OutBack Power EnergyCell TT Series User manual

Quick Start Guide
Specifications
IMPORTANT:
Not intended for use with
life support equipment.
Contact Information
Mailing 1628 – West Williams Drive
Address: Phoenix, AZ 85027 USA
Web Site: www.outbackpower.com
Date and Revision
August 2020, Revision A
Audience
This guide is for use by qualified personnel who meet all local and governmental
code requirements for licensing and training for the installation of batteries and
related products. The installer should be familiar with battery test procedures.
Be sure to review carefully and identify potential safety risks before proceeding.
The installer must be familiar with all features and functions of this battery before
proceeding. Failure to install or use this battery as instructed can result in
damage to the battery that may not be covered under the limited warranty.
Product
The EnergyCell™ TT is a series of top-terminal 12 Vdc valve-regulated lead-acid
(VRLA) absorbed glass-mat (AGM) batteries. These batteries are for backup or
light duty cycling applications.
Storage
oAll lead-acid batteries experience self-discharge while in storage. This
causes circuit voltage and capacity to decrease.
oThe self-discharge rate is related to ambient temperature. The lower the
temperature, the lower the discharge rate. Batteries should be stored in
a clean, ventilated, and dry location with an ambient temperature of
32°F to 77°F (0°C to 25°C).
oIt is important to track open-circuit voltage (OCV) when batteries are
disconnected. If OCV is lower than 12.6V or the batteries have been stored
beyond the limits shown in the Storage Time vs. Temperature graph, the
batteries should be charged to avoid damage caused by self-discharge.
oRecharge at 14.4 Vdc for 12 hours prior to battery reaching 12.6 Vdc.
oAll batteries should be fully charged before storage. Record the storage
date and next supplemental charge date in a maintenance record and
on the battery. See the voltage log on the next sheet.
oUpon battery deployment, verify that all batteries within each string measure
in the range of +/- 0.3 Vdc of the string average while in "float" charger mode.
Capacity
The battery’s actual capacity is influenced by temperature, depth of discharge,
discharge rate, and the resulting voltage.
oThe higher the discharge rate, the lower the available capacity.
oThe available capacity is also reduced as batteries become colder. This is
related to the internal electrochemical reactions and the resistivity of the
electrolyte. It is depicted in the Capacity vs. Temperature graph.
Note that battery cycle life is also affected by depth of discharge, as shown in the
Cycle Life graph.
Operating Conditions
EnergyCell TT batteries are valve-regulated and sealed. They do not give off
perceptible amounts of gas under normal operating conditions.
oOperating temperature range (ambient): –40°F to 140°F (–40°C to 60°C)
oOptimal operating temperature (ambient): 68°F to 77°F (20°F to 25°F)
oAmbient humidity: ≤95%
EnergyCell TT Series Battery
Electrical
900-00270-01-001 REV A
©2020 OutBack Power. All Rights Reserved.
NOTE:
Although the battery can operate at
temperatures below –4°F (–20°C),
the capacity and ability to discharge
will be dramatically decreased.
