Abt Powerline SC Series User manual

SC
Powerline
Series
Product Guide
SEALED LEAD
ACID BATTERY
VALVE-REGULATED
Standard Commercial

Contents
Introduction...................................01
TechnicalFeatures..............................01
Applications
Construction...................................02
GeneralSpecifications...........................03
Discharge.....................................05
Charge.......................................07
...............11
.........................12
...................................02
Expected Service Life of Powerline SC
Design/Application Suggestions to
Ensure Maximum Service

ABT Powerline SC is a Standard Commercial battery according to Eurobat Classification design life for
standby application with 5 years . As with all ABT batteries, all are rechargeable , highly efficient,
leakage proof and maintenance free.
Technical Features
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Sealed Construction
Electrolyte Suspension System
Gas Generation
Maintenance Free Operation
Operation In Any Orientation
Low Pressure Venting System
high quality alloy
Floating Service Life
Self Discharge -- Shelf Life
Operating Temperature
Deep Discharge Recovery
The construction and sealing techniques of Powerline SC guarantee leakage proof operation in any
position with no adverse effect to capacity or service life.
Powerline SC utilize an electrolyte suspension system consisting of microporous glass fibre separator
material. This suspension system helps to achieve maximum service life, by fully retaining the
electrolyte and preventing its escape from the separator material.
Powerline SC incorporates a unique design that effectively recombines over 99% of the gas generated
during floating usage.
DuringthelifeofPowerlineSC,thereisnoneedtocheckthespecificgravityoraddwateretc.Infact,
there are no provisions for such maintenance functions to be carried out.
The combination of sealed construction and it's electrolyte suspension system permits operation of
Powerline SC in any orientation (excluding continuous inverted use) without loss of capacity, service life,
or leakage of electrolyte. The Powerline SC also conforms to IEC 60896-21/22(2004).
Powerline SC are equipped with a safe, low pressure venting system, which is designed to release excess
gas and close automatically as the internal gas pressure rising to an unacceptable level. This low
pressure venting system, coupled with the significantly high recombination efficiency, make Powerline
SC one of the safest valve regulated lead acid batteries available.
The positive grid alloy contained high Tin and low calcium quantity in Powerline SC should provide an
extra margin of performance and service life in floating applications.
The expected service life of the standard model Powerline SC when used in floating application is
typically 3- 5 years; however, experience has shown that their service life often exceeds 5 years, if the
Powerline SC are operated strictly within specification.
Powerline SC recover their capacities even after deep discharges.
At temperatures of between 20 & 25 C, the self discharge rate of Powerline SC per month is
approximately3%oftheratedcapacity.Thislowselfdischargeratepermitsstorageforuptooneyear
without any appreciable deterioration of battery performance.
Powerline SC can be used over a wide range of ambient temperatures:
, allowing considerable flexibility in system design and location.
o
discharge -20 60 C,charge-10
60 C,storage -20 60 C
～～
～
O
OO
Introduction
01
POWERLINE
SC SERIES
Introduction

POWERLINE
SC SERIES
02
Construction
Applications
Alistofsomeofthemorecommonapplicationsforstandbyorprincipalpowerisgivenbelow:
Alarm Systems
Cable Television
Communications Equipment
Computers
Control Equipment
Electronic Cash Registers
Electronic Test Equipment
Emergency Lighting Systems
Fire&SecuritySystems
Geophysical Equipment
Medical Equipment
Microprocessor Based Office machines
Solar Powered Systems
Telecommunication Systems
Television & Video Recorders
UPS/EPS
Vending Machines
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Applications

03
POWERLINE
SC SERIES
General Specifications
General Specifications
CAh
20/CAh
10/
SC6-12
SC12-7
SC12-7.5
SC1-8
SC12-12
SC12-18
6
12
12
12
12
12
12
7
7.5
8
12
18
11.1
6.3
6.98
7.45
11.1
16.74
151
151
151
151
151
181
50
65
65
65
98
76
94
93
93
93
94
166
100
98
98
98
100
166
1.80
2.40
2.58
2.58
3.57
5.80
84
49
52
56
84
126
240
140
150
160
240
360
9.5
22
20
20
16
14
F1orF2
F1orF2
F1orF2
F1orF2
F1orF2
M5xØ12
A
D
D
D
D
B
Certification
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CE
UL
ISO9001
ISO14001
OHSAS18001
lGOST
Terminals
Terminal Layout
F1 F2 M5x 12φ
A B D
4.80
6.35
3.25
6.35
7.95
4.25
0.80
M5
φ12
0.80

