Sacred Sun FAJ Series User manual

FAJ Series
Valve-regulated Sealed Lead Acid Battery
Technical Manual
山东圣阳电源股份有限公司
SHANDONG SACRED SUN POWER SOURCES CO.,LTD

C on ten t s
Chapter I: Product Introduction
1. Product Characteristics ...............................................................................................01
2. Main Applications ........................................................................................................02
3. Battery Construction ....................................................................................................02
4. General Specifications .................................................................................................03
5. Working Principle ........................................................................................................04
Chapter II: Electrical Characteristics
1. Discharge Curve ..........................................................................................................05
2. Charge Curve ..............................................................................................................06
Chapter III: Operation and maintenance
1. Safety Instructions......................................................................................07
2. Operating Conditions and parameters .........................................................................08
3. Factors Influencing Capacity .........................................................................10
4. Temperature Effect on Battery Capacity ........................................ ..........................10
5. Recharge ............................................................................................11
6. Temperature Effect on Battery Design Life ..........................................................12
7. Charge Requirement ..................................................................................13
8. Storage.....................................................................................................13
9. Maintenance..............................................................................................15

Chapter I: Product Introduction
Product Characteristics
Advantages
Design life: 12 years (25℃)
EUROBAT Classification: Long life
High discharge performance
High gas recombination efficiency
Maximum charge efficiency
Low self-discharge rate
Easy installation and handling
Centralized venting system
Design Features
Positive plates
Negative plates
Container and lid
Terminal posts
Posts sealing
Vents
Electrolyte
Plates suspension
Inter-cell connectors
Terminal hardware
Thick flat pasted plate with lead-calcium-tin grid alloy;
Flat pasted plate with lead-calcium grid alloy;
High-strength ABS (option: available in Flame Retardant UL94 V0 version);
High-conductivity terminals with threaded inserts;
Double sealing structure;
High-efficiency low pressure venting system;
GEL electrolyte;
Bottom supported;
Insulated rigid copper;
Stainless steel + Plastic cover.
01

Main Applications
Telecommunications
Emergency power
UPS
Power system
Data center
Standards
IEC60896-21/22: 2004
BS 6290-4:1997
YD/T2343-2011
Eurobat guide
Installation compliant with EN50272-2
Battery Construction
02

General Specifications
FAJ series
Table 1-1 FAJ series battery general specifications
Battery
Model
Nominal
Voltage
(V)
Nominal
Capacity
(Ah,25℃)
Dimensions (mm)
Weight
(kg)
Short
Circuit
Current
(A)
Internal
Resistance
(mΩ,25℃)
Terminal
Type
Terminal
Layout
C10
1.80V/cell
Length
Width
Height
FAJ12-80B
12
80
395
110
288
26.0
2300
5.2
FT-52
C
FAJ12-95B
12
95
395
105
270
28.5
2500
4.8
FT-54
C
FAJ12-100B
12
100
395
110
288
31.4
2100
5.5
FT-57
C
FAJ12-125A
12
125
558
125
270
45.2
3000
4.0
FT-55
C
FAJ12-150A
12
150
558
125
311
52.7
3200
3.6
FT-55
C
FAJ12-200A
12
200
546
125
324
59.0
3800
4.0
FT-55
C
Terminals
Terminal Layout
Terminal Type
03

Working Principle
The electrochemical reaction of batteries in charge and discharge process is as follows:
Discharge
PbO2 +2H2SO4 + Pb PbSO4 + 2H2O + PbSO
4
Charge
In the final stage of charge process, active substance in positive plate is fully transformed to lead
dioxide, but negative plate has not reached fully charged stage, the process of active substance in
negative plate transforming to spongy lead is not finished, oxygen gas generated in positive plate
reaches the negative plate through separator pores and then reacts with active substance in
negative plate, resulting depolarized state in negative plate, and restraining the generation of
hydrogen.
Principle of the oxygen reduction cycle is as follows:
04