Percent State of Charge (%)
Storage Time (Months)
0 2 4 6 8 10 12 14 16 18 20 22 24
100
95
90
85
80
75
70
13.00
12.95
12.90
12.85
12.80
12.75
12.70
12.65
12.60
Voltage
Storage Time vs. Temperature
Percent Rated
Capacity Available (%)
100
90
80
70
60
50
40
30
20
10
0
Temperature
–40°F –22°F –4°F 14°F 32°F 50°F 68°F 86°F 104°F
–40°C –30°C –20°C –10°C 0°C 10°C 20°C 30°C 40°C
Capacity vs. Temperature
Number of Cycles (times)
200 400 600 800 1000 1200
Capacity (%)
120
100
80
60
40
20
0
Cycle Life
at different depth of discharge (DoD) levels
Mechanical
Environmental
106TT
Threaded alloy insert terminal to accept M6 × 20 mm bolt
44.9 in-lb (5.1 Nm)
115TTSpecification
Terminal Type
Terminal Hardware Torque
1 yearWarranty
66.56 lb / 30.2 kg 75.38 lb / 34.2 kgWeight
8.41 × 12.78 × 6.65"
213.6 × 324.7 × 169.0 mm
8.54 × 13.5 × 6.69"
216.9 × 343.0 × 170.0 mm
Dimensions (H × L × W)
27 31Case Size
106TT
12 Vdc
6
115TT
Specification
Nominal Voltage
Cells per Unit
500 cycles
14.4 to 15 Vdc
Cycle Life (50% Depth of Discharge)
Absorption Voltage (25°C)
3.5 hours
13.5 to 13.8 Vdc
Absorption Time
Float Voltage (25°C)
24/7
15 Vdc for 16 hours every 2 months or 25 cycles
Float Time
Equalize Voltage, Time, and Frequency
12 Vdc
30 Adc 33 Adc
Re-Bulk Voltage
Maximum Charge Current (per Battery)
±3.3 mV per cell per °C
12 months at 77°F (25°C) before a recharge is required
Temperature Compensation Factor
Self-Discharge Frequency
106TT
–40 to 140°F (–40 to 60°C)
14 to 104°F (–10 to 40°C)
115TTSpecification
Operating Temperature (compensated)
Storage Temperature
Ampere-Hour Capacity to 1.75 Volts per Cell @77°F (25°C)
Discharge in Hours
1
65.5
81.7
2
75.2
91.0
3
80.7
96.3
4
84.0
100.0
5
86.5
99.0
8
90.4
104.0
10
94.0
104.0
20
100.0
112.0
24
101.2
111.3
48
104.6
115.2
100
106.0
117.0
Model
EnergyCell 106TT
EnergyCell 115TT
100% DoD
100%
DoD
50%
DoD
30%
DoD

Connections
900-00270-01-001 REV A
©2020 OutBack Power. All Rights Reserved.
Three-Stage Charging
EnergyCell TT batteries are usually charged using a “three-stage” charging cycle: bulk stage, absorption stage, and float
stage. However, not all chargers are designed or programmed the same way. The settings should be checked and changed
to match the recommendations below if necessary.
Bulk Stage
The bulk stage is a constant-current stage. The charge current is
maintained at a constant high level. The battery voltage will rise
as long as the current flows, raising the battery to a high voltage
(usually called bulk or absorption voltage). This typically restores
the battery to 85 to 90% state of charge (SoC). This battery has a
recommended maximum current limit which should not be exceeded.
See the Specifications table.
Absorption Stage
The absorption stage is a constant-voltage stage, established upon reaching the bulk target voltage. The charger maintains
this voltage as the current decreases until the batteries are full. A large current is required to reach absorption level. Less is
required to maintain it there. This requirement tends to decrease as long as absorption is maintained. This decreasing
current flow typically goes to a very low number (though not zero), known as “return amps”. This “tops off the tank”, leaving
the battery at 100% SoC. The battery is considered to be completely full upon the following conditions: The charge rate
must decrease to a level of current equal to between 1% and 3% of the total battery amp-hours while maintaining the
absorption voltage. At this point the charger is allowed to exit the absorption stage and enter the next stage.
NOTE: Not all chargers use return amps. Many chargers absorb for a timed period (one or two hours), assuming that the
current will decrease to that level. However, if it exits absorption and ends the charge before reaching return amps, the
battery may not reach 100% SoC. Repeated failure to complete the charge will cause decreased battery life.
Float Stage
The float stage is a maintenance stage which provides current to counter the battery’s natural self-discharge. As with
absorption, float is a constant-voltage stage which supplies only enough current to maintain the designated voltage.
Constant-Float Charging
“Constant-float” charging may be used in backup power applications
where the battery is rarely discharged. When a discharge occurs, it is
critical to recharge the battery as soon as possible afterward. The
voltage range is listed under Specifications. The batteries are
considered fully charged when the voltage is maintained at this level
and the current drops to a low level over a long period of time. If using
a battery monitor device such as an OutBack FLEXnet DC, use the
settings shown to the right.