Discharge
Discharge Characteristics
Figure1. Discharge Characteristics
Table 1. Discharge current at stipulated discharge
rates
The curves shown in Figure and the discharge current
rates shown in Table 3 illustrate the typical discharge
characteristics of Powerline SC at an ambient
temperature of 20 C. The symbol "C"expresses the
nominal capacity of the battery measured at a 20-Hour
discharge rate. Please refer to General Specifications to
determine the nominal capacity rating of specific
Powerline SC models. The standard industry practice to
determine the nominal capacity of a valve regulated
lead acid battery is to discharge the battery under test
at C and 1.75Vpc.
Table3showsthedifferentcurrentsthatcanbedrawn
at various discharge capacity rates.
Table4showsthattheratednominalcapacityofa
battery is reduced when it is discharged at a value of
current that exceeds its 20-Hour discharge rate. This
shouldbetakenintoconsiderationwhenabatteryis
being selected for a particular application.
1
o
20
Table 2. Discharge capacity at various discharge
rates
Temperature characteristics
Over Discharge (Deep Discharge)
Table 3. Final discharge voltage
ThedottedlineinFigure1indicatesthelowest
recommended voltage under load, or cut off voltage, for
Powerline SC at various discharge rates. In general, lead
acid batteries are damaged in terms of capacity and
service life if discharged below the recommended cut off
voltages. It is generally recognized that all lead calcium
alloy grid batteries are subject to over discharge damage.
For example, if a lead acid battery were discharged to
zero volts, and left standing in either "on" or "off" load
conditions for a long period of time, severe sulphation
would occur, raising the internal resistance of the battery
abnormally high. In such an extreme case, the battery
maynotacceptcharge.PowerlineSChavebeendesigned
to withstand some levels of over-discharge. However,
whilst this is not the recommended way of operation,
Powerline SC can recover their capacity when recharged
correctly. Final discharge voltage is shown in Table 3.
Ifabatteryistobedischargedatarateinexcessof3C
Amps, please contact us prior to use.
At higher temperatures, the electrical (Ah) capacity of a
battery increases and conversely at lower temperatures,
the electrical (Ah) capacity of a battery decreases.
0.05C 0.10C 0.15C 0.20C 0.25C 0.40C 0.60C 1.0C 2.0C 3.0C
20 Hr.
Capacity
Discharge Current(A,20 C)
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7 0.35 0.70 1.05 1.4 1.75 2.8 4.2 7.0 14.0 21.0
8 0.40 0.80 1.20 1.6 2.0 3.2 4.8 8 16 24
12 0.60 1.20 1.80 2.4 3.0 4.8 7.2 12 24 36
18 0.90 1.80 2.70 3.6 4.5 7.2 10.8 18 36 54
7.5 0.375 0.75 1.125 1.5 1.875 3.0 4.5 7.5 15 22.5
20 Hr.
Capacity
Discharge Current(A,20 C)
o
TO 1.75V/C TO 1.75V/C TO 1.75V/C TO 1.70V/C TO 1.60V/C
20Hr 10Hr 5Hr 3Hr 1Hr
7 0.350 0.651 1.180 1.865 4.410
7
8 0.400 0.745 1.374 2.128 5.040
12 0.600 1.116 2.057 3.197 7.560
18 0.900 1.674 2.978 4.688 11.340
.5 0.375 0.698 1.287 2.020 4.775
3C 2C 1C
0.25C
0.17C0.019C
0.6C
0.05C
Min
Discharge time
Hr
1 2 3 5 10 20 30 60 2 3 5 10 20 30
Terminal Voltage
13.0
12.0
11.0
10.0
9.0
8.0
7.0
6.5
6.0
5.5
5.0
4.5
4.0
3.5
v/6v v/12v
POWERLINE
SC SERIES
04
Discharge
Discharge current
(Ampere)
Final discharge voltage
(V/c)
I0≤0.2 C20
0.2 C ≤ 0.5 C0I<0
20 20
0.5 C ≤ 1.0 C0I<
20 20
1.0C ≤
20 I
1.75
1.70
1.65
1.60

