurements
• Capacity test to determine battery state of health
Health and Safety

Always follow supplied instructions For


• Weight
• Sulphuric Acid
• Electrical Hazard
• Hydrogen Gas
• And Fumes
Weight

• Take care when transporting, lifting and installing batteries.


• Also consider floor loadings of installations.

Note: Do not use terminal posts to lift or handle cells


Sulphuric Acid

• Electrolyte is very corrosive.


• Flush any acid splashes from eyes and off skin with plenty of clean water.
• Seek medical aid immediately.
• With flooded batteries, always wear safety glasses and protective clothing.
Electrical Hazard

• Batteries are always live.


• Only use fully insulated tools.
• Remove all rings, watches and necklaces.
• Break high voltage batteries down to 60V units before working on them.
• Always wear safety glasses.
Explosive Gas

• Risk of explosion and fire.


• When the concentration of hydrogen exceeds 3.8% (LEL) the atmosphere
becomes explosive.
• Note the requirements of BS6133 and EN50272. Advised to keep level
below 1%.
Transportation

Classified as Non- Spill-able and exempt from hazardous good requirements,


in accordance with:-
– 1) US Dept. of Transportation – 49 CFR Section 173.159a
– 2) ICAO/IATA Packing Instruction 872, Special Provision A67.
– 3) IMDG Class 8,UN ID 2800,Special provision 238, exemption for Non-
Spill-able batteries
when securely packed and protected against short circuits.
Storage – Shelf Life
Max Storage Duration before refresh charge:
- 24 months at 20°C
- 12 months at 30oC Note: Regular OCV Auditing Required
- 6 months at 40oC

• Refresh Charge:
2.33 to 2.40Vpc (4 x I 10A max) 12 to 24 hrs.
• Continued storage beyond these times increases the risk of reduced
capacity and service life as a consequence of build up of irreversible
sulphation.
• Temperatures in excess of 20°C reduces the interval between refresh
charges
Operating Temperature

• Recommended operating temperature range is:


• -40°C to +50°C.
• Higher temperatures reduce the operational life.
• Lower temperatures reduce the available capacity.
• Consideration must be given to depth of discharge low temperatures) and
ventilation (high temperatures).
Significant Benefits of SBS EON Technology

Superb charge acceptance rates for fast recharge capability


Ideal for hybrid systems
The generator’s run time to achieve the battery’s full state of charge
is significantly reduced
This leads to a very competitive total cost of ownership
Lower generator maintenance/replacement costs,
comprehensive savings in fuel consumption…

Class-leading volumetric and gravimetric energy density


Significantly more energy and power than a conventional VRLA
battery of the same size
Significant Benefits of SBS EON Technology
• Exceptional cycling performance in both float and fast charge applications
– PowerSafe SBS EON has a proven track record in off-grid hybrid
applications

• Market-leading shelf life due to low rate of self-discharge


– Up to 24 month storage (20°C) compared to conventional VRLA batteries

• Resilient to hot and harsh environments


– Wide operating temperature range (-40°C to +50°C) for greater application
flexibility

• Eurobat’s “Long Life” classification


– 15 year design life at 20°C
Product Marking

Product-specific label Ink-jet printed details


(stuck onto container) (on lid)
Installation

• Electrical protective measures and the accommodation


and ventilation of the battery installation must be in
accordance with applicable rules and regulations.
Specifically EN 50272-2
• Adequate ventilation when installed in cabinets
• Install in a clean dry area
• Cells will not emit corrosive gases under normal operation
and can be installed together with other electrical
equipment
• Avoid placing in a warm place or in direct sunlight
• Approved racks are recommended for proper installation
• Place the cells on the rack and arrange the positive and
negative terminals for connection according to the wiring
Installation

• SBS EON Blocs and cells can be mounted in any orientation except
inverted
• Do no use terminal posts to lift or handle units
• Do not install the cells in such a way that the box-lid bond is resting
on the runners
• Ensure spacing between blocs and cells are adequate
• Do not invert the cells (vents upside down) or allow the front of the
cells to be positioned lower than the base of the cell
May bloc safety valve or damage the runner
Installation

Check all contact surfaces are clean. If required clean with a brass brush
Tighten the terminal screws to the correct torque loading, as specified on the
label
Fit the covers supplied for protection against inadvertent contact
Follow polarity sequence to avoid short circuiting cell/ groups
With charger switched OFF, the battery fuses removed and the load
disconnected, connect the battery to the D.C. power supply.
Ensure polarity is correct positive terminal of battery to the positive terminal of
the charger
Installation

• Blocs and cells can be connected in parallel strings to


give higher current capability
• Use cells/ batteries of the same capacity, design and
age
• The resistance of the cables in each string must be
the same
• Connect the battery strings in parallel at the charger
terminal
Commissioning

