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Emerson Network Power provides customers with technical support. Users may contact the nearest Emerson local sales office or service center.
Copyright 2004 by Emerson Network Power Co., Ltd.. All rights reserved. The contents in this document are subject to change without notice.
Emerson Network Power Co., Ltd. Address: No.1 Kefa Rd., Science & Industry Park, Nanshan District 518057, Shenzhen China Homepage: www.emersonnetworkpower.com E-mail: support@emersonnetwork.com.cn
Hazardous Voltage
Batteries always have hazardous voltage even if they are not being charged! Do not short-circuit the battery! A short circuit current between the poles is dangerous. Therefore, do not place any metal component close to the batteries and protect the battery terminals against any physical contact. Use insulated tools when working with batteries. Non-standard operations on the battery will cause danger. In operation, be sure to take precautions to avoid battery short circuit and overflow of electrolyte. The overflow of electrolyte will pose potential threat to the equipment because it will erode the metal objects and PCBs, thus causing equipment damage and short circuit of PCBs. Pay attention to the following rules when or before operating the batteries: Remove the watch, bracelet, ring, and other metal items.
Use insulated tools. Use protective goggles when working with batteries. Wear rubber gloves and apron to guard against electrolyte spillage. When transporting batteries, the electrode of the battery should always be kept facing upward. Never place the battery upside down or tilt the battery.
Explosive Gases
The batteries contain potentially explosive gases, which may be released during charging or abnormal operations, such as rectifier malfunction or high temperature. Do not smoke and keep the battery away from the fire! Do not dispose the battery into fire! Use protective goggles when working with batteries. Do not remove the valves of the batteries.
Acid
The battery contains diluted sulphuric acid, which is strongly corrosive to metals and skin. Any fluid on the battery should be regarded as acid. Use gloves when handling the batteries. In case of skin contact with the electrolyte, remove contaminated clothing and flush affected areas thoroughly with water. Seek medical attention if a rash persists after the flushing. If eye contact has occurred, flush the eyes with large amounts of running water and seek medical attention. Acid spilled on the clothes should be rinsed with water.
Poisonous Material
The batteries contain acid, lead and other poisonous material. Always wash your hands after finishing the work on the batteries. Follow the local environmental regulations for disposing the batteries.
Heavy Object
The batteries are heavy. Be careful when lifting them! The batteries may break and acid may come out if they are dropped. A dropped battery may crush your feet!
Contents
Chapter 1 Overview ................................................................................................1 1.1 Introduction ................................................................................................1 1.2 Features ....................................................................................................1 1.3 Key Designs...............................................................................................2 1.3.1 Battery Grids....................................................................................2 1.3.2 Valve................................................................................................2 1.3.3 PTFE Acid Filter ..............................................................................3 1.3.4 Special Multi-barrier Sealing Structure ............................................3 1.3.5 AGM Separator................................................................................4 1.3.6 Threaded Copper Insert Terminal....................................................4 1.3.7 Unique Safety Filter .........................................................................4 1.3.8 Integrated Design ............................................................................4 1.3.9 Unique Appearance Design.............................................................5 1.4 Application .................................................................................................5 1.5 Specifications.............................................................................................6 1.5.1 Model And Specifications ................................................................6 1.5.2 Outline Drawings .............................................................................6 Chapter 2 Construction & Operating Principle ........................................................9 2.1 Construction ..............................................................................................9 2.2 Operating Principle ..................................................................................10 2.3 Sealing Design.........................................................................................10 Chapter 3 Technical Characteristics .....................................................................12 3.1 Discharge ................................................................................................12 3.1.1 Discharge Characteristic Curves At Various Rates .......................12 3.1.2 Discharge Characteristic................................................................13 3.1.3 Discharge Datasheets ...................................................................15 3.2 Charge.....................................................................................................16 3.2.1 Considerations...............................................................................16 3.2.2 Charge Characteristic Curves........................................................17 3.3 Storage ....................................................................................................17