Figure 2 shows the effects of different temperatures
in relation to battery capacity.
The self discharge rate of Powerline SC is
approximately3%permonthwhenstoredatan
ambient temperature of 20 C. The self discharge rate
will vary as a function of ambient storage
temperature. Figure 3 shows the relationship between
storage times at various temperatures and the
remaining capacity.
In general, when lead acid batteries of any type are
stored for extended periods of time, lead sulphate is
formed on the negative plates of the batteries. This
phenomenon is referred to as "sulphation". Since the
lead sulphate acts as an insulator, it has a direct
detrimentaleffectonchargeacceptance.Themore
advanced the sulphation, the lower the
charge acceptance.
Table4belowshowsthenormalstoragetimeorshelf
life at various ambient temperatures.
In general, to optimize performance and service life, it
is recommended that powerline sc which are to be
storedforextendedperiodsoftimebegivena
supplementary charge, commonly referred to as a "top
charge", periodically. Please refer to the
recommendations listed on page 24 under top
charging.
The approximate depth of discharge, or remaining
capacity,inapowerlinescbatterycanbeempirically
determined by referring to figure 5.
Storage, self discharge and shelf life
Self discharge
Shelf Life
Recharging stored batteries
Figure 6. Internal resistance of SC battery
o
Table 4. Shelf life at various temperatures
Available capacity, measured by open circuit voltage
Figure 4 shows extrapolated service life condition for
powerline sc at different ambient temperatures. As can be
seen from figure 4 higher ambient temperatures will
reduce service life.
Impedance
figure 4. Temperature/Life characteristics of
powerline SC
The internal resistance (impedance) of a battery is
lowest when the battery is in a fully charged state. The
internal resistance increases gradually during
discharge, Figure 6 shows the internal resistance of an
Powerline SC12-7 model measured through a 1,000 Hz
AC bridge.
Temperature Shelf Life
15 months
12 months
9months
5months
2.5 months
-20C(-4F)to-1C(-30.2F)
oo o o
0C(32F)to20C(68F)
oo oo
21 C(70 F) to 30 C(86 F)
oo oo
31 C(88 F) to 40 C(104 F)
oo o o
41 C(106 F) to 50 C(122 F)
oo oo
-20o-10o
-4o14o0o
32o
10o
50o20o
68o
30o
86o
TEMPERATURE
(%)
120
100
80
6
40
20
0
PERCENTAGE OF CAPACITY AVAILABLE
40o
104o122o
50oC
F
0.05XC(A)
0.1XC(A)
0.2XC(A)
1.0XC(A)
2.0XC(A)
3.0XC(A)
Figure 2. Temperature effects in relation
to battery capacity
Figure 3. Self discharge characteristics
(%)100
75
50
25
0
036912 15 18
40 C(104 F)
oo 30 C(86 F)
oo
20 C(68 F)
oo
10 C(50 F)
oo
0 C(32 F)
oo
REMAINING CAPACITY
STORAGE TIME (MONTHS)
YEARS OF DESIGN LIFE
Floating Voltage:2.27V/cell at 20 C battery temperature
o
Years
100%
75%
33%
7%
3%
20 30 40 50 60 oC
TEMPERATURE
Figure 5. Open circuit voltage
vs remaining capacity
(V)
FOR 12v
BATTERY
(V)
FOR 6V
BATTERY AT 20 C(68 F)
oo
220 40 60 80 100
REMAINING CAPACITY(%)
5.0
5.5
6.0
6.5
7.0
14.0
13.0
12.0
11.0
10.0
OPEN CIRCUIT VOLTAGE
05
POWERLINE
SC SERIES
Discharge

06
POWERLINE
SC SERIES
Charge
Charge
Correctchargingisoneofthemostimportant
factors to consider when using valve regulated lead
acid batteries. Battery performance and service life
will be directly affected by the efficiency of the
charger selected. The basic charging methods are:
Constant Voltage Charging
Constant Current Charging
Two Stage Constant Voltage Charging
Chargingatconstantvoltageisthemostsuitable
andcommonlyusedmethodforchargingvalve
regulatedleadacidbatteries.Figures8-13show
the charging characteristics of Powerline SC when
charged by constant voltage chargers at 2.275
volts/cell, 2.40 volts/cell and 2.50 volts/cell when
the initial charging current is controlled at 0.1C
Amps and 0.25C Amps.
Figure7showsoneexampleofaconstantvoltage
charging circuit. In this circuit, the initial charging
current is limited by the series resistance R1.
The recommended float charge voltage for
Powerline SC at 20 C is 2.275vpc ±0.005v. this
should be the measured average for the total
battery, however when measured within a battery
network or string the allowable tolerances can be
expected between 2.25vpc to 2.30vpc.
●
●
●
Constant Voltage Charging
Note
o
Figure 7. One example of constant voltage
chargeine circuit
AC
TD1
C1
11
12
6
5
R3
7
IC
10 2
13 C2R4
R5
R1
TR1
R2VR
Batt.
D2
LOAD
4
3
CHARGING TIME (HOUSE)
Figure 8. Charging characteristics
(%) (xCA) (V)
0.1CA-6.825V(13.65V,4.55V)CONSTANT VOLTAGE
CHARGING AT20 C(68 F)
oo
CHARGED
VOLUME
CHARGING
CURRENT
CHARGE
VOLTAGE
FOR 6V
BATTERY
CHARGED VOLUME
CHARGE VOLTAGE
CHARGING CURRENT
AFTER 100% DISCHARGE
AFTER 50% DISCHARGE
CHARGE VOLTAGE
FOR 12V BATTERY
CHARGE VOLTAGE
FOR 4V BATTERY
120
100
80
60
40
20
0
0.02
0.08
0.1
0510 15 20 25 30 35 40
11.0
12.0
13.0
14.0
4.50
4.00
3.50
0
(V)
0.04
0.06
7.50
7.00
6.50
6.00
5.50
140
120
100
80
60
40
20
0
5.00
4.50
4.00
3.50
0 2 4 6 8101214161820
CHARGE VOLTAGE
CHARGED VOLUME
AFTER 50% DISCHARGE
AFTER 100% DISCHARGE
CHARGING TIME (HOURS)
7.50
7.00
6.50
6.00
5.50
CHARGING CURRENT
11.0
12.0
13.0
14.0
15.0
(V)
0.1CA - 7.20V(14.4V,4.8V) CONSTANT VOLTAGE
CHARGINGAT 20 C (68 F)
oo
Figure9. Charging characteristics
CHARGED VOLUME
CHARGING CURRENT
CHARGE VOLTAGE FOR 6V BATTERY
CHARGE VOLTAGE FOR 12V BATTERY CHARGE VOLTAGE FOR 4V BATTERY
(%) (xCA) (V)
0.1
0.06
0.04
0
0.08
0.02
140
120
100
80
60
40
20
0
5.00
4.50
4.00
3.50
0 2 4 6 810121416 1820
CHARGE VOLTAGE
CHARGED VOLUME
AFTER 50% DISCHARGE
AFTER 100% DISCHARGE
CHARGING TIME (HOURS)
7.50
7.00
6.50
6.00
5.50
CHARGING CURRENT
11.0
12.0
13.0
14.0
15.0
(V)
0.1CA - 7.50V(15.0V,5.0V) CONSTANT VOLTAGE CHARGING
Figure10. Charging characteristics
CHARGED VOLUME
CHARGING CURRENT
CHARGE VOLTAGE FOR 6V BATTERY
CHARGE VOLTAGE FOR 12V BATTERY CHARGE VOLTAGE FOR 4V BATTERY
AT 20 C (68 F)
oo
(%) (xCA) (V)
0.1
0.06
0.04
0
0.08
0.02
Figure 11. Charging characteristics
(%)
140
120
100
80
60
40
20
0
0.05
0.10
0.15
0.20
0.25
7.50
7.00
6.50
6.00
5.50
(xCA) (V)
0.25CA-6.825V(13.65V,4.55V)CONSTANT
VOLTAGE CHARGING AT20 C(68 F)
oo
CHARGED
VOLUME
CHARGING
CURRENT
CHARGE
VOLTAGE
FOR 6V
BATTERY
CHARGED VOLUME
CHARGE VOLTAGE
CHARGING CURRENT
AFTER 100% DISCHARGE
AFTER 50% DISCHARGE
0246810 12 14 16 18 20
11.0
12.0
13.0
14.0
15.0 5.00
4.50
4.00
3.50
CHARGE VOLTAGE
FOR 12V BATTERY
CHARGE VOLTAGE
FOR 4V BATTERY
CHARGING TIME (HOUSE)
0
(V)
INTERNAL
RESISTANCE
(m )Ω
TERMINAL
VOLTAGE
(V)
BATTERY:SC12-7
AMBIENT TEMPERATURE:20 C(68 F)
MEASURED WITH 1000H AC BRIDGE
oo
Z
0
10
20
30
40
50
60
70
80
100
110
120
13.0
12.0
11.0
10.0
9.0
0246810 12 14 16 18 20 22
DISCHARGE TIME(HOUSE)
3Hr 5Hr
10Hr 20Hr