• The first charge must be monitored to ensure that the limits are not
exceeded & that no unacceptable temperatures occur.
• Before conducting a capacity discharge or fully loaded duty cycle test, the
battery must be given a commissioning charge. Two methods of
commissioning SBS EON blocs and cells:
• In float applications the commissioning charge shall consist of 7 continuous
days of float charge at the recommended float voltage (2.29Vpc at 20°C)
with no load connected to the battery.
• In hybrid applications/ using fast charge the commissioning charge shall
consist of 24 hours charge at a voltage equivalent to 2.40 Volts/cell with no
load connected.
Recharge Parameters - Grid

• SBS EON Float Voltage


• Constant voltage chargers are recommended.
• The charging voltage should be set at the equivalent of 2.29Vpc at
20°C/68°F or 2.27Vpc at 25°C/77°F.
Charger voltage = 2.27 Vpc x No. of cells
• Minimum charge current limit = load + 0.1C10A, Maximum = Unlimited
• The recommended float voltage temperature compensation is:
Optimum Charge Parameters – Grid

Stable Grid
• Temperature compensated float voltage equivalent to 2.29Vpc @ 20°C
• Charge current - minimum 0.1C10A, maximum unlimited
• Grid Assist Boost voltage equivalent to 2.40vpc @ 20oC to fast charge
• Charge current –minimum 0.1C10A, maximum unlimited
• Followed by float voltage with temperature compensation applied as
required
Unreliable Grid
• (uncontrolled PSoC) Boost voltage equivalent to 2.40vpc @ 20oC to
fast charge
• Charge current –minimum 0.1C10A, maximum unlimited
• Followed by float voltage with temperature compensation applied as
required
Discharge Parameters - Grid

• The battery must not be discharged more than the capacity specified in
the performance tables.
• Deeper discharges may damage the battery and shorten its operational
life.
• As a general rule the end of discharge voltage shall be limited to the
values listed below
• A low discharge disconnect is recommended to prevent deep discharge
• Attention should be given to small loads that are not automatically
disconnected at the end of discharge

Oct 2015
Discharge Parameters - Grid

• SBS/ SBS EON batteries must not be left in a discharged condition


after supplying the load but must be immediately returned to recharge
mode.
• Failure to observe these conditions may result in greatly reduced
service life and unreliability.

Oct 2015
Accidental Deep Discharge

• Following accidental deep discharge, the battery must be recharged at


2.29 Vpc followed by an equalizing charge. As the internal resistance is
high at first, the initial charge current is low.
• Each deep discharge is abusive, and could affect the life expectancy of
the battery.
Oct 2015
Maintenance

• SBS/ SBS EON batteries are maintenance free, sealed, lead acid
batteries and do not have to be topped up with water or
electrolyte.
• The containers and lids should be kept dry and free from dust.
• Cleaning must be undertaken with a damp cotton cloth without
manmade fibers or addition of cleaning agents.

Avoid use of grease as this can damage the plastic materials


Maintenance

• Maintenance schedules are designed by customer. We would


recommend the following:
1. Every 6 months, check the total voltage at the battery terminals, the
cell voltages of pilot cells and the temperature.
2. Once a year, in addition to the above, take readings of individual cell
voltages.
3. Keep a logbook in which the measured values can be noted as well
as power cuts, discharge tests, etc.
4. For hybrid cyclic applications data logs of battery voltage, current,
temperature over time
• Do not attempt to open the safety valve.
• Opening could cause lasting damage to the battery and is prohibited.
Ohmic Measurements as a Maintenance Tool

• Use of Ohmic measurements on lead acid stationary cells


continues to gain in popularity
• Traditional flooded cells use electrolyte specific gravity, level
and voltage; as well as visual observations to help determine
the state of health
• With the increasing use of sealed VRLA (valve regulated lead
acid) cells in the early and mid 1980’s, maintenance
technicians lost the use of most of the above tools:
– VRLA designs utilized opaque containers and “starved”
electrolyte systems that were immobilized in a gel or porous
separator.
Ohmic Measurements as a Maintenance Tool

• Ohmic measurements are not a substitute for capacity testing and


should not be used to predict absolute capacity values.
• Ohmic measurements can be used as a trending tool over time in
field service to identify weak cells that may require further evaluation.
• Ohmic measurements taken at the manufacturing factory can be
misleading and at times not useful as baseline data for trending
studies in field service.
• Ohmic readings should always be acquired utilizing the same testing
equipment, to assure accurate / consistent results. Changing test
equipment can nullify previous data for trending purposes
• Since Ohmic readings depend greatly on the surface condition of the
connection and the location of the connection of the instrument, care
must be taken for data trending to be effective companies
Capacity Discharge Testing

• The only true measurement of the state of health of a battery


• Always complete a full discharge test
• Ensure the battery is fully recharged before capacity testing
• Best practice is to define the discharge test based on the
application in terms of the load and autonomy or what is practical
• Discharge in comparison to published values
• Log individual cell/ bloc voltage throughout the duration of the
test at regular intervals
Battery Disposal

NOTE: Please refer to the respective battery/ cell instruction


manual for further guidance
For further information visit the
EnerSys® website:
www.enersys.com