moll OPzS.solar User manual

Operating instructions
Stationary solar vented lead-acid batteries
OPzS.solar & OPzS.block.solar
Assembly and CE-marking by............................
.....................................................................
Commissioning by ...........................................
Date............................
Date............................
Number of cells/blocks:
...................................................
Type: ..........................................
WARNINGS
Observe operating instructions and position them within sight of
the battery! Work only on batteries under instruction of skilled
personnel!
When working on batteries wear safety glasses and protective
clothing! Comply with accident prevention rules as well as with
DIN VDE 0510, VDE 0105 part 1!
No smoking! Do not expose the battery to an open flame, a
glowing fire or sparks as explosion and fire hazards exist.
Acid splashes in the eyes or on the skin must be washed out or
off with plenty of water. Then see a doctor immediately. Clothing
exposed to acid should be washed out with water without delay.
Dangerous voltages!
The electrolyte (diluted sulphuric acid) is extremely corrosive.
Block batteries or cells are heavy! Ensure secure installation!
Only use suitable transport equipment!
Explosion and fire hazard due to explosive gases escaping from
the battery. Caution! Metal parts of the battery are always live;
therefore do not place items or tools on the battery! Avoid short
circuits!
Usage of the battery which does not comply with the OPERATING INSTRUCTIONS,
repairs carried out with spare parts not approved by the manufacturer, use of additives
in the electrolyte or unauthorised interference with the battery will invalidate any claim
for warranty.
Used batteries with this symbol are reusable goods
and must be returned to the recycling process or
must be disposed in accordance with the rules of the
country concerned.
1. Commissioning of filled and charged batteries
Before commissioning all cells/blocks must be inspected for mechanical damage.
Assemble the cells/blocks in accordance with their polarity. If necessary, the contact
surface of the poles and the connectors has to be cleaned. The connectors have to be
firmly seated by tightening the terminal screws with a torque of 22±1 Nm. The distance
between block batteries and cells should be 10 mm in an installation. Observe the
Installation Instruction. Check the electrolyte level in all cells. If necessary top up with
purified water as specified under DIN 43530 part 4 all cells having lower level of electrolyte.
Be aware that the electrolyte level will increase during charging. during charging. Connect
the battery to the DC power supply, with the charger switched off, battery fuses removed
and the load disconnected, ensuring that the
polarity is correct: Positive terminal of the battery
to the positive terminal of the charger. Multipole
cells have to be connected using all poles with
same diameter and length of connectors. Switch
on the charger and charge as per point 2.3.
In case of alternative power supplies like solar
photovoltaic installations or wind turbines (point
2.3), all cells of the battery have to be fully
charged until the absolute deviation of the
voltages per cell is less than 1 % and the density
of the electrolyte has reached the nominal value
according to the specification.
No load has to be connected to the installation
until the battery is fully charged.
2. Operation
At installation and operation of stationary batteries
for solar applications the standard EN 50 272-2
has to be observed.
Solar block batteries and cells should always be
operated with charge controllers and deep
discharge protection. Any exposure to direct
sunlight as well as any change of ambient
temperature >10 K should be avoided.
2.1. Operation modes standby and buffer
In this case the load, the DC power supply and
the battery must be connected permanently in
parallel. Thereby the charging voltage is the
operational voltage of the battery and also the
system voltage.
a) During standby operation (float) the DC power
supply must be always able to provide the
maximum load current and the battery charging
current. The battery only supplies current, if the
DC power supply fails. The charge voltage at
20°C must be set for OPzS.solar ±1% measured
at the batteries terminals.
b) During buffer operation the DC power supply is
not always able to provide the maximum load
current. The load current temporarily exceeds the
rated current of the DC power supply. During this
time the battery supplies current. The battery is
not always fully charged. Depending on the load,
the charge voltage should be set at (2.25 to
2.30 V) x number of cells.
2.2. Discharge
The batteries should not be discharged below the
nominal capacity and final voltage per cell as
indicated in the technical specification. Deep
discharges of more than 80 % of the nominal
capacity have to be avoided as the life time of the
batteries will be reduced.
Batteries have to be recharged immediately
after a partial or complete discharge but at
least within a period of one week up to 4
weeks to 100 %.
To prevent electrolyte stratification, an equalizing
charge must be carried out according to operating
instructions at DOD > 30 % C10 per day or
batteries with electrolyte circulation have to be
used.