3.3.1 Relations Between Temperature And State Of Charge .................17 3.3.2 Relation Between Open-circuit Voltage and State Of Charge .......18 3.4 Service Life ..............................................................................................19 3.4.1 Grids Corrosion Effect ...................................................................19 3.4.2 Relation Between Ambient Temperature And Battery Float Life....19 Chapter 4 Installation & Use .................................................................................20 4.1 Storage Prior Installation .........................................................................20 4.2 Installation Considerations.......................................................................20 4.2.1 Ventilation......................................................................................20 4.2.2 Temperature And Humidity............................................................21 4.2.3 Use Conditions ..............................................................................21 4.3 Installation ...............................................................................................22 4.3.1 Unpacking And inspection .............................................................22 4.3.2 Installation Notes ...........................................................................22 4.3.3 Installation And Wiring ...................................................................22 4.4 Use ..........................................................................................................23 4.4.1 Charge...........................................................................................23 4.4.2 Discharge ......................................................................................24 Chapter 5 Maintenance.........................................................................................25 5.1 Before Use...............................................................................................25 5.1.1 Storage And Supplementary..........................................................25 5.1.2 Transporting ..................................................................................25 5.2 Daily Inspection .......................................................................................25 5.3 Replacement............................................................................................26 5.3.1 Replacing Criterion ........................................................................26
Chapter 1 Overview
Chapter 1 Overview
1.1 Introduction
Emerson Network Power Co., Ltd. focuses on power electronics and relevant control technologies. It provides total power solutions to customers worldwide with broad range of products, including DC Power System, Board Mounted Power Supply, Customized Power System, Power Supply Monitoring Systems, UPS, Variable Speed Driver, Electric Power System, Air Conditioner, and VRLA Batteries. Emerson Duration Range VRLA Battery is a dependable range of front access batteries, and in all design aspects they have a lasting, reliable and efficient operating characteristics. They have a very good capability to withstand even harsh climatic and electric environments, and guarantee a reliable source of power.
1.2 Features
Long life: up to 10-year designing float-charging life at 25C Long cyclic life Excellent deep-discharge recovery capability Bar code tracking system for easy tracking products Front terminal batteries with strong rope handles Long storage life (about 1 year @ 25C) Thermal runaway resistance Compliance with IEC60896-21: 2004 and BS6290 Part4: 1997 UL 94-V0 flame retardant material High Tin low Calcium alloy Super high purity lead formed active material
Emerson Duration Range VRLA Battery Technical Manual
Chapter 1 Overview
Float charge at 2.23-2.27 V/cell at 25 C Standard dimensions: fit 19 and 23 cabinet High energy density: volumetric energy density 96.9Wh/L; gravimetric energy density 34.3Wh/kg.
0.07Ca-2.5Sn
0.07Ca
Figure 1-1
1.3.2
Valve
The valve releases the overpressure generated inside the battery and prevents the air outside from entering the battery. Thanks to about 99%
Emerson Duration Range VRLA Battery Technical Manual
Chapter 1 Overview
oxygen recombination efficiency, the battery barely loses electrolyte and requires no addition of distilled water throughout the service life.
1.3.3
1.3.4
Polarity Polarity indication epoxy indicating epoxy Epoxy fill Threaded nut
Battery lid
Figure 1-2
Chapter 1 Overview
1.3.5
AGM Separator
AGM separator features a high porosity to achieve good absorption of the electrolyte, and its flexibility and resilience helps to keep the pressure of the plates thus prolonging the battery cyclic life. Due to the good absorption of the separator, it will keep the electrolyte absorbed even in the event of battery breakage, which will enhance the safety of batteries.
1.3.6
1.3.7
Figure 1-3
Chapter 1 Overview
Mobile Base Station etc. At the same time, the environment safety protections are provided for chemical application to ensure reliable system operating.
Figure 1-4
1.4 Application
DC power supply for telecom application (Access Network, Micro Cell Base Station, Mobile, 3G, etc.,) Electric power supply Solar energy power system Emergency power source UPS (uninterrupted power supply)
Chapter 1 Overview
1.5 Specifications
1.5.1 Model And Specifications
Table 1-1
Type T12V40EF/A T12V100EF/A T12V165EF/A Voltage 12 12 12
1.5.2
Outline Drawings
Figure 1-5
Chapter 1 Overview
Figure 1-6
Figure 1-7
Chapter 1 Overview
Figure 1-8
Figure 2-1
Container and cover ---- superior strength and fire-retardant ABS-plastic. Safety valve ---- equipped with gas collection and exhaust tri-outlet valve, safety valve acts as a pressure relief valve and for preventing ignition entering the battery as well as acid fumes escaping. Terminal ---- with silver-plated copper or brass insert in order to minimize the contact resistance. Group bar ---- designed to conduct big currents, withstand short circuit current, endure acid erosion, and resist oxidation. AGM separator ---- Micro porous fiber glass acts as both a separator and an electrolyte absorber.
