EmersonDurationRange VRLABattery Technical Manual

Emerson Duration Range VRLA Battery Technical Manual
Version: Revision date: BOM: V1.0 Sept 27, 2004 31020591
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
Warnings and Cautions

To reduce the chance of accident, please read the safety precautions very carefully before operation. The "Note" symbol in this manual does not represent all the safety precautions to be observed, and is only used as a supplement to various operation safety rules. Therefore, the installation and operation personnel must be strictly trained so as to understand and master the correct operations and all the safety precautions before any actual operation. When operating Emerson products, the safety rules in the industry, the general safety precautions and special safety instructions provided by Emerson must be strictly observed.
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
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.
1.3 Key Designs

1.3.1 Battery Grids
The alloy grids are synthesized by four elements of lead, calcium, tin, and aluminum using a special formulation (alloy character is shown in the Figure 1-1). They have high corrosion & extension resistance, together with great improvement of recharging capability after deep discharge, thus extending the battery life and reliability. At the same time the chosen alloy maintains the high hydrogen overvoltage on the negative plates, which is necessary to minimize the water losses.
7 10 8.6 8 8 6.6 6 6 4.6 4 4 3.6 3 2 0 0 80 60 120 120 130 180 240 240 300 300 380 360
tensile strength (kg/mm Tensile Strength (kg/mm ) )
2 2 tensile strength g/mm 2 k
0.07Ca-2.5Sn
Emerson battery alloy ingredient Emerson battery alloy ingredinet

0.07Ca-0.6Sn
0.07Ca
time ay d time(day) Time (day)
Figure 1-1
Alloy characteristic of VRLA battery
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%
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
PTFE Acid Filter

The acid filter made of PTFE maintains two functions: 1. Filtering out small droplets of acid that may be generated during misusing; 2. Preventing the external flame from spreading into the battery so as to prevent internal explosions.
1.3.4
Special Multi-barrier Sealing Structure

The sealing of the battery terminals is highly reliable. The primary seal is an O-ring with rectangular cross section placed in the well of the enclosure around the post. A thin plastic washer is placed on top, and a threaded plastic nut is screwed down over the washer. The well is then filled with an epoxy glue, which not only fills any remaining space between the lead post and the threaded nut, but also covers the entire nut, creating a secondary seal. A polarity color-coded epoxy fill is placed over the glue seal to form the third seal.
Polarity Polarity indication epoxy indicating epoxy Epoxy fill Threaded nut
Battery lid
Threaded post enclosure Plastic washer
O-ring Lead post Bass insert Brass insert Cell wall
Figure 1-2
Multi- barrier seal structure
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
Threaded Copper Insert Terminal

The battery poles with tin-plated threaded copper insert terminals deliver exceptional performance, and reduce the battery internal resistance to the minimum.
1.3.7
Unique Safety Filter

The Duration range has the special safety filter Environmental Acid Fog Neutralization Box, as shown in Figure 1-3. It attaches to the vent tubing using connecting pieces. It has acid entrainment and neutralization components inside. In the event of charger failure or other malfunction, which affects prolonged overcharge safety, the filter will filter out all acid mist generated and thereby protect the equipment and human safety.
Figure 1-3
Battery string with acid fog neutralization box
1.3.8 Integrated Design

The TELECOM battery has been developed and refined in fully consideration of matching the communication system of Exchange, Access,
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.
1.3.9 Unique Appearance Design

Use unique baguet structure of 23 with front access mode.
Figure 1-4
Unique appearance design
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
Duration range VRLA battery model and specifications

Dimension (mm) L 274 520 528 W 105 107 125 H Short circuit Bolts InternalWt. (kg) resistance (m) currentA mm 6.3 2.8 1.6 1850 3200 5000 M6 M6 M6
Ah @ 10hrs 40 100 165
218 16 263 36.5 318 55
1.5.2
Outline Drawings
Figure 1-5
T12V40EF/A outline drawing
Chapter 1 Overview
Figure 1-6
Figure 1-7
Chapter 1 Overview
Figure 1-8
Installation outline drawings
Chapter 2 Construction & Operating Principle

2.1 Construction
Container and cover Safety valve Terminal Group bar AGM Separator Positive & negative plates Container and cover
Figure 2-1
Duration range VRLA Battery construction
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.
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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.
2.3 Sealing Design

The basic phenomenon behind VRLA technology is a process called recombination. During cycling of conventional flooded lead acid cells, water is lost from the cell due to electrolysis and results in the venting of hydrogen, oxygen and droplets of sulfuric acid entrapped in the gas stream. This results in the need for regular battery checks and periodic topping-up with water to maintain the electrolyte at the proper level. Valve regulated lead acid batteries resolve this problem through continuous recombination of the oxygen during float charging and boost charging. The oxygen recombination process occurs if the separators are not completely filled with electrolyte. This allows some pores to be free for the oxygen diffusion from the positive plates (where it is generated) directly to the negative plates where it reacts to reform water.
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:
O2 + 2H+ + 2e- H2O