Constant Current Charging
Two Stage Constant Voltage Charging
This charging method is not often utilised for valve
regulated lead acid batteries, but is an effective
methodforcharginganumberofseriesconnected
batteries at the same time, and/or as an equalising
charge to correct variances in capacity between
batteries in a series group.
ExtremecareisrequiredwhenchargingPowerline
SCwithaconstantcurrent.If,afterthebatteryhas
reached a fully charged state, the charge is
continued at the same rate, for an extended period
oftime,severeoverchargemayoccur,resultingin
damage to the battery. Figure 14 shows a typical
constant current charging circuit; Figure 15 shows
the characteristics of two Powerline SC12-6 under
continuous overcharge conditions.
Two stage constant voltage charging is a
recommended method for charging valve regulated
lead acid batteries in a short period of time and then
maintaining them in a fully charged float or standby
condition. Figure 16 illustrates the characteristics of a
two stage constant voltage charger.
The characteristics shown in Fig.16 are those of a
constant voltage, current limited charger. In the
initial charging stage, the current flowing into the
battery is limited to a value of 0.30C Amps. The
charging voltage across the battery terminals rises,
during the charging process, to a value equal to the
constant voltage output of the charger, which is set to
2.45voltspercell.Whilstcontinuingtocharge,in
stage1(A-B),at2.45voltspercell,thecurrentwill
eventually decrease to point "Y", where the value of
this decreasing current is"sensed" causing the circuit
to switch into the second stage (B-C), reducing the
chargingvoltagefrom2.45voltspercelltoaconstant
voltage, float/standby, level of 2.3 volts per cell. The
switchtostagetwo,wheretheconstantvoltagelevel
of 2.3 volts per cell is applied, occurs after the battery
hasrecoveredabout80%ofitsratedcapacity.Thisis
one of the most efficient charging methods available
as the recharge time is minimized during the initial
stage whilst the battery is protected from overcharge
bythesystemswitchingtostage2(float/standby)
charge at the switching point"Y".
POWERLINE
SC SERIES
07
Charge
Figure 15. Characteristics of two SC12-6 under
conditions of continuous overcharge
OVERCHARGING CURRENT:0.6A(0.1CA)
AMBIENT TEMPERATURE:20 C(68 F)
CAPACITY TEST:1.5A to 10.2V EVERY 100 HOURS
n=2
oo
CHARGING TIME (HOURS)
CAPACITY AT 3HR DISCHARGE
0 100 200 300 400 500 600 700 800 900
1HR
2HR
3HR
4HR
AC
Figure 14. Constant current charging
Figure 16. Charging characteristics of a two
stage constant voltage charger
CHARGE VOLTAGE
CHARGEING CURRENT
CHARGE CURRENT
CHARGE VOLTAGE
"Y" SWITCHING POINT
NOTE:Current can drop
to as low as 0.002C Amps
ABC
CHARGING TIME
AC
TD1
C1
11
12
6
5
R37
IC
10 2
13 C2R4
R5
R1
TR1
R2
VR Batt.
D2
Figure17. Example of a two stage constant
voltage,Current limited charging circuit
4
3
VD
0123456
78910
CHARGE VOLTAGE
CHARGED VOLUME
AFTER 50% DISCHARGE
AFTER 100% DISCHARGE
CHARGING TIME (HOURS)
7.50
7.00
6.50
6.00
5.50
CHARGING CURRENT
140
120
100
80
60
40
20
0
0.25
0.20
0.15
0.10
0.05
0
5.00
4.50
4.00
3.50
11.0
12.0
13.0
14.0
15.0
(V)
0.25CA - 7.50V(15.0V,5.0V) CONSTANT VOLTAGE
CHARGING AT 20 C (68 F)
oo
Figure13.charging characteristics
CHARGED VOLUME
CHARGING CURRENT
CHARGE VOLTAGE FOR 6V BATTERY
(%) (xCA) (V)
CHARGE VOLTAGE
FOR 12V BATTERY
CHARGE VOLTAGE
FOR 4V BATTERY
Figure 12. Charging characteristics
(%)
140
120
100
80
60
40
20
0
0.05
0.10
0.15
0.20
0.25
7.50
7.00
6.50
6.00
5.50
(xCA) (V)
0.25CA-7.20V(14.4V,4.8V)CONSTANT VOLTAGE
CHARGING AT20 C(68 F)
oo
CHARGED
VOLUME
CHARGING
CURRENT
CHARGE
VOLTAGE
FOR 6V
BATTERY
CHARGED VOLUME
CHARGE VOLTAGE
CHARGING CURRENT
AFTER 100% DISCHARGE
AFTER 50% DISCHARGE
0246810 12 14 16 18 20
11.0
12.0
13.0
14.0
15.0 5.00
4.50
4.00
3.50
CHARGE VOLTAGE
FOR 12V BATTERY
CHARGE VOLTAGE
FOR 4V BATTERY
CHARGING TIME (HOUSE)
0
(V)
R6