Chapter II: Electrical Characteristics
Discharge Curve
The battery capacity is directly related to the discharge current, end voltage and discharge temperature.
In general, the smaller discharge current, the lower end voltage, the higher temperature will cause larger
discharge capacity. Figure 2-1 describes the discharge curves of FAJ Series at different discharge rate
at ambient temperature 25℃.
Figure 2-1 Discharge curve under different discharge rates (25℃)
Table 2-1 FAJ Series Battery End Voltage at Different Discharge Rate (25℃)
Discharge Rate (A)
End Voltage (V)
I≤0.01C10
1.95
0.01C10<I≤0.05C10
1.90
0.05C10<I≤0.28C10
1.80
0.28C10<I≤0.55C10
1.75
0.55C10<I≤0.65C10
1.65
Electrical Characteristics
05

Charge Curve
Figure 2-2 Charge curve under different depth of discharge (25℃)
Electrical Characteristics
06

Chapter III: Operation and Maintenance
Safety Instructions
Please read these instructions carefully in order to ensure correct, safe and effective operation.
This manual provides you very important guidance for installation and operation, which will
guarantee your equipment with optimal performance and longer service life.
For your safety, please do not open the batteries;
As batteries contain lead which can potentially be harmful to the environment and health, and
as batteries are connected to electricity, they must be installed, maintained and replaced by
skilled personnel only.
Used batteries must be recycled and disposed properly as improper disposal of batteries is
harmful to the environment and health. Used batteries shall be properly disposed following
relative regulations and laws.
It is strictly forbidden to mix batteries with different specifications, manufacturers and
capacities.
All installations must comply with the safety regulations and norms. Read through our
Operation Guide / Safety Instructions before starting any installation work.
Notices
Warning
Electrical shock
Protective eyewear and
clothing required
Keep children away from
the batteries
No short circuit
No flames and sparks
Recycle
Proper disposal
Read instructions
Electrolyte is highly
corrosive
Operation and maintenance
07

Operation Conditions and Paramters
Temperature range is -15℃~50℃, the optimal operation temperature is 20℃~30℃, max. ambient
humidity is ≤95%, height above sea level less than 3000 Meter
Charge current-limiting valve: charge current-limiting valve range is 0.1C10-0.2C10
According to the grid condition of the BTS, we divided the grid conditions into five types,
see the table 3-1 below:
Table 3-1 Grid conditions definition
In case the grid condition is type V, contact our technical team for assistance.
See below Table 3-2 for the recommended rectifier parameters settings (48V system), other
system voltage value are calculated according to the parameters.
Type I: Total power failure time per month <10 hours
Type II: Total power failure time per week <10 hours
Type III: Power failure time every day ≥2hours, but <4 hours
Type IV: Power failure time every day ≥4hours, but <8 hours
Type V: (Including no grid): Power failure time every day ≥8hours
Operation and maintenance
08

Table 3-2 Recommended settings for rectifier parameters (48V system, 25℃)
No.
Parameter type
IGrid type
II Grid type
III Grid
type
IV Grid
type
1
Floating charge voltage (V)
54.48
54.48
54.48
54.48
2
Equalizing charge voltage (V)
57.6
57.6
57.6
57.6
3
Charge current limitation (A/group)
0.10C10
0.10C10
0.15C10
0.2C10
4
High voltage alarm voltage (V)
59
59
59
59
5
Low voltage alarm voltage (V)
46.8
46.8
46.8
46.8
6
Low voltage load disconnect-LVLD (V)
45
45
45
46
7
Low voltage battery disconnect-LVBD (V)
44
44
45
45
8
The battery protection voltage (V)
43.2
43.2
43.2
43.2
9
Reset voltage (V)
50
50
50
50
10
Conditions for
starting equalizing
charge (fulfill one
of the conditions)
Discharging voltage as the conditions (V)
49.2
49.2
49.5
50.0
Discharging time as the conditions (h)
0.5
1.0
1.0
0.5
Discharging capacity as the conditions (Ah)
15% C10
15% C10
10% C10
5% C10
Initial charging current as the conditions (A)
≥0.05C10
≥0.05C10
≥0.05C10
≥0.05C10
11
Equalizing charging period (days)
180
90
60
30
12
Conditions for
ending equalizing
charge (fulfill one
of the conditions)
Equalizing charge time as the conditions (h)
10
10
15
20
13
The charge coefficient as the condition
1.05~1.10
1.05~1.10
1.10~1.15
1.10~1.15
14
The equalizing charge tail current as the
condition (A)
0.01C10
0.01C10
0.005C10
0.005C10
15
Temperature
compensation
Temperature compensation coefficient
(mV/℃/cell) (reference temperature: 25℃)
-3.5
-3.5
-3.5
-3.5
High limited voltage of floating charging
temperature compensation (V)
56.88
56.88
56.88
56.88
Low limited voltage of floating charging
temperature compensation (V)
52.80
52.80
52.80
52.80
Operation and maintenance
09