The net effect of the recombination is that there is a slight generation of heat. Due to the high purity of the Emerson Duration Battery this heating effect is reduced to a minimum. Special separators with high porosity and very small pore diameter are used in order to facilitate the oxygen recombination cycle. In addition, a carefully controlled quantity of electrolyte is added into every single cell in order to maintain sufficient electrolyte to enable the discharge reactions while maintaining a sufficient quantity of pores free of electrolyte to maintain the gas diffusion. These unique requirements also result in the fact that the entire electrolyte is retained in the separator and plates and there is no free electrolyte. The gas pressure within the cells during operation is normally higher than the normal atmospheric pressure and the gas within the cells consists of oxygen, hydrogen, nitrogen and carbon dioxide. It is thus necessary for every cell to have an outlet for the release of gases that have not recombined to avoid excessive internal pressure. Valves are used for this purpose. The valves are very important because they prevent air from entering the cell. Oxygen in outside air causes the negative plates to oxidize and shorten the life of the battery. Therefore, to allow excess internal gas to escape, while keeping the external air from getting into the battery, every cell has a one-way pressure relief valve. For this reason these batteries are not 100% sealed batteries, so valve regulated lead acid (VRLA) batteries are used to give a more accurate description.
12
Chapter 3 Technical Characteristics

3.1 Discharge
Relation between discharge capacity and discharge current: The lower the discharge current, the bigger the discharge capacity; the higher the discharge current, the smaller the discharge capacity. Relation between discharge capacity and temperature: Within the normal operation temperature range, the higher the temperature, the bigger the discharge capacity; the lower the temperature, the smaller the discharge capacity.
3.1.1 Discharge Characteristic Curves At Various Rates

14
Discharge Voltage(V) Discharge Voltage (V)
13
12
11
3Hr 5Hr 6Hr 8Hr 10Hr 1Hr
10
0.25Hr
0.5Hr
9 0.1 1 10
Discharge Time Discharge Time

Discharge characteristic curves at various rates (25)
Figure 3-1
13
3.1.2
Discharge Characteristic
50 50
2412108 6 5 4 3 2 1 Hr
40 40
Capacity (Ah) CapacityAh
0.5 Hr
30 30
20 20
0.25Hr
10 10
1.87 1.85 1.9VPC
1.70 1.80 1.75
0 0
0 0
10 10
20 20
30 30
40 40
50 50
60 60
70 70
Discharge CurrentA Discharge Current (A)
Figure 3-2
T12V40EF/A discharge characteristic curves (25)
14
120 120
2412108 6 5 4
1 Hr
100 100
Capacity (Ah) Capacity (Ah)
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

3 2 1 Hr
2412108 6 5
180 180
Capacity (Ah) Capacity (Ah)
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
3.1.3 Discharge Datasheets

Table 3-1
Type T12V40EF/A T12V100EF/A T12V165EF/A 15m 45.6 107 176 30m 33.3 81.0 134 1h 20.2 50.6 83.5
Final dscharge voltage (25) 1.90V/cell

2h 12.5 31.3 51.6 3h 9.3 23.4 38.6 4h 7.6 19.1 31.5 5h 6.2 15.6 25.7 6h 5.5 13.8 22.8 8h 4.2 10.5 17.3 10h 3.5 8.8 14.5 12h 3 7.5 12.3 24h 1.6 4.2 6.9
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
Final discharge voltage (25) 1.87V/cell

2h 13.2 33 54.5 3h 9.8 24.5 40.4 4h 8 20.0 33.0 5h 6.5 16.3 26.9 6h 5.7 14.4 23.8 8h 4.4 11.1 18.3 10h 3.7 9.3 15.3 12h 3.2 7.9 13.0 24h 1.7 4.4 7.3
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

2h 13.7 34.3 56.6 3h 10.2 25.5 42 4h 8.3 20.6 34 5h 6.7 16.8 27.7 6h 6.0 14.9 24.6 8h 4.6 11.5 18.9 10h 3.8 9.6 15.8 12h 3.3 8.2 13.5 24h 1.8 4.6 7.6
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

2h 14.4 36.1 59.6 3h 10.7 26.7 44.1 4h 8.6 21.5 35.5 5h 7.0 17.5 28.9 6h 6.2 15.4 25.4 8h 4.8 12 19.8 10h 4.0 10.0 16.5 12h 3.4 8.5 14.0 24h 1.9 4.7 7.8
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

2h 14.8 36.9 60.9 3h 10.9 27.2 44.9 4h 8.8 21.9 36.1 5h 7.1 17.8 29.4 6h 6.3 15.7 25.9 8h 4.9 12.3 20.3 10h 4.1 10.3 17.0 12h 3.5 8.7 14.4 24h 1.9 4.8 7.9
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