08
POWERLINE
SC SERIES
Charge
When this charging method is used, the output
values will be as follows:
InitialChargeCurrent.....0.30CAmps(max.)
Charge Voltage:
1stStage.........2.45V/cell(2.40to2.50
v/cell, max.)
2ndStage........2.275V/cell(2.25 to 2.30
v/cell, max.)Switching Current From
1stStageto2ndStage..........0.05CAmps
(0.04C to 0.08C Amps)
Note:Thischargingmethodcannotbeusedin
applications where the load and the battery are
connected in parallel.
The C.V.C.C. is a fully regulated automatic charging
module designed for batteries. There are two 6 volt
versions available; one for standby applications and
the other for cyclic applications. Also there are two 1
2 volt versions available, again one for standby
applications and the other for cyclic applications.
When interfaced with the appropriate AC or DC
power supply, the C.V.C.C. guarantees safe charging
andmaximumbatterylife.Figure18isablock
diagram of the C.V.C.C.
The C.V.C.C. modules are protected from both the
short circuiting of their D.C. output voltage and from
being reverse polarity connected to the battery.
Detailed specifications are available on request.
In designing a solar powered system, consideration
shouldbegiventothefactthatinadditiontonormal
periods of darkness, weather conditions may be such
that solar energy is limited, or virtually unavailable
forlongperiodsoftime.Inextremecases,asystem
mayhavetooperatefor10to20dayswithlittleorno
power available for charging. Therefore, when
selecting the correct battery for a solar application,
the capacity should be determined based upon
maximum load conditions for the maximum period of
timethesystemmaybeexpectedtobewithout
adequate solar input.
In many instances the battery capacity will be 10 to
50 times greater than the maximum output of the
solar panels. Under these circumstances, the
maximum output of the solar array should be
dedicated to charging the battery with no load
sharing or intervening control devices of any kind.
Naturally, in cases where the output of the solar array
exceeds the capacity of the battery, and weather
conditions are such that the potential for
overcharging the battery exists, appropriate
regulated charging circuitry between the solar panels
and the battery is recommended.
Remote sites and other outdoor applications is where
most solar powered systems are to be normally found.
Whendesigningasolarpoweredsystemforthisclass
of application, a great deal of consideration must be
given to environmental conditions. For example,
enclosures which may be used to house batteries and
other equipment may be subject to extremely high
internal temperatures when exposed to direct
sunlight. Under such conditions, insulating the
enclosure and/or treating the surface of the enclosure
with a highly reflective, heat resistive material is
highly recommended.
In general, when designing a solar powered system,
consultation with the manufacturers of both the solar
panel and the battery is strongly advised.
The charging voltage should be chosen according to
the type of service in which the battery will be used.
Generally, the following voltages are used:
Forfloat(standby)use.......2.25to2.30volts
per cell
Forcyclicuse.. ..2.40to2.50voltspercell
In a constant voltage charging system, a large amount of
current will flow during the initial stage of charging but will
decrease as the charging progresses. When charging at
2.275 volts per cell, the current at the final stage of
charging will drop typically to a value of between 0.0005C
Amps and 0.004C Amps. When a battery has been charged
up to a level of 100% of the discharged ampere hours, the
electrical energy stored and available for discharge will be
90% or more, of the energy applied during charging.
Charging voltage should be regulated in relation to
C.V.C.C. CONSTANT VOLTAGE, CONSTANT
CURRENT CHARGE MODULE
Charging Voltage
Solar Powered Chargers
A battery is an indispensable component of any solar
poweredsystemdesignedfordemandenergyuse.Since
solar cells have inherent constant voltage
characteristics, Powerline SC can be charged directly
from the solar array using a simple diode regulated
circuit as shown in Figure 19.
Figure 19. BLOCK DIAGRAM OF A
SOLAR POWERED CHARGING SYSTEM
SOLAR CELL
OR PANEL LOAD
BATTERY
Figure 18. Block diagram of C.V.C.C.
C.V.C.C.
CHARGE UNIT
WHITE
WHITE
BLUE
GREEN
BLUE
YELLOW
BLACK
RED
LED
LED
LED
LED
+
{
{
{
{
Input
Input Indicator
Charge Indicator
DC Output
+
+