2.3. Charging with external charger
Charging must only be carried out with direct current. Chargers with
IU-, IUI- or W-characteristics according to DIN 41773, DIN 41776 and
DIN 41774 may be used.
2.3.1. IU (or IUU) characteristics
Starting with a given initially constant charging current ("I") the cell or
battery voltage reaches the given final value which depends on the
charging requirement by the application. The charger automatically
switches then to constant operating voltage ("U"). As long as the final
voltage is not reached, the charging current is limited by the charger only.
Typical values for constant currents are 0.5 to 2.0 times I10. Typical
constant voltages are 2.23, 2.25, 2.30, 2.40 V/cell. The different voltages
are given by the application. The IUU characteristic provides a switching
point after a higher first constant voltage to operating voltage.
2.3.2. IUI characteristics
This characteristic is a very effective method in order to recharge batteries
in short time and to crack sulphations. At first, an IU characteristic is
applied to the battery. After a given time held out at constant voltage, the
charging method is then extended by using a reduced constant current
("I"). This current is limited to 5 A/100 Ah C10. The cell or battery voltage
reaches values between 2.60 and 2.75 V/cell. Check if loads have to be
disconnected before, in order to prevent damage. On exceeding the
maximum temperature of 55°C/131 F, the charging has to be either
stopped or proceed with reduced current or be switched to float charge as
per item 2.3.3 in order to allow the temperature to drop. The fully charged
state is reached, when the cell voltages have not risen for a period of 2 h.
2.3.3. Float charge (float voltage)
A battery is float charged, when the electrodes are sufficiently polarized in
that quantity that the floating current compensates the self discharge rate
of the battery. A fully charged battery remains at 100 % SOC while being
floated. The float voltage depends on acid density. Please take the values
from following table:
Floating voltage
Battery type
2.23 V/cell ± 1 %
OPzS.solar
2.4. Charging with alternative power supply
When using an alternative power supply, the battery charger is not always
able to supply the maximum load current. The load current can exceed
the nominal current of the battery charger. The battery supplies power
during this period and the battery will not fully charged. The charge
voltage has, therefore, to be set at 2.23 - 2.35 V per cell ±1% x number of
cells.
At regular discharges of approx. 0.2 x C10 a charging voltage of 2.30 V to
2.35 V per cell has to be used.
At regular discharges from 0.2 to 0.3 x C10 the charging voltage should
be 2.35 V to 2.40 V per cell.
In accordance with item 2.5 the charging time at those increased voltages
shall be limited to maximum 72 h. If no discharge follows then switch to
standby operation.
At standby operation without cycling the batteries should be operated at
float charge with 2.23 V/cell ± 1 % per cell.
After deep discharge or after inadequate recharging an equalizing
charging as per item 2.5 is necessary.
2.5. Equalizing or boost charge
Charging method with increased gassing activity at higher cell voltages
(>2.33 V/cell), done with either increased constant voltage (e.g. 2.33 to
2.40 V/cell) or constant current. The application of this method shall be
time (max. 72h) and temperature (max. 55°C (131 °F)) limited. Please
take the values from following table:
Charging
characteristics
Maximum current
in A / 100 Ah C10
Voltage per cell
I
5.0
2.60 - 2.75
W
7.0
3.5
2.40
2.65
On exceeding the temperature maximum, the charging must either be
stopped or proceeded with reduced current or be switched to float charge
to allow the temperature to drop. The equalizing charge, if executed with
constant current is completed, when the individual cell voltages does not
increase longer within 2 hours.
2.6. Ripple currents
During recharging up to 2.40 V/cell the RMS value of the AC ripple current
may reach temporarily max. 20 A/100 Ah C10. After recharging and at
standby (float) or buffer operation the RMS value of the ripple current
must not exceed 5 A/100 Ah C10.
3. Battery temperature and related charging voltage
All technical data refer to the nominal temperature of 20°C (68 °F).