Factors Influencing Capacity
Battery capacity consists both of nominal capacity and actual capacity, for nominal capacities of
the FAJ series battery please refer to Table 1-1. Actual capacity is the real quantity of electricity
battery discharge under certain condition, it equals to discharge current multiplied by discharge
time, the unit is Ah.
Battery capacity is directly related to discharge current, end voltage and discharge
temperature.
Temperature Effect on Battery Capacity
Figure 3-1 describes temperature effect on battery capacity (C10). For example, if temperature
falls from 25℃to 0℃, battery capacity will be 85% of the nominal capacity, low temperature will
cause long term charge shortage, negative plates will be irreversibly sulfated and as a result the
battery cannot be used normally.
As temperature rises, battery capacity will increase to a certain point. For example, if temperature
rises from 25℃to 35℃, battery capacity will be approximately 105% of the nominal capacity.
From 35℃to 50℃, the capacity increase is very low and if temperature rises beyond 50℃, there
is no increase in battery capacity.
Figure 3-1 temperature effect on battery capacity curve
Operation and maintenance
10

Floating charge
FAJ series batteries can be used in floating and cycle application.
Floating operation is the best operation condition for the battery. In floating operation, if the
battery is kept at fully charged state, the battery can reach the longest service life. At the
ambient temperature of 25℃, recommended floating charge voltage setting value is 2.25V/ cell.
In such a condition, it takes 72~96h for the battery to be fully charged. In order to achieve
optimum performance, floating charge voltage must be adjusted according to the ambient
temperature (Table 3-3).
Table 3-3 Floating charge voltage at different temperatures
Ambient
Temperature(℃)
Floating Charge Voltage
(V/cell)
0
2.34
5
2.32
10
2.31
15
2.29
20
2.27
25
2.25
30
2.24
35
2.22
40
2.20
45
2.18
50
2.16
Recharge
Recharge the battery immediately after discharge according to the method described below:
Charge the battery with constant current of no more than 0.2C10(A), until the battery voltage rises
to 2.33~2.37V / cell, then change to constant voltage charge of 2.33~2.37V / cell until the charge
completed. Meeting one of the following two conditions can be regarded as fully charged.
Refer to the required charge time specified in the Table 3-4
In constant voltage case, the charge current must be kept unchanged for 3 hours in the final
stage of charge.
Charge voltage shall be adjusted according to the ambient temperature, temperature
compensation coefficient is -3.5mV/℃/ cell.
Operation and maintenance
11

Table 3-4 Required charge time in different depth of discharge
Depth of
discharge(%)
Charge current at
constant current
charge period (A)
Constant current
charge time (h)
Charge voltage at
constant voltage
charge period (V/cell)
Constant voltage
charge time(h)
20
0.1C10
1.6
2.35
12
0.15C10
1.2
2.35
10
50
0.1C10
4.3
2.35
18
0.15C10
3.3
2.35
16
80
0.1C10
6.8
2.35
20
0.15C10
5.5
2.35
18
100
0.1C10
8.7
2.35
24
0.15C10
6.8
2.35
22
Temperature Effect on Battery Design Life
Higher temperature will speed up battery grid corrosion and water loss, thus greatly shorten the
battery life. If temperature is above 25℃, the service life of the battery will be shortened by half
when temperature increases by 10℃. For example, if the design life of a battery is 10 years at
25℃, its service life will be shortened down to 5 years if ambient temperature is always at 35℃.
Refer to the following formula:
t25℃= tT×2 (T-25)/10
T --- Ambient temperature.
tT--- Design life at temperature of T.
t25℃--- Design life at temperature of 25℃.
Figure 3-2 Temperature effect on battery design life
Operation and maintenance
12

