FAAM FLL 6V Series User manual

VALVE REGULATED LEAD-ACID BATTERY
FLL 6V-12V SERIES
OPERATION MANUAL
FAAM SpA
via Monti - zona industriale
63026 Monterubbiano (AP)
Tel. [phone] –Fax [phone]
Internet: www.faam.com - E-mail: [email protected]

2
Please carefully read all instructions in this manual before you proceed with installation.
And please keep the manual for reference during operation.
It is forbidden to overcharge battery shortly and short circuit shall be avoided. Please
do not attempt to dismantle the battery if some abnormal phenomena happen. You
should contact us immediately and our technicians will handle the problems or replace
the battery in time.
The manufacturer reserves the right to make alterations without prior notice
concerning the operation manual.

3
Contents
I. Brief Introduction..............................................................................................................................1
Indication of Type...................................................................................................................................2
Types and Dimensions............................................................................................................................3
II. Technical Characteristics.................................................................................................................3
2 Temperature and Floating Voltage.......................................................................................................6
2.1 Ambient Temperature ...................................................................................................................6
3Type Selection......................................................................................................................................8
12VAmpere/Monoblock at 20°C 1,65V/Cell ........................................................................................8
12VAmpere/Monoblock at 20°C 1,70V/Cell ........................................................................................9
12VAmpere/Monoblock at 20°C 1,80V/Cell ......................................................................................10
4 Installation.........................................................................................................................................11
5 Operation...........................................................................................................................................12
6. Storage..............................................................................................................................................15
The quality certificates of FAAM FLL batteries record the latest charge time of the batteries, the next
charge time can be calculated according to this charge time.7 Maintenance.......................................15
7 Maintenance ......................................................................................................................................16

1
I. Brief Introduction
Features
Basic Characteristics
Adopts the design of barren-electrolyte and utilizes AGM (microporous glass
fiber) separator. Thus there is a path existing between the positive and the
negative. Also non-Sb alloy grid is chosen to increase vent hydrogen
over-potential on the negative plate, which prevent generation of Hydrogen,
finally reaches the goal of no water losing. So during the operation life, there’s no
need to add acid and water, neither to adjust the gravity of the solution.
Reliable seal performance, not emission of acid mist, not erosion to equipment.
Long life and low self-discharge.
Compact structure, shock-proof and high energy density design.
Reliable Seal Technology
Container and lid made of ABS flame retardant FV class V-0. Adopt heat seal
technology of ABS container and lid. The technology conquers epoxy’s
weaknesses of aging and brickle. And the amalgamation of the same ABS
material ensures no leakage of solution.
Explosive proof valve with an acid filtering structure. If the pressure inside the
battery exceeds a certain value, the safety valve will automatically open to
decrease the pressure. And it will close till the pressure is normal. The acid
filtering structure in the safety valve prevents emission of acid mist when the
safety valve opens.
Excellent resist characteristics of mechanical impact and heat impact, prolong
the corruption distance of sulfuric acid.
Excellent high rate discharge performance
Unique multiple-segment radial grid
Copper insert pillar, the copper insert’s diameter is as long as 20mm, suitable for
high rate discharge
Silver-coated flexible connector, good electric performance and low
voltage-decrease.
Extremely equalized float charge voltage
A unique homogeneous working procedure ensures homogeneous float charge
voltage of FAAM FLL batteries.