the ambient temperature. When the temperature is
higher, the charging voltage should be lower and
conversely when the temperature is lower, the
charging voltage should be higher. For specific
recommendations, please refer to the section on
Temperature Compensation. Similarly, charged
volume (measured in ampere hours) realized over a
giventimewillvaryindirectrelationtotheambient
temperature; the higher the ambient temperature,
thehigherthechargedvolumeinagivenperiodof
time and the lower the ambient temperature, the
lowerthechargedvolumeinthesamegivenperiod
of time. Figure 20 shows the relationship between
charged volume and temperature.
Initial Charge Current Limit
A discharged battery will accept a high charging
current at the initial stage of charging. High
charging current can cause abnormal internal
heating which may damage the battery. Therefore,
when applying a suitable voltage to recharge a
battery that is being used in a recycling application it
is necessary to limit the charging current to a value
of 0.30C Amps(max.). However, in float/standby use,
PowerlineSCaredesignedsothatevenifthe
available charging current is higher than the
recommendedlimit,theywillnotacceptmorethan
2C Amps and the charging current will fall to a
relativelysmallvalueinaverybriefperiodoftime.
Normally, therefore, in the majority of float/standby
applications no current limit is required. Figure 21
shows current acceptance in Powerline SC charged
ataconstantvoltageof2.30Vpcwithout
current limit.
Whendesigningacharger,itisrecommendedthat
suitable circuitry is employed to prevent damage to
the charger caused by short circuiting the charger
output or connecting it in reverse polarity to the
battery. The use of current limiting and heat sensing
circuits fitted within the charger are normally
sufficient for the purpose.
To ensure the correct voltage is set accurately, when
adjusting the output voltage of a constant voltage
charger, all adjustments must be made with the
charger "ON LOAD" Adjusting the output voltage with
the charger in an"OFF LOAD" condition may result in
undercharging. The constant voltage range required
by a battery is always defined as the voltage range
applied to a battery which is fully charged. Therefore,
a charger having the output characteristics illustrated
in Figure 22, should be adjusted with the output
voltage based on point A. The most important factor in
adjusting charger output voltage is the accuracy at
point A, which should be in the range of
2.275vpc 0.005 volts per cell; however this accuracy
is not normally required over the entire range of the
load. A charger adjusted in accordance with Figure 22
will never damage a battery, even if the charger has the
characteristics Shown by the broken line in Figure 22.
As the temperature rises, electrochemical activity in a
battery increases and conversely decreases as
temperature falls. Therefore, as the temperature
rises, the charging voltage should be reduced to
prevent overcharge and increased, as the
temperature falls, to avoid undercharge. In general,
inordertoattainoptimumservicelife,theuseofa
temperature compensated charger is recommended.
TherecommendedcompensationfactorforPowerline
SC is -3mV/ C/Cell (for float/standby) and -4mV / C
/Cell (cyclic use). The standard centre point for
temperature compensation is 20 C. Figure 23 shows
the relationship between temperatures and charging
voltages in both cyclic and float/standby applications.
Charge Output Regulation and Accuracy
Temperature Compensation
o o
o
POWERLINE
SC SERIES
09
Charge
Figure 20. Charging characteristics at
different temperatures
(%) (xCA) (V)
0.1CA-6.825V(13.65V)CONSTANT
VOLTAGE CHARGING
CHARGED
VOLUME
CHARGING
CURRENT
CHARGE
VOLTAGE
FOR 6V
BATTERY
CHARGED VOLUME
CHARGE
VOLTAGE
CHARGING CURRENT
CHARGE VOLTAGE
FOR 12V BATTERY
120
100
80
60
40
20
0
0.02
0.08
0.1
0510 15 20 25 30 35 40
11.0
12.0
13.0
14.0
CHARGING TIME (HOUSE)
0
(V)
0.04
0.06
7.00
6.50
6.00
5.50
AT 0 C(32 F)
oo
AT 20 C(68 F)
oo
AT 40 C(104 F)
oo
Figure21. Constant voltage charge
characteristics with no
current limit
CHARGE VOLTAGE:2.30V/C
TEMPERATURE:20 C (68 F)
oo
CHARGING TIME (SECONDS)
CHARGING CURRENT
0.5
1.0
1.5
2.0
(xCA)
0246810 20 30 40 50 60
Figure 22. Output voltage adjustment
CHARGING CHARACTERISTICS OUTPUT CHARACTERISTICS
A
CHARGING TIME OUTPUT CURRENT
OUTPUT VOLTAGE
CHARGING CURRENT
A