The ideal operating temperature range is
20 °C ± 5 K (59 °F to 77 °F). The recommended operating
temperature range is 10 °C (50 °F) to 30 °C (86 °F). Higher
temperatures reduce the working life. Lower temperatures reduce
the available capacity. Exceeding the temperature limit of
45 °C (113 °F) up to 55 °C (131 °F) is acceptable only for short
periods. Exceeding the temperature limit of 55 °C (131 °F) is not
permissible. A temperature-related adjustment of the charging
voltage within monthly averaged battery temperature of
10 °C (50 °F) to 30 °C (86 °F) is not necessary. Below 10 °C (50 °F)
in the monthly average the charging voltage should be increased
(-0.003 V/cell K) for a faster recharging. Above 30 °C (86 °F) in the
monthly average voltage may be reduced (-0.003 V/cell K) to
reduce water decomposition and corrosion.
4. Electrolyte
The electrolyte is diluted sulphuric acid. The rated specific gravity of
the electrolyte in the fully charged state is based on 20 °C (68 °F)
and the “MAX“ electrolyte level with a maximum deviation
± 0.01 kg/l. The rated specific gravity is printed on every type label.
Higher temperatures reduce the specific gravity of the electrolyte,
lower temperatures increase it. The temperature correction factor is
-0.0007 kg/l per K.
Examples: Electrolyte specific gravity 1.23 kg/l at +35 °C (95 °F)
corresponds to 1.24 kg/l at +20 °C (68 °F). Electrolyte specific
gravity 1.247 kg/l at +10 °C (50 °F) corresponds to 1.24 kg/l at
20 °C (68 °F).
5. Maintenance
To avoid leakage currents and the associated risk of fire keep the
battery dry and clean. Cleaning with clear water, no solvents, and
no detergents. Avoid electrostatic charges. If the electrolyte level
has dropped to the „MIN“ mark, purified water as specified under
DIN 43 530 Part 4 (maximum conductivity 30 µS/cm) must be used
to top up the electrolyte level to the „MAX“ mark.
To be measured and listed every 6 months:
•battery voltage
•the voltage of some cells/block batteries (pilot cells)
•the temperature of the electrolyte in some cells/block
batteries (pilot cells).
Every 12 months:
•The voltages and densities/temperatures of the electrolyte
in all cells/blocks have to be measured and listed.
•Connectors, racks and ventilation have to be visually
checked and restored if necessary.
Should the float charge voltage in single cells deviate more than
+0.10 V or -0.05 V from the average value (see item 2.3.3), the
customer service should be called.
6. Testing
Tests must be conducted according to DIN 43 539 Part 1 and 4 and
IEC 60896 - 11. Special test instructions, e. g. to prove operational
safety in accordance with DIN VDE 0107 and DIN VDE 0108 must
be observed.
7. Storage and taking out of operation
If filled lead acid accumulators are to be taken out of operation for a
longer period of time, they must be placed fully charged in a dry,
frost-free room. To avoid damage periodical equalising charges
(every 6 weeks) or permanent float charging have to be made.
8. Transport
OPzS.solar block batteries and cells are protected against short-
circuit. They are not subject to the German Regulations on
Dangerous Goods carried on road and railway (GGVS, GGVE,
ADR), if they show no damage, are protected against sliding, falling
over and damaging and are piled up on pallets appropriately
(ADR, Annexe A, Chapter 3.3, Special Provision 598).These
cells/batteries are dangerous goods on sea and air transport.
Declaration and packaging must comply with the requirements of
IMDG-Codes or IATA-DGR. Cells/batteries without electrolyte are
generally no dangerous goods on all kinds of transportation.