2
Fig. 1-1 Battery image
Indication of Type
FLL—× × × ×
20 or 10hr Rated Capacity
LIFE
LONG
FAAM
6 or 12V

3
Types and Dimensions
Cell Type
Rated
Voltage
(V)
Rated Capacity (Ah)
Dimensions(mm)
Weight
(Kg)
C10 Vf
1,80V
C5Vf
1,80V
C3vf
1,7V
C1 vf
1,6V
Length
Width
Height
Overall
Height
FLL 12-17
12
15
12,95
11,55
9,21
181
77
167
167
5,6
FLL 12-24
12
22
19,00
16,95
13,50
166
176
125
125
8,5
FLL 12-31
12
25
21,60
19,05
15,35
194
133
172
172
11,2
FLL 12-42
12
37
32,00
28,50
22,70
198
166
172
172
14,2
FLL 12-60
12
50
43,25
38,50
30,70
259
168
208
220
23
FLL 12-70
12
65
56,20
50,04
39,90
350
167
178
178
22,8
FLL12-100
12
85
73,50
65,43
52,18
331
176
214
218
30,5
FLL 12-120
12
100
86,45
76,98
61,38
407
174
209
233
38,0
FLL 12-150
12
135
116,70
103,95
82,87
485
172
240
240
46
FLL 12-200
12
180
155,60
138,60
110,50
521
269
203
208
62,5
FLL 6-100
6
100
86,45
76,98
61,40
195
170
206
213
15,5
FLL 6-150
6
150
129,70
115,50
92,08
260
180
247
254
24,5
FLL 6-180
6
180
155,60
138,60
110,49
306
168
222
229
28
FLL 6-200
6
200
172,90
153,99
122,77
323
178
224
231
30,5
FLL 6-225
6
225
194,50
173,22
138,11
260
180
247
254
31
II. Technical Characteristics
Capacity and Influence Factor
Capacity of Battery
The capacity of battery is the capacity that battery can be discharged on the
established conditions, expressed as signal C. The usual unit of capacity is ampere
hour, shortened as AH.
The capacity can be expressed in Rated Capacity or Actual Capacity. The Rated
Capacity of FAAM FLL battery please see Table 1-1. The Actual Capacity is the
product of the discharge current and the discharge time, the unit is Ah.
The Influence Factor of the Actual Capacity
The actual capacity is mainly related with the positive and negative active materials
and their utilization rate. The utilization rate of the materials is mainly influenced with
the DOD, the structure of the battery and manufacture technology. In using process
the factors that influence the actual capacity are discharge rate, discharge modality,
end voltage and temperature.

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Discharge Rate
The discharge rate is often described as hour-rate and multiple rates.
Figure 2-2 is the discharge characteristics curves at different discharge rates. From the
figure we can see that when we adopt same type battery to discharge, if the discharge
rate is higher and the discharge current is larger, then the discharge time is shorter, and
the capacity which can be discharged is less.
Fig. 2-1 Discharge Performance Curves at Different Discharge Rates (20°C) for
FLL12-100 as example

5
Temperature
Temperature affects capacity of the battery. Fig. 2-2 is the available capacity curve vs.
ambient temperature. If the ambient temperature is not 20°C, it’s necessary to change
the measured capacity to actual capacity Ceat 20°C according to following formula:
Ce= CT/(1 + K (T-20))
T = the ambient temperature
K = temperature modulus, 10hr rate capacity test K=0.006/°C
3hr rate capacity test K=0.008/°C
1hr rate capacity test K=0.01/°C
Fig. 2-2 Available Capacity VS.Ambient Temperature
End voltage
The end voltage is the lowest working voltage below which the battery can’t be
discharged any more. Usually the 10hr rate end voltage of lead-acid battery is 1.80V,
and 1hr rate end voltage are 1.6V, under the CEI IEC 60896-21 & 22

6
2 Temperature and Floating Voltage
2.1 Ambient Temperature
The best ambient temperature of using FAAM FLL battery is 20°C. At 20°C,
FAAM battery can be discharged 100% of its capacity. If the ambient temperature is
different, it can be improved with methods as follows:
Change the environment, such as adopting cooling system, changing the position of
the batteries, and improve ventilation.
Adopt temperature revising method, if the ambient temperature is higher, decrease
the floating charge voltage; if lower, increase the floating charge voltage.
Floating Voltage
The purpose of choosing certain floating voltage is to reach the designed life and rated
capacity of the battery. If the floating voltage is higher, then the floating current is also
higher, it will accelerate the corruption the grid and shorten the life of the battery. If
the floating voltage is lower, the battery can’t be kept in full charged state, this will
crystallize PbSO4, decrease the capacity, and also shorten the life of the battery.
At 20°C, if the floating voltage is 2.27±0.02V/cell, the designed use life of FAAM
FLL battery is over12 years, in accordance with the Eurobat Guide In other degree,
please adjust according to Table 4-2.
Internal resistance and short circuit current
The internal resistance of the battery is a dynamic nonlinear parameter that is
continuously changed along with the temperature and discharge state. The internal
resistance is the lowest when battery is full charged. The table 2-1 shows the internal
resistance and short circuit current of FAAM battery in fully charged state.

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Table 2-1. Internal resistance, short circuit current (20°C)±10% Terminal type
Battery Type
Internal resistance (mΩ)± 10%
Short circuit current (A)±10%
Terminal Type
FLL 12-17
15,3
350
M5
FLL 12-24
10,2
530
M5
FLL 12-31
15,0
800
M6
FLL 12-42
12,0
1050
M6
FLL 12-60
10,0
1260
M6
FLL 12-70
7,5
1720
M6
FLL 12-100
5,0
2150
M8
FLL 12-120
4,7
2380
M8
FLL 12-150
3,8
3200
M8
FLL 12-200
3,4
3500
M8
FLL 6-100
2,1
2600
M8
FLL 6-150
3,2
3100
M8
FLL 6-180
3,1
3800
M8
FLL 6-200
4,4
4100
M8
FLL 6-225
4,1
4300
M8
Note: Short circuit current will decrease the voltage of the battery to 0V, and damage the
internal components of the battery.