In constant-float charging, it is critical to compensate the charger
settings for temperature.
Temperature Compensation
Battery performance changes when the temperature varies above or below room temperature (77°F or 25°C). When a
battery is cooler than room temperature, its internal resistance goes up and the battery will be undercharged. When warmer
than room temperature, its internal resistance goes down and the battery will tend to be overcharged.
To compensate, a charger must have its voltages raised by a specified amount for every degree below room temperature,
or lowered for every degree above room temperature. For the EnergyCell TT, the required compensation coefficient is
–0.0033 volts per cell per degree C (–0.0018 V/cell/°F). This is also multiplied by the number of batteries in a string.
Charging
Series Strings
Batteries wired in series (negative to positive) have additive voltages.
This is known as a “string”. In the example below, a string of four
EnergyCell TT batteries would have a nominal voltage of 48 Vdc.
However, batteries in series do not have additive amp-hours.
Series / Parallel Strings
Batteries wired in parallel (positive to positive, negative to negative)
have additive amp-hour capacity. Placing several strings in parallel
(series / parallel) gives additive voltages and capacity. In the
example below, the system uses four batteries, but not all are in
series. This system uses pairs of batteries in series for 24 volts.
Two pairs are shown in parallel for double the amp-hours.
NOTE: Consult a professional installer before connecting more than
three strings in parallel.
Hardware
EnergyCell TT terminals consist of a
threaded hole which receives an
M6 × 12 mm bolt. Terminal hardware
is assembled as shown in this image.
Bulk
Bulk
Absorption
Absorption
Float
Float
DC
Volts
Amperes
(typical)
Hours (typical)
Hours (typical)
15
14
13
12
11
10
20
15
10
5
0
–5
1 2 3
1 2 3
Charging Graphs
Charging Voltages (multiplied by the
number of batteries in a series string)
oAbsorb Charging Voltage: 14.4 to 15.0 Vdc
oEqualize Charging Voltage: 15.0 Vdc
(16 hours every 2 months or 25 cycles)
oFloat Voltage: 13.5 to 13.8 Vdc
Settings
oBattery Amp-Hours: Based on the rated
20-hour capacity (see Specifications)
oCharged Voltage: 14.0 Vdc
(0.4 volts below absorption setting)
oCharged Return Amps: 1 to 3% Adc
oTime: 1 minute
oCharge Factor: 97%
M6 Bolt
Lock Washer
Flat Washer
Cable Lug or
Interconnect
Battery Terminal
Surface
Positive (+) Negative (–)
Positive (+) Negative (–)

Troubleshooting
900-00270-01-001 REV A
©2020 OutBack Power. All Rights Reserved.
Symptom Possible Cause Possible Remedy
Reduced operating time Replace entire battery system when at 70% of rated
(at 77°F / 25°C) with Normal life cycle capacity (or before).
smooth voltage decline
Reduced operating time
(at 77°F / 25°C) with steep Individual cells with low capacity Replace afflicted batteries as necessary.
voltage decline or plateaus
Excessive initial voltage  Battery extremely cold  Heat the battery.
drop, even to the point of  Cable gauge too small  Increase cable gauge or run parallel cables.
dropping the load in the first  High-resistance connections  Clean and reassemble connections.
few seconds  Battery bank undersized  Add required parallel strings.
 Shorted cells  Replace afflicted batteries. Evaluate the entire string.
Cover or container crack Handling or impact damage Replace afflicted batteries as necessary.
Ignition of cell internal gases
Cover or container explosion due to external source, fusing, Replaced afflicted batteries as necessary.
or internal conductive path or Evaluate the entire string.
internal spark due to shorting
Burned area on container; Damaged container that allows Replace afflicted batteries as necessary.
ground fault in system electrolyte to wick to grounded Evaluate the entire string. Clear any ground fault errors.
rack or tray
Permanently deformed Thermal runaway, possibly
(swollen) container caused by high-temperature Replace the battery system. Correct items that led to
environment, overcharging, thermal runaway.
excessive recharge current,
Rotten-egg odor shorted cells, or a combination
Hot connections due to
excessive resistance from  Clean and reassemble the connection.