9. Technical data
OPzS.block.solar
Type
C1 h
Ah
C10 h
Ah
C20 h
Ah
C72 h
Ah
C100 h
Ah
C120 h
Ah
C240 h
Ah
Ri1)
mΩ
Ik2)
kA
Length
mm
Width
mm
Height
mm
Weight
(dry)
kg
Weight
(filled)
kg
Ue [V per cell]
1.65
1.80
1.80
1.80
1.80
1.80
1.80
12#V#1#OPzS.block.solar#70#
32.3#
56.2#
63.8#
72#
72.8#
73.3#
75.1#
19.20#
0.64#
272#
205#
385#
29.5#
41.0#
12#V#2#OPzS.block.solar#
140#
62.3#
108#
122#
137#
139#
139#
144#
9.60#
1.28#
272#
205#
385#
38#
47.6#
12#V#3#OPzS.block.solar#
220#
96.9#
168#
191#
216#
218#
219#
225#
6.40#
1.92#
380#
205#
385#
51#
69.4#
6#V#4#OPzS.block.solar#290#
129#
225#
254#
288#
291#
292#
300#
2.40#
2.56#
272#
205#
385#
33#
46.5#
6#V#5#OPzS.block.solar#360#
161#
281#
318#
360#
364#
366#
374#
1.92#
3.20#
380#
205#
385#
41.7#
60.4#
6#V#6#OPzS.block.solar#440#
193#
337#
382#
432#
437#
440#
451#
1.60#
3.84#
380#
205#
385#
48.5#
66.5#
OPzS.solar
Type
C1 h
Ah
C10 h
Ah
C20 h
Ah
C72 h
Ah
C100 h
Ah
C120 h
Ah
C240 h
Ah
Ri 1)
mΩ
Ik2)
kA
Length
mm
Width
mm
Height
mm
Weight
(dry) kg
Weight
(filled)
kg
Ue
[V per cell ]
1.65
1.80
1.80
1.80
1.80
1.80
1.80
4#OPzS.solar#290#
99.8##
201##
232##
278##
285##
286##
295#
0.95#
2.16#
105#
208#
420#
12.5#
17.0#
5#OPzS.solar#370#
127##
257##
298##
358##
366##
369##
379#
0.76#
2.70#
126#
208#
420#
15.2#
21.0#
6#OPzS.solar#450#
156##
317##
368##
444##
454##
458##
470#
0.63#
3.24#
147#
208#
420#
17.8#
25.0#
###
#
#
#
#
#
#
#
#
#
#
#
#
#
#
5#OPzS.solar#490#
211##
371##
414##
475##
488##
496##
528##
0.70#
2.90#
126#
208#
535#
20.0#
27.0#
6#OPzS.solar#620#
263##
468##
522##
604##
620##
628##
669##
0.58#
3.48#
147#
208#
535#
22.8#
32.0#
7#OPzS.solar#720#
306##
543##
606##
700##
718##
729##
777##
0.50#
4.06#
168#
208#
535#
26.4#
37.0#
##
#
#
#
#
#
#
#
#
#
#
#
#
#
#
6#OPzS.solar#930#
359##
670##
752##
900##
933##
944##
976##
0.47#
4.32#
147#
208#
710#
32.7#
46.0#
8#OPzS.solar#1300#
494##
932##
1,044##
1,260##
1,300##
1,308##
1,365##
0.35#
5.76#
215#
193#
710#
44.6#
64.0#
10#OPzS.solar#
1510#
589##
1,090##
1,226##
1,468##
1,510##
1,536##
1,588##
0.28#
7.20#
215#
235#
710#
54.3#
75.9#
12#OPzS.solar#
1840#
714##
1,320##
1,490##
1,792##
1,840##
1,860##
1,934##
0.23#
8.64#
215#
277#
710#
63.4#
89.7#
###
#
#
#
#
#
#
#
#
#
#
#
#
#
#
12#OPzS.solar#
2250#
882##
1,670##
1,866##
2,181##
2,250##
2,280##
2,397##
0.22#
9.18#
215#
277#
855#
75.4#
110.0#
16#OPzS.solar#
2860#
1,139##
2,130##
2,380##
2,779##
2,860##
2,904##
3,024##
0.17#
12.24#
215#
400#
815#
117#
150.0#
20#OPzS.solar#
3750#
1,470##
2,780##
3,100##
3,643##
3,750##
3,804##
3,984##
0.14#
15.30#
215#
490#
815#
127#
187.0#
22#OPzS.solar#
4130#
1,617##
3,060##
3,420##
4,003##
4,130##
4,188##
4,392##
0.12#
16.83#
215#
580#
815#
141#
205.0#
24#OPzS.solar#
4710#
1,814##
3,470##
3,880##
4,564##
4,710##
4,776##
5,016##
0.11#
18.36#
215#
580#
815#
146#
218.8#
26#OPzS.solar#
4880#
1,911##
3,620##
4,040##
4,737##
4,880##
4,956##
5,184##
0.10#
19.97#
215#
580#
815#
156#
231.0#
1), 2) - Riand Ikaccording to IEC 60896-11
Reference temperature for all data is 20 °C (68 °F). The manufacturer
reserves the right to alter technical specifications.
1,2 ) internal resistance and short circuit current according to IEC 60896-11
02/2011