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3Type Selection
Please select batteries according to table 3.1 .
First confirm the discharge watt and end voltage.
Confirm the continual working time and ambient temperature.
Select right battery type according to table 3.1
12VAmpere/Monoblock at 20°C 1,65V/Cell
Type
Voltage
V
Time
5min
15min
30min
60min
90min
3hour
5hour
8hour
10hour
FLL12-17
12
22,70
16,10
11,27
9,53
7,55
3,86
2,65
1,82
1,58
FLL12-24
12
33,29
23,61
16,53
13,98
11,08
5,66
3,88
2,68
2,31
FLL12-31
12
37,83
26,83
18,78
15,89
12,59
6,43
4,41
3,04
2,63
FLL12-42
12
55,99
39,71
27,79
23,51
18,63
9,52
6,53
4,50
3,89
FLL12-60
12
75,66
53,66
37,56
31,77
25,18
12,86
8,82
6,08
5,25
FLL12-70
12
98,36
69,76
48,82
41,31
32,73
16,72
11,47
7,91
6,83
FLL12-100
12
128,62
91,22
63,85
54,02
42,80
21,86
14,99
10,34
8,93
FLL12-120
12
151,32
107,32
75,11
63,55
50,35
25,72
17,64
12,16
10,50
FLL12-150
12
204,28
144,89
101,40
85,79
67,98
34,72
23,82
16,42
14,18
FLL12-200
12
272,37
193,18
135,21
114,38
90,64
46,30
31,75
21,89
18,90
FLL6-100
6
151,32
107,32
75,11
63,55
50,35
25,72
17,64
12,16
10,50
FLL6-150
6
226,97
160,98
112,67
95,32
75,53
38,58
26,46
18,24
15,75
FLL6-180
6
272,37
193,18
135,21
114,38
90,64
46,30
31,75
21,89
18,90
FLL6-200
6
302,63
214,65
150,23
127,09
100,71
51,44
35,28
24,32
21,00
FLL6-225
6
340,46
241,48
169,01
142,98
113,30
57,87
39,69
27,36
23,63

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12VAmpere/Monoblock at 20°C 1,70V/Cell
Type
Voltage
V
Time
5min
15min
30min
60min
90min
3hour
5hour
8hour
10hour
FLL12-17
12
20,63
15,93
10,93
7,83
6,20
3,85
2,64
1,82
1,55
FLL12-24
12
30,25
23,37
16,03
11,48
9,10
5,65
3,87
2,66
2,28
FLL12-31
12
34,38
26,55
18,22
13,04
10,34
6,42
4,39
3,03
2,59
FLL12-42
12
50,88
39,30
26,96
19,31
15,30
9,50
6,50
4,48
3,83
FLL12-60
12
68,76
53,11
36,44
26,09
20,67
12,83
8,79
6,06
5,17
FLL12-70
12
89,38
69,04
47,37
33,92
26,87
16,68
11,42
7,87
6,72
FLL12-100
12
116,88
90,28
61,94
44,35
35,14
21,81
14,93
10,30
8,79
FLL12-120
12
137,51
106,21
72,87
52,18
41,35
25,66
17,57
12,11
10,35
FLL12-150
12
185,64
143,39
98,38
70,44
55,82
34,65
23,72
16,35
13,97
FLL12-200
12
247,52
191,18
131,17
93,92
74,42
46,20
31,63
21,80
18,62
FLL6-100
6
137,51
106,21
72,87
52,18
41,35
25,66
17,57
12,11
10,35
FLL6-150
6
206,27
159,32
109,31
78,27
62,02
38,50
26,36
18,17
15,52
FLL6-180
6
247,52
191,18
131,17
93,92
74,42
46,20
31,63
21,80
18,62
FLL6-200
6
275,02
212,43
145,74
104,36
82,69
51,33
35,14
24,23
20,69
FLL6-225
6
309,40
238,98
163,96
117,40
93,03
57,74
39,53
27,25
23,28