Melted grease at terminals loose connections, dirty contact  Replace batteries with damaged connections.
surfaces, or corrosion within
the connection
Disassemble and clean the connection. Coat connecting
Corrosion at terminals Electrolyte leaking from surfaces and terminal area seal with anti-oxidation
within the battery grease, and reassemble the connection. If there is
obvious leakage, replace batteries as necessary.
Symptoms and Remedies
Symptom Possible Cause Possible Remedy
System float voltage
greater than 13.8 volts Charger voltage set too high Reset charger output voltage to recommended values.
per battery at 77°F / 25°C
System float voltage Reset charger output voltage to recommended values.
less than 13.5 volts Charger voltage set too low Equalize the battery system (48 to 72 hours) and perform
per battery at 77°F / 25°C a capacity test. If capacity loss is permanent, replace
the battery system.
DC voltage measured
between battery system
output terminals and ground
(rack or tray) Damaged container that allows Replace afflicted batteries as necessary.
electrolyte to wick to grounded Evaluate the entire string. Clear any ground fault errors.
rack or tray
Ground fault indicated by
automatic measuring
equipment
Elevated room temperature Control the room temperature.
Elevated battery temperature Inadequate ventilation Improve ventilation of room or battery cabinet.
High discharge or  Reduce current to within specifications.
recharge current 
Charge voltage set too high  Reset charger output voltage to recommended values.
High recharge current Charger current set too high  Reduce recharge current to within specifications.
Shorted cells  Replace afflicted batteries. Evaluate the entire string.
Float current to one string Open connection in a Verify with voltage checks or impedance checks of
is zero series string individual batteries. Repair any open or loose
connections. Replace any battery with open cells.
Float current (at float voltage) Battery discharged  Recharge batteries.
exceeds 3 milliamperes per Shorted cells  Replace afflicted batteries. Evaluate the entire string.
amp-hour of rated capacity Thermal runaway  Replace the battery system. Correct items that led to
at 77°F / 25°C thermal runaway.
Impedance / resistance Battery discharged  Recharge batteries.
increase by 50%, or Battery material deteriorating  Replace afflicted batteries. Evaluate the entire string.
conductance declines Shorted or open cells  Replace afflicted batteries. Evaluate the entire string.
by 50%, from original value
Troubleshooting

Troubleshooting
900-00270-01-001 REV A
©2020 OutBack Power. All Rights Reserved.
Battery Voltage Records
Symptom Possible Cause Possible Remedy
Repetitive cycling causes  Tighten connection to specified torque values.
heating / cooling and loosening
Connection resistance of connection, resulting in
increase 20% or more resistance increase
from original value Excessive resistance from  Clean and reassemble the connection.
loose connections, dirty contact
surfaces, or corrosion within
the connection
Connection hardware
tightness is less than Individual cells with low capacity Replace afflicted batteries.
voltage decline or plateaus
AC ripple voltage (p-p) is
greater than 4% of the value Poor filtering of charger output Improve charger output filtering.
of the DC float voltage
Individual battery exhibits Proportionately higher impedance
AC ripple voltage twice that due to deteriorating material or Replace afflicted batteries. Evaluate the entire string.
of other typical batteries shorted or open cell
in the string
Symptoms and Remedies Date: Date: Date:
Battery 1
Battery 2
Battery 3
Battery 4
Battery 5
Battery 6
Battery 7
Battery 8
Battery 9
Battery 10
Battery 11
Battery 12
Battery 13
Battery 14
Battery 15
Battery 16
Battery 17
Battery 18
Battery 19
Battery 20
Battery 21
Battery 22
Battery 23
Battery 24