Expected Service Life of Powerline SC
10
POWERLINE
SC SERIES
In practice where there are short term temperature
fluctuations between 5 C and 40 C, temperature
compensation is not absolutely essential. However,
itisdesirabletosetthevoltageatavalueshownin
Figure 23 which, as closely as possible, corresponds
to the average ambient temperature of the battery
during its service life. When designing a charger
equipped with temperature compensation, the
temperature sensor must sense only the
temperatureofthebattery.Therefore,consideration
should be given to thermally isolating the battery
and temperature sensor from other heat generating
components in the system.
oo
Charging Efficiency
cyclic service life
Figure 26. Cycle service life in relation to depth
of discharge
Float Service Life
The charging efficiency of a battery is expressed
by the following formula:
The charging efficiency varies depending upon the
stateofchargeofthebattery,temperaturesand
charging rates. Figure 24 illustrates the concept of
the state of charge and charging efficiency. As
showninFigure25, PowerlineSCexhibitveryhigh
charging efficiency, even at low charging rates,
unlike some nickel cadmium batteries.
Thereareanumberoffactorsthatwillaffectthe
lengthofcyclicserviceofabattery.Themost
significant are ambient operating temperature,
discharge rate, depth of discharge, and the manner
in which the battery is recharged.
Generally speaking, the most important factor is
depth of discharge. Figure 26 illustrates the effects of
depth of discharge on cyclic life.
Therelationshipbetweenthenumberofcycleswhich
can be expected and the depth of discharge is readily
apparent. If an extended cycle life is required then it
is common practice to select a battery with a larger
capacity than the one that is required to carry the
load. Thus, at the specified discharge rate over the
specified time, the depth of discharge will be
shallower and cyclic service life will be longer.
Powerline SC are designed to operate in
float/standby service for approximately 5 yrs based
upon a normal service condition in which float
charge voltage is maintained between
2.275vpc 0.005 volts per cell in an ambient
temperature of approximately 20 C. Figure 27 shows
the float service life characteristics of Powerline SC
when discharged once every three months to 100%
depth of discharge.
η
Expected Service Life of
Powerline SC
o
(Ah)Ampere hours Discharged
(Ah)Ampere hours Charged
η=
Figure 24. Charging efficiency vs
state of charge
CHARGE EFFICIENCY
STATE OF CHARGE(%)
(%)
100
50
050
100
Figure25. Charging efficiency
CHARGE EFFICIENCY ( )η
AT 40 C
o
AT 25 C
o
AT 0 C
o
70
80
90
100
0.001 0.002 0.005 0.01 0.02 0.05 0.1
CHARGING CURRENT(xCA)
0
13.2
13.8
14.4
15.0
15.6
6.6
6.9
7.2
7.5
7.8
2.2
2.3
2.4
2.5
2.6
14 32 50 68 86 104 122 140( F)
o
-10 0 10 20 30 40 50 60( C)
o
AMBIENT TEMPERATURE
CHARGING VOLTAGE
Figure 23. Relationship between charging
voltage and temperature
(V)12V BATTERY
(V)6V BATTERY
(V/CELL)
0
CYCLE USE
STAND-BY USE
100%
80%
60%
40%
20%
0%
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Thousand cycles
D.O D. in%.