Charge Requirement
Equalizing Charge
Equalizing charge is needed in the following cases:
When there are more than two batteries in a battery string with voltage of lower than
2.18V / cell.
The battery has been in floating operation more than 3 months.
Recommended charge method as follows:
Charge the battery with constant current of no more than 0.15C10(A), until the battery voltage
rises to 2.35V / cell, then change to constant voltage charge of 2.35V / cell for approximately
24 hours.
Recharge
Recharge is needed in the following cases, the recharge method is same as described above
for equalizing charge.
After battery is discharged.
After finishing battery system installation.
The following condition can be regarded as the fully charged.
In constant voltage charge period, the charge current must be kept unchanged for 3 hours in
the final stage of charge.
Storage
Storage Interval:
Battery should be stored in fully charged state. It is strictly prohibited to storage after discharge.
Battery storage location must be away from heat, sparks and smoke.
Battery must be stored in an upright position, avoiding impacts of external force or abrupt loads.
Safety valve should be tightened.
It is strictly prohibited to stack battery without properly protective packaging.
Battery can be stored in -10～45℃environment.
Operation and maintenance
13

Storage
temperature
Maximum storage times /
Refreshing charge intervals
Recommended refreshing charge method
-10～30℃
Every 6 months
Using constant current 0.1C10A～0.15C10A to
charge battery bank till battery average voltage rises to
equalizing charge voltage, then switch to constant
voltage charging. Charging time is generally 10~20h.
31～45℃
Every 3 months
Maximum storage time (Shelf life) is 18 months (25℃).
Battery must be stored in a dry, ventilated and clean environment.
Protect the battery from harsh weather, moisture, flooding, direct or indirect sun radiation,
organic solvents, corrosive substances and gas.
The state of charge can be verified by testing the open circuit voltage after storage for 24 hours at
25℃.
Table 3-3 Open circuit voltage at different state of charge
State of Charge
Voltage (V/cell)
100%
≥2.18
80%
≥2.15
60%
≥2.10
40%
≥2.07
20%
≥2.04
Testing the open circuit of the stored battery will show whether a freshening charge is needed. If the
voltage drops to 2.15V/cell, the battery shall be freshening charged in time.
Figure 3-3 Remaining capacity curve at different temperature and different storage time
Operation and maintenance
14

Maintenance
1. Cleaning Notes:
Battery appearance, terminal area and working environment must be kept clean and dry.
In battery cleaning process, avoid use of electrostatic cleaning tools.
Clean the battery with damp cloth. Do not use of gasoline, alcohol or other organic solvents;
also do not use cloth containing these substances.
2. Inspection and Maintenance
VRLA batteries are not maintenance-free batteries, battery operation process gradually
changes with time. In order to ensure good battery usage, operational management and
control are very important. To understand the operation status of batteries and equipment
and to prevent accidental damage, regular maintenance is required. Periodically check
and record the measurements using the following method for batteries used in UPS system
room and base station (including outdoor station) site.
2.1 Monthly Maintenance Inspection Items
Item
Content
Standard
Maintenance
1-Temperature
Detection
1-Measure and record
battery terminal and
container temperature
by using infrared
thermometer.
2-Use infrared
thermometer to measure
ambient temperature.
1-Ambient Temp:
-20℃~+55℃
2-Recommended
Temperature:
25±5℃
1-Check that the battery temperature
compensation functions are turned on and
that the battery temperature probe is
properly installed.
2-Check that the room temperature
conditioning equipment such as
air-conditioning is turned on.
2- Battery Float
Voltage
Measurement
Measure floating voltage
on positive and negative
terminal of the battery
group with multimeter.
Measurement and
control module
display operating
voltage differences
within 0.05V
If the monitoring module shows
inconsistency even after adjusting, replace
or repair it.
3-Battery
Appearance
Inspect the battery
container for bulging,
leakage and damage.
Normal
Appearance
Confirm the reason for any abnormal
appearance, if it affects normal use,
replace the battery.
Check for dirt stains
Clean Appearance
Clean dust and dirt with damp cloth
Inspect the connection
cables, terminals, etc.
for oxidation, rust &
other abnormalities
No oxidation, rust
If you find oxidation or rust, replace the
connecting wire, and swab terminal with
Vaseline etc.
Operation and maintenance
15