10
Positive & negative plates ---- special Pb-Ca-Sn-Al alloy grids, with characteristics of corrosion & extension resistance, and high hydrogen-electrolysis potential.
2.2
Operating Principle
The chemical reaction in the charging and discharging processes of VRLA battery is described below: PbO2 + 2H2SO4 + Pb
Discharge <==> PbSO4 + 2H2O + PbSO4 Charge
During discharging process, lead dioxide in positive plates and spongy lead in negative plates react with sulphuric acid in the electrolyte and gradually turn into lead sulphate, while the sulphuric acid concentration decreases. On the contrary, during charging process, the active materials in the positive and negative plates which have been turned into lead sulphate, gradually revert to lead dioxide and spongy lead respectively, while the sulphuric acid concentration increases.
11
During float charging and boost charging the following reactions occur: 1) Oxygen is evolved at the positive plate by the reaction: H2O O2 + 2H + 2e
+ -
And it diffuses through the unfilled pores of the separator to the surface of the negative plate. 2) The process is reversed at the negative plate:
12
13
12
11
3Hr 5Hr 6Hr 8Hr 10Hr 1Hr
10
0.25Hr
0.5Hr
9 0.1 1 10
Figure 3-1
13
3.1.2
Discharge Characteristic
50 50
2412108 6 5 4 3 2 1 Hr
40 40
0.5 Hr
30 30
20 20
0.25Hr
10 10
0 0
0 0
10 10
20 20
30 30
40 40
50 50
60 60
70 70
Figure 3-2
14
120 120
2412108 6 5 4
1 Hr
100 100
0.5 Hr
80 80
60 60
0.25H
40 40
20 20 0 0
1.87 1.9VPC
30 30 60 90 120 60 90 120 Discharge Current (A) Discharge Current (A)
1.85 1.80
1.70 1.75
150 150
180 180
Figure 3-3
210 210
2412108 6 5
180 180
150 150
0.5 Hr
120 120
90 90
0.25Hr
60 60
30 30
1.9VPC
1.87 1.85
1.801.75
1.70
50 50
100 150 200 100 150 200 Discharge Current (A) Discharge Current (A)
250 250
300 300
15
Figure 3-4
Table 3-2
Type T12V40EF/A T12V100EF/A T12V165EF/A 15m 48.2 121 200 30m 35 87.5 144 1h 21.5 53.9 88.9
Table 3-3
Type T12V40EF/A T12V100EF/A T12V165EF/A 15m 52.8 132 218 30m 36.8 92 152 1h 22.1 55.2 91
16
Table 3-4
Type T12V40EF/A T12V100EF/A T12V165EF/A 15m 58.8 147 242 30m 39.7 99.2 163 1h 23.5 58.7 96.9
Table 3-5
Type T12V40EF/A T12V100EF/A T12V165EF/A 15m 62.0 155 255 30m 41.6 104 171 1h 24.0 60 99.0
Table 3-6
Type T12V40EF/A T12V100EF/A T12V165EF/A 15m 64.8 162 267 30m 43.2 108 178 1h 24.5 61.3 101
3.2 Charge
3.2.1 Considerations
Following issues shall be taken into consideration for choosing the float charge voltage: High enough to compensate for self-discharge and to have a fast recharge. Not too high in order to decrease the corrosion and water loss. The recommended float charge voltage at normal temperature: 2.25V/cell.
Emerson Duration Range VRLA Battery Technical Manual
17
3.2.2
Figure 3-5
3.3 Storage
3.3.1 Relations Between Temperature And State Of Charge
Relations between ambient temperature, storage time and capacity retention of the battery are shown in Figure 3-6.
18
15
40
6 8
35
10 12
30
14 16 17
25
18 20 24
Month Month
Figure 3-6
3.3.2
2.10
2.05
2.00
1.95
1.90 0 25 50 75 100 125 State of charge (%) Stage of Charge (%) State of Charge (%)
19
Note
After a long period of storage, the battery should be charged/discharged for several cycles to restore its capacity.
3.4.2
10 10 8 8 6
4 4 2 2 0 0 20 20
30 30
40 40
50 50
o
60 60
Temprature/ Temperature ( )C
Figure 3-8 Relation between ambient temperature and battery float life
20
Avoid storing the battery in the ambient above 40C. 4. Store the batteries in the cool, dry, and well-ventilated place. 5. Try to shorten the storage time of batteries.