10
12VAmpere/Monoblock at 20°C 1,80V/Cell
Type
Voltage
V
Time
5min
15min
30min
60min
90min
3hour
5hour
8hour
10hour
FLL12-17
12
16,57
13,88
10,38
7,64
6,06
3,81
2,59
1,79
1,50
FLL12-24
12
24,30
20,35
15,23
11,21
8,88
5,58
3,80
2,62
2,20
FLL12-31
12
27,61
23,13
17,31
12,74
10,10
6,35
4,32
2,98
2,50
FLL12-42
12
40,87
34,23
25,62
18,86
14,94
9,39
6,40
4,41
3,70
FLL12-60
12
55,23
46,26
34,62
25,48
20,19
12,69
8,65
5,96
5,00
FLL12-70
12
71,79
60,14
45,00
33,12
26,25
16,50
11,24
7,75
6,50
FLL12-100
12
93,88
78,64
58,85
43,32
34,32
21,57
14,70
10,13
8,50
FLL12-120
12
110,45
92,52
69,23
50,96
40,38
25,38
17,29
11,92
10,00
FLL12-150
12
149,11
124,90
93,46
68,80
54,51
34,26
23,34
16,09
13,50
FLL12-200
12
198,81
166,54
124,61
91,73
72,68
45,68
31,12
21,46
18,00
FLL6-100
6
110,45
92,52
69,23
50,96
40,38
25,38
17,29
11,92
10,00
FLL6-150
6
165,68
138,78
103,85
76,44
60,57
38,07
25,94
17,88
15,00
FLL6-180
6
198,81
166,54
124,61
91,73
72,68
45,68
31,12
21,46
18,00
FLL6-200
6
220,90
185,04
138,46
101,92
80,76
50,76
34,58
23,84
20,00
FLL6-225
6
248,51
208,17
155,77
114,66
90,86
57,11
38,90
26,82
22,50

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4Installation
1. Installation Precautions
The customer can adopt flexible installation methods according to the condition
of installation area. However detailed requirements about installation shall be
submitted when placing the order so that best connection scheme can be
determined and installation drawings can be provided
Please strictly refer to installation drawings when make serial and connection.
Batteries of different capacity and performance can not be connected together.
Batteries must be strictly series-wound or shunt-wound connected according to
installation drawing.
Use insulating instruments during installation.
Do not use large torque to connect batteries.
Installation of abnormal batteries is prohibited.
Batteries are of sealed structure, in normal condition, there’s no danger of
cauterization of sulphuric acid. But if batteries are broken in transportation or
unloading, wash cauterized skin and/or eyes with plenty of water immediately,
and the person should be sent to hospital as quickly as possible.
The batteries system should be installed nearer to the load as possible as it can, in
orders to avoid voltage drop of the wire.
After installation, check again the system voltage, the polarity of positive and
negative post to ensure the correct installation
Follow the installation instruction and maintenance that are sending with the
battery

12
5 Operation
Condition
The FAAM FLL battery can be used from –15°C to +45°C of the ambient environment.
The best ambient temperature is 20°C.
Floating Operation
FAAM FLL battery can be either floating used or cycle used.
Floating using is the best operation condition of the battery. The battery is all the while fully
charged in operation, in this condition battery can be used for longest life. During floating
operation, please adjust the charge voltage according to environmental temperature, see Table
4-1:
Table 4-1 Floating Voltage VS. Ambient Temperature
Environmental Temperature (°C)
Floating Voltage ( V±0.02V/Cell)
0—10
2.32
11—15
2.30
16—25
2.27
26—30
2.25
31—35
2.24
36—40
2.23
Equalized Charge
FAAM FLL battery need to be equalized charge on conditions as follows:
After installation of the battery system, the batteries need to be supplemental charged.
Floating operation over three months, and the voltage of at least two batteries are lower than
2.23V.
Storage over three months.
Floating operation for three months.

13
The method of equalized charge is suggested as follows:
Charge with 2.35V–2.40V/Cell for 24 hours.
Note: Above-mentioned charge time is on condition that temperature changes from 20°C to
30°C. If the ambient temperature decreases, it’s better to increase the charge time; otherwise,
decrease the charge time.
Charge
After discharge, the batteries should be charged in time. The method is recommended as
follows:
The batteries first should be charged on the constant current of 0.1C10A till the average
voltage of the batteries increases to 2.35–2.40V, then the batteries should be charged with
constant voltage of 2.35–2.40V/Cell, till the charge is finished.
Whether the batteries are fully charged can be decided according to any one of two standards
as follows:
The charge time is 18–24 hours (the charge time can be shortened when the batteries weren’t
deep discharged, e.g. , the charge time of 20% DOD batteries can be shortened to 10hours.)
On condition of constant voltage, the value of charge current hasn’t varied for continuous
three hours.
On special condition, the batteries need to be fully charged as soon as possible, then fast
charge should be adopted: the value of limit current should not be longer than 0.25C10A, and
the charge voltage should be 2.35–2.40V per cell.
Fig. 4-1 shows recharge characteristics curve of 100% DOD FLL12-100 batteries with
0.1C10A current and limit voltage 2.35V/Cell (25°C). It can be found the fully discharged
batteries can be charged 100% capacity in 15 hours. Fig. 4-2 shows recharge characteristics
curve of 100% DOD FLL12-100 batteries with 0.1C10A current and limit voltage 2.27V/Cell
(25°C). It can be found the fully discharged batteries can be charged 100% capacity in 24
hours.