2h 15.1 37.7 62.2 3h 11.1 27.7 45.7 4h 8.9 22.3 36.8 5h 7.2 18.1 29.9 6h 6.4 16 26.4 8h 5.0 12.6 20.8 10h 4.2 10.5 17.3 12h 3.6 8.9 14.7 24h 2.0 4.9 8.1
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.
17
3.2.2
Charge Characteristic Curves
Figure 3-5
Boost charge curves after 100% discharge (2.35V/cell)
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

100% 95%
State State of Charge Charge
90% 85% 80% 75% 70% 0 4
15
40
6 8
35
10 12
30
14 16 17
25
18 20 24
Month Month
Figure 3-6
Relations between temperature and state of charge
3.3.2
Relation Between Open-circuit Voltage and State Of Charge

Relation between open-circuit voltage and capacity retention is shown in Figure 3-7. (Test after the fully charged battery has been stored for some period.)
2.15
2.10
Open Circuit Voltage (V)
2.05
2.00
1.95
1.90 0 25 50 75 100 125 State of charge (%) Stage of Charge (%) State of Charge (%)
Figure 3-7 Relation between open-circuit voltage and 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 Service Life

3.4.1 Grids Corrosion Effect
The battery life ultimately ends when the positive plate has been eroded extensively. The corrosion is strongly influenced by voltage and temperature. Please set the floating charge voltage to 2.25V/cell, and the recommended precision of the charger is within 1%.
3.4.2
Relation Between Ambient Temperature And Battery Float Life

Avoid using the battery in high temperature environment. Generally the life of Emerson Duration Range VRLA Battery is ten years in normal applications (the total discharge capacity of a month is below the rated capacity, temperature is 5C ~30C).
12 12
Float Life/Years Floating life/years
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
Chapter 4 Installation & Use

4.1 Storage Prior Installation
1. The ambient temperature range for the battery storage is: -15C~45C. 2. The battery must be fully charged before storage. When using a battery that has been stored for some period, always carry out supplementary charge before using it, because part of battery capacity will be lost during transporting or storage period. 3. Supplementary charge should be carried out for compensating the self-discharge in the long period storage. For supplementary charge, please refer to the following table: Table 4-1
Storage temperature Below 25C 25~30C 30~35C 35~40C
Storage temperature and interval for supplementary charge

Interval for supplementary charge Each 12 months Each 8 months Each 6 months Each 4 months Supplementary charge method (choose any one) 36~48 hours charge with constant voltage current-limiting: 0.25C10A, 2.4V/cell 6~10 hours charge with a constant current: 0.05C10A
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
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
Temperature And Humidity

The higher the temperature is, the more the life of the battery decreases. At a rise of the average temperature from 25C to 35C the life will be reduced by 50%. The batter life will be further decreased at higher temperatures. For operation in the range up to 40C the life can be estimated from this rule of thumb summed over every day. So take every action to ascertain that the batteries are placed in a cool environment. The room where the batteries are installed should be dry and cool, free of heat source and direct sunlight. Relative humidity shall be less than 90%. Duration Range batteries can be reliable used under ambient temperature: -15C ~45C.
4.2.3 Use Conditions

Multi-layer installation: temperature difference between layers shall be controlled within 3C. Heat rejection: The original connectors provided with the batteries will help to keep enough clearance between the units. Dont mix the batteries with different brands or different ages in a battery string. Floating charge voltage: 2.25V/cell.
22
The recommended operating temperature: 20~25C
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
Installation And Wiring

1. Wrap the metal mounting tool (such as a spanner) with insulating tape. 2. First carry through the connections between the batteries, and then connect the battery string to the charger or load. 3. When connecting multi-battery strings in parallel, make the series connections first and then the parallel connections. Keep the space of 5mm~10mm between every batteries to assure better heat dissipation.
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
Discharg current (A) <0.1C10 0.1C10 0.17C10 0.25C10 0.6C10
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
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.
5.2 Daily Inspection

1. Check the battery regularly. The battery needs to be replaced if any abnormal condition occurs, such as: any voltage abnormalities; any physical defects (e.g., a cracked or deformed container cover); any electrolyte leakage; any abnormal heat generation.
26
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.

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Emerson Duration Range VRLA Battery Technical Manual

Version: Revision date: BOM: V1.0 Sept 27, 2004 31020591

Warnings and Cautions

1.3 Key Designs

tensile strength (kg/mm Tensile Strength (kg/mm ) )

2 2 tensile strength g/mm 2 k

Emerson battery alloy ingredient Emerson battery alloy ingredinet

time ay d time(day) Time (day)

Alloy characteristic of VRLA battery

PTFE Acid Filter

Special Multi-barrier Sealing Structure

Threaded post enclosure Plastic washer

O-ring Lead post Bass insert Brass insert Cell wall

Multi- barrier seal structure