4.2
Installation Considerations
4.2.1 Ventilation
Check that the space where the batteries are to be placed is well ventilated. Normal in-door environments without precautions to limit ventilation can be
Emerson Duration Range VRLA Battery Technical Manual
21
considered to provide adequate ventilation for the VRLA batteries. During float charge period, gassing rate is about 4~5l/cell/AH/hour. Check your local regulations for the safety requirements. In absence of regulations we recommend the following ventilation; T12V40EF/A T12V100EF/A T12V165EF/A 50 liter / (hour, 48 V battery) 130 liter / (hour, 48V battery) 210 liter / (hour, 48 V battery)
In case that the batteries are charged at boost charge voltage, the ventilation needs to be five (5) times higher than the figures listed above!!!
4.2.2
22
4.3
4.3.1
Installation
Unpacking And inspection
Check the consignment for damages and check the goods according to the packing list. In case of any damage to the package, the forwarder should be notified. Check that the units are not damaged and that no fluid is present on the units.
4.3.2
Installation Notes
1. Fix the Emerson battery to avoid vibration and shock. 2. Combustible gas (hydrogen) will be generated during the charge and storage period, so keep the battery away from spark source (like switch and fuse). 3. Do not use the sealed container or container within which the combustible gases easily accumulated. 4. When installing the battery inside an equipment, place the battery at the bottom of the equipment to avoid overheating. Besides, keep the battery from the inner wall or other batteries. 5. Keep the battery away from heat source (such as a transformer).
4.3.3
23
4. Spread a quantity of antirust onto the terminal surface of the battery before or after the installation. 5. Check the total voltage of the battery string before connecting the string to the load.
4.4 Use
4.4.1 Charge
1. Floating Charge Charge voltage: 2.25V/cell (25C) Charge time: 36h~48h Temperature compensation coefficient: -3mv/C.cell (25C reference)
Note
The voltages of the units vary noticeably during the first year of operation. 2. Boost Charge Charge voltage: 2.35~2.40V/cell (25C) Charge time: 36h~48h
Note
It is recommended to conduct the boost charge in case of any one of the following situations: 1) Discharged capacity is more than 20% of rated capacity. 2) Storage period is longer than six months. 3) Continuous floating charge for three to six months or the voltage drops behind in the battery string. 4) Supplementary charge before capacity testing. 3. Charge capacity is set up as 105%~110% of discharge capacity. But when the ambient temperature is below 5C, it is set up as 110%~120%.
24
4. The lower the temperature is (below 5C), the longer the charge time is. The higher the temperature is (above 35C), the higher the chance overcharge takes place. The recommended temperature for charging is between 5C~30C, especially in the cycle service. 5. It is recommended to install a charge timer or change floating charge mode automatically to prevent overcharge. 6. The battery temperature should be controlled between -15C ~45C during the charge process.
4.4.2 Discharge
1. Keep the battery temperature between -15C ~50C during the discharge process. 2. Discharge current is controlled below 3C10A when the battery during discharge continuously. 3. Final discharge voltage varies depending on the charge current, and the discharge voltage cannot be lower than the specified voltage. Table 4-2 Discharge current and final discharge voltage
Final discharge voltage (V)/cell 1.9 1.8 1.75 1.7 1.6
4. The battery shall be charged as soon as the discharge process is over. If the battery is over-discharged for carelessness, please charge it as soon as possible.
Chapter 5 Maintenance
25
Chapter 5 Maintenance
5.1 Before Use
5.1.1 Storage And Supplementary
During storage, the capacity of the battery decreases because of self-discharging. When using a stored battery, always carry out supplementary charging before use. For supplementary charging, please refer to section 4.1 Storage prior Installation. Store the battery in a cool dry place.
5.1.2
Transporting
When transporting the battery, never vibrate or impact it excessively. We recommend transporting the battery in an upright position. When transporting a battery connected to the equipment, secure it firmly and keep the circuit open.
26
Chapter 5 Maintenance
2. Clean any dust contamination with a wet cloth. Never use organic solvents (gasoline or thinners), otherwise the container or cover may crack. 3. Voltage Checks. Total voltage The total voltage of the batteries should not deviate from the recommended 2.25 V per cell (54V in a 48V DC power system at reference temperature). If it deviates, check your system to see that the setting is correct and that the temperature compensation is correct. Unit voltage After one year of operation, all the units should be within the range of 13.500.48V.
5.3 Replacement
5.3.1 Replacing Criterion
Replace the battery if its capacity measured during the battery test is less than 80% of the battery rated capacity. The capacity measured during the battery test shall be evaluated at a discharge rate close to its actual use.