POWERLINE
SC SERIES
11
Inanormalfloatservice,wherethechargingvoltage
is maintained at 2.275vpc 0.005 volts per cell (see
Fig.28),thegasesgeneratedinsideanPowerlineSC
battery are continually recombined into the negative
plates and return to the water content of the
electrolyte. Therefore, electrical capacity is
effectively not lost due to the "drying up" of the
electrolyte;thelossofcapacityandeventualendof
service life is brought about by the gradual corrosion
of the electrodes. It should be noted that this
corrosive process will be accelerated by high
ambient operating temperatures and/or high
charging voltage. When designing a float service
system, always consider the following:
Powerline SC are highly efficient maintenance free
electrochemical systems designed to provide years of
trouble free electrical energy. The performance and
service life of these batteries can be maximized by
observing the following guidelines:
1. Heat kills batteries. Avoid placing batteries in
close proximity to heat sources of any kind. The
longest service life will be attained where the
battery temperature does not exceed 20 C. (also
seenotes3&8hereunder). When calculating the
correct float voltage setting, whether or not
temperature compensation is required, full
consideration must be given to the temperature of
thebatteryandroomambient.Forthepurposeof
the calculation, consider the temperature of a
battery on float to be 1 C. above local ambient.
Also, if the battery is used in an enclosure, the
temperature gradient of the enclosure itself must
be included in the calculation. i.e. The operating
temperature of the battery is given by: Room
temperature + enclosure temperature +1 C.
2. Since a battery may generate ignitable gases, do
not install close to any equipment that can
produce electrical discharges in the form of
sparks.
3. When the battery is operated in a confined space,
adequate ventilation should be provided.
4. Thebatterycaseismanufacturedfromhigh
impact ABS plastic resin. It should not be placed in
anatmosphereof,orincontactwithorganic
solvents or adhesive materials.
5. Correct terminals should be used on battery
connecting wires. Soldering is not recommended
but if unavoidable please refer to us for
further guidance.
6. Avoidoperatingattemperaturesoutsidethe
requested range.
7. When there is a possibility of the battery being
subjected to heavy vibration or mechanical shock,
it should be fastened securely and the use of
shock absorbent material is advisable.
8. When connecting the batteries, free air space
must be provided between each battery. The
recommended minimum space between batteries
is 0.2 inches (5mm) to 0.4 inches (10mm). In all
installations due consideration must be given to
adequate ventilation for the purposes of cooling.
9. When the batteries are to be assembled in series
toprovidemorethan100V,properhandlingand
safety procedures must be observed to prevent
accidental electric shock).
10.If2ormorebatterygroupsaretobeused,
connected in parallel, they must be connected to
the load through lengths of wires, cables or
busbars that have the same loop line resistance as
each other. This makes sure that each parallel
±
LENGTH OF
SERVICE LIFE WILL BE DIRECTLY AFFECTED BY THE NUMBER OF
DISCHARGE CYCLES, DEPTH OF DISCHARGE, AMBIENT
TEMPERATURE AND CHARGING VOLTAGE.
Design/Application
Suggestions to Ensure
Maximum Service
o
o
o
Design/ Application
Figure 28.
Relationship between float charge
UNDER CHARGE OVER CHARGE
(%) BATTERY LIFE
FLOAT CHARGE VOLTAGE(V/CELL)
25
50
75
100
2.1 2.2 2.3 2.4 2.5
2.275
Figure 27. Float service life
PERCENTAGE OF
CAPACITY AVAILABLE
(AH)%
LIFE(YEARS)
TESTING CONDITIONS:FLOATING VOLTAGE:2.275VPC 0.005V/CELL
AMBIENTTEMPERATURE:20CTO22C(68FTO72F)
oooo
0
20
40
60
80
100
120
123455.5

bank of batteries presents the same impedance to the load as any other of the parallel banks thereby
ensuring correct equalization of the source to allow for maximum energy transfer to the load.
11. Ripple current (the AC component on the DC charge current). Ideally this should be zero, as it will reduce
the service life of a cell/battery, the larger the component the greater the reduction it will cause. For
example 0.1C Amps R.M.S will reduce the optimum service life by a minimum 3%.) Ripple current can be
source or load generated. ) Ripple current can vary with load change and is often its greatest at part load.
12. When cleaning the battery case, ALWAYS use a water dampened cloth but NEVER use oils, organic solvents
such as petrol, paint thinners etc. DO NOT even use a cloth that is impregnated or has been in contact with
any of these or similar substances.
13. Do not attempt to dismantle the battery. If accidental skin/eye contact is made with the electrolyte, wash
or bathe the affected area/part straight away with liberal amounts of clean fresh water and seek
IMMEDIATE medical attention.
14.DONOTINCINERATEbatteriesastheyareliabletoruptureifplacedintoafire.Batteries,thathave
reached the end of their service life, can be returned to us for safe disposal.
15. Touching electrically conductive parts might result in an electric shock. Be sure to wear rubber gloves
before inspection or maintenance work.
16. The use of mixed batteries with different capacities, that may have been subjected to different uses, be of
different ages and are of different manufacturers is liable to cause damage to the battery itself and/or the
associated equipment. If this is unavoidable please consult us beforehand.
17.Toobtainmaximumlife,batteriesshouldneverbestoredinadischargedstate.
18.Inordertoobtainmaximumworkinglife,whenthebatteriesareusedinanUPSsystemthefollowingis
advised:
(a) Where the D.C. input exceeds 60 volts, each battery should be insulated from the battery stand by using
suitable polypropylene or polyethylene material.
(b) In high voltage systems the resistance between battery and stand should always be greater than 1 M . An
appropriate alarm circuit could be incorporated to monitor any current flow.
Ω
12
POWERLINE
SC SERIES
Design /Application

Shandong Sacred Sun Power Sources Co.,Ltd.
Add: 1, Shengyang Road, Qufu 273100 China
Tel: [phone] extn 6028 Fax:[phone]
Website: www.abtbatt.com www.sacredsun.com
Email: [email protected]
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