14
Fig. 4-1 Recharge Characteristics Curve of 100% DOD FLL12-100 Batteries with
0.1C10ACurrent and Limit Voltage 2.35V/Cell (25°C)
Fig. 4-2 Recharge Characteristics Curve of 100% DOD FLL12-100 Batteries with
0.1C10ACurrent and Limit Voltage 2.23V/Cell (25°C)
0
5
10
15
20
25
30
1.9
2.0
2.1
2.2
2.3
Charging Voltage
Per Cell
(V)
Charging Time (h)
0
20
40
60
80
100
120
140
Charging Voltage Per Cell
Charging Current
Capacity Charged
Charged (%)
0
10
20
30
40
50
60
70
Charging
Capacity
Current
(A)
0
5
10
15
20
25
30
1.9
2.0
2.1
2.2
2.3
2.4
Charging Voltage Per Cell
Capacity Charged
Charging Current
Per Cell
Charging Voltage
(V)
Charging Time (h)
0
10
20
30
40
50
60
70
Charging
Current
(A)
0
20
40
60
80
100
120
140
Capacity
Charged
(%)

15
6. Storage
All lead acid batteries self-discharge in open circuit. The result is that the voltage of open
circuit is decreased, and the capacity also decreased. During storage please note:
The self-discharge rate is related with ambient temperature. The self-discharge degree is
smaller when the ambient temperature is lower, otherwise is larger. The requirement
temperature of FAAM FLL batteries’ storage environment is from 0°Cto 35°C. The
storage place must be clean, ventilated and dry.
An important parameter in storage is open circuit voltage, which is related with density of the
electrolyte. In order to avoid perpetual damage to the plate caused by self-discharge, the
batteries should be supplemental charged if they have been stored for three months. The
equalized charge method should be adopted.
During storage, if the open circuit voltage is lower than 2.10V/Cell, the batteries should be
supplemental charged before use. The equalized charge method should be adopted.
All batteries, which are ready to store, should be fully charged before storage. It’s suggested
record the storage time in the periodic maintenance record and record the time when another
necessary supplemental charge should be made.
The quality certificates of FAAM FLL batteries record the latest charge time of
the batteries, the next charge time can be calculated according to this charge
time.

16
7 Maintenance
In order to assure life, the batteries should be correctly inspected and maintained. The
maintenance methods of FAAM FLL batteries is recommended as follows:
Monthly Maintenance
Implement the under-mentioned inspection every month:
Keep the battery-room clean.
Measure and record the ambient temperature of the battery-room.
Check each battery’s cleanness, check damage and calorific trace of the terminal, container
and lid.
Measure and record the total voltage and floating current of the battery system.
Quarter Maintenance
Repeat monthly inspection.
Measure and record floating voltage of every on-line battery. If more than two monoblocks
voltage is less than 13,38V for FLL 12V or 6,69V after temperature adjustment, the batteries
need to be equalized charged. If the problem is still existed after adopting such measures, the
batteries need to yearly maintenance or even three years’ maintenance. should be processed If
all methods are ineffective, please contact us.
Yearly Maintenance
Repeat quarter maintenance and inspection.
Check whether connectors are loose or not every year.
Make a discharge test to check with exact load every year, discharging 30-40% of rated
capacity.
Three-years’ Maintenance
Make a capacity test once every three years and once every year after six years’ operation. If
the capacity of the battery decreases to lower than 80% of rated capacity, the battery should be
replaced.
Operation and Maintenance Precautions
Use insulating instruments in operating and maintaining batteries. Do not lay metal
instruments on batteries.
—Do not use any organic cleanser to clean batteries.
Do not dismantle the safety valves of batteries and add anything into batteries.
Do not smoke or use fire near batteries.
Do not use abnormal batteries. (E.g., fast inflation, serious transmogrification and vent valve
detonation.)
—All maintenance works should be done by professionals.