Item
Content
Standard
Maintenance
4- Joints
Use hex or torque
wrench to tighten loose
bolts.
Securely connected
If found bolt loosened, tighten it
1-Battery cables,
terminals clean /
non-corrosive.
2- Follow the installation
sequence: 1. Spring
washers 2. Flat washers
3, Nuts
No evidence of
corrosion
If slight corrosion found after connecting
bar removed, clean it with cloth. If severe
corrosion, replace the connection bar and
clean terminal with sandpaper before
tightening.
5-Safety Valve
Testing
Inspect for white
crystalline or liquid
surrounding the safety
valve.
No crystalline or
liquid surrounding
the safety valve
1-For crystalline, use a dry cloth for
cleaning.
2-If there is crystalline or liquid, clean it
with a dry cloth. Check and tighten the
safety valve
2.2 Quarterly Maintenance Inspection Items
In addition to the monthly maintenance items above, inspect the following items:
Item
Content
Standard
Maintenance
1- Measurement
of each battery’s
floating voltage
Measure each battery’s
floating voltage by using
multimeter.
Battery floating
voltage differential
pressure must meet
the following
values:
2V series 90 mV
6V series 240 mV
12V series 480 mV
If there are deviations from the reference
values, first discharge the battery group
and then equalizing charge. After
equalizing charge is completed, change to
float charge and run for two months. If
there are still deviations from the
reference values, replace and recycle the
battery.
2-Use the
equalizing charge
to recover the
batteries which
have either lower
capacity or
discharge voltage
than the other
batteries.
Use the equalizing
charge to charge the
battery 10 hours or
more. In case a battery
has a severe deviation
compared to other
batteries, perform
charge / discharge
cycles three times.
Single battery
discharge voltage in
the battery group
must meet the
following values:
2V: 200mV, 6V:
350mV
12V: 600mV
If the battery performance cannot be
recovered, it must be replaced.
Operation and maintenance
20

2.3 Annual Maintenance Inspection Items
In addition to the quarterly maintenance items above, inspect the following items:
Item
Content
Standard
Maintenance
1- Discharge test
Disconnect the AC, take
load discharge or
discharge online method
to check that discharge
capacity is minimum
30%-40% of nominal
capacity
At the end of
discharge, battery
voltage should be
more than
1.90V/cell,
differential pressure
must meet the
following values:
2V series 200mV
6V series 350mV
12V series 600mV
If the battery voltage is lower
than a voltage reference value or the
differential pressure is greater than the
reference value, discharge the battery,
then equalizing charge, then change to
float charge and run for 1-2 months. If
reference values still exceeded, contact
our technical team for assistance.
2- Capacity Test
Use on-line or off-line
intelligent discharge
device for discharging
batteries until the end
voltage has reached
1.80V / cell
In back-up use the
capacity to be
maintained must be
more than 80% and
in energy storage
use more than 60%
of the reference
capacity
Recovery test: measure and record
various parameters specified in the
monthly / quarterly maintenance items as
well each battery’s end voltage during the
discharge test. If the battery performance
cannot be recovered, replace and re-cycle
the battery.
3-Measure and
verify the
controller
parameters
1-Measure the limited
charging current values.
2-Check that the
equalizing charge starts
and ends automatically.
3- Verify the automatic
start of battery discharge
protection.
Actual operation
parameters to meet
with the set
parameters
In case power equipment and/or controller
fails, arrange repair in a due course to
ensure correct battery performance and
avoidance of reduced battery lifetime.
Maintenance notes
Operate and store batteries only in an upright position.
Ensure that the battery installation complies with the design requirements and installation
documents.
Please use only insulated tools during operation and maintenance, any metal objects to
be put on top of the battery is strictly prohibited.
Operation and maintenance
21

No.1,Shengyang Road, Qufu City,
Shandong Province,273100,P.R.China
Tel:[phone]
Fax:[phone]
E-mail:[e-mail]