Sacred Sun FCP Owner's manual

FCP Battery Installation and Operation
Instruction
Shandong Sacred Sun Power Sources Co., Ltd.

C on ten t s
1. Battery Mold Decomposition Diagram............................. .............................01
2. Battery Accessories List................................ ......... ........................................01
3. Battery Rack Installation Procedures...........................................................05
4. Safety Cautions................................ ......... ........................................................12
5. Matters Requiring Safety Cautions ...............................................................13
6. Use Environment and Use Conditions..........................................................14
7. Handling When Commencing Use ................................................................15
8. Everyday Maintenance and Handling ...........................................................19
9. Measures at Abnormalities ..............................................................................24
10. Measures When Suspending Use.................................................................25
11. Other Points of Care When Handling...........................................................25
12. Measures for Product Disposal.....................................................................26
13. Expected Cycle Life..........................................................................................26
14. Troubleshooting................................................................................................27
15. Battery setting charging/discharge parameters.......................................28

1. Battery mold decomposition diagram:
2. Battery accessories list
2.1 Rack accessories
No.
Name
Type
Quantity
Remark
1
Base
1
Insulation shields
Terminal block
Insulating base
Terminal
block
fixing
plate
Unit
brace
Battery Barrier
Base

No.
Name
Type
Quantity
Remark
2
Unit brace
4
3
Barrier
FCP-500: 218×24×4
12
218×24×4
FCP-1000: 980×42×3
8
980×42×3
4
Terminal block fixing
plate
J00109610102
2
5
Insulating base
FCP-500
WX-195
2
FCP-1000
WX-121
2

No.
Name
Type
Quantity
Remark
6
Terminal block
FCP-1000:
J00109660100
2
7
Insulation shields
FCP-1000
WX-122
2
8
Fixing bolt
GB/T70.1-2008-M6×12
FCP-500: 25
1Bag
FCP-1000:33
Flat washer
GB95-2002-C-Ø6
FCP-500:25
FCP-1000:33
9
Fixing bolt
GB/T70.1-2008-M8×16
9
1Bag
Flat washer
GB95-2002-C-Ø8
9
Spring washer
GB859-1987- Ø8
9
10
Fixing bolt
GB/T70.1-2008-M8×16
13
1Bag
Flat washer
GB95-2002-C-Ø8
26
Nut
GB/T41-2000-C-M8
13
11
Fixing bolt
GB/T70.1-2008-M8×25
10
1Bag (only for FCP-1000)
Flat washer
GB95-2002-C-Ø8
10
Spring washer
GB859-1987- Ø8
10
12
Fixing bolt
GB/T70.1-2008-M8×25
2
1Bag (only for FCP-1000)
Flat washer
GB95-2002-C-Ø8
4
Spring washer
GB859-1987- Ø8
2
Nut
GB/T41-2000-C-M8
2
13
Fixing bolt
GB/T5781-2000-M14×4
0
4
1Bag (only for FCP-1000)
Flat washer
GB95-2002-C-Ø14
8
Spring washer
GB859-1987- Ø14
4
Nut
GB/T41-2000-C-M14
4
14
Steel bulge bolt
M10×80
4
1Bag
15
Installation manual
1 set
16
Installation drawing
1

No.
Name
Type
Quantity
Remark
17
Ball hexagonal
spanner
5#
1
18
Insulated spanner
TB8
1
19
Locating pins
WX-089
2
20
Unloading valve tool
WX-251
1
21
QC passed
1 set
22
Packing list
1 set
2.2 Connectors part
No.
Name
Type
Quantity
Remark
1
battery connection
between layers
FCP-500:
OX185/240
3
FCP-1000:
OX185/380
2
battery connection
of output
FCP-500:
OXD150/185
2
FCP-1000:
OXD185/180
3
Rigid connector
between batteries
FCP-500:
180×30×5
20

No.
Name
Type
Quantity
Remark
FCP-1000
224×50×5
4
Protection for rigid
connector
FCP-500:
WX-249
42
FCP-1000:
WX-250
5
Inner hexagon
screw
GB/T70.1-200
8-M10×25
49
6
Flat washer
GB95-2002-C-
Ø10
49
7
Spring washer
GB859-1987-
Ø10
49
8
Hexagon spanner
8#
1
1Bag
9
Packing list
1 set
10
QC passed
1 set
11
label (1 to 24)
1 set
12
Battery connection
drawing
1set
3 Battery Rack installation procedures:
3.1 Unpacking Caution:
3.1.1 Battery mold rack is assembled before delivery, pay attention when unpacking to avoid mutual bump between
components.
3.1.2 Unit mold rack needs individually stacking installation, this needs disassembled all molds during unpacking.
3.1.3 For easy installation, the battery mold rack can also be the whole installation, or more than one unit mold as
large module decomposition before installation.
3.1.4 The bolts, flat washers, spring washers, nuts and other good which disassembled from the battery mold
should be stored well for use when reinstalling.
3.2 Installation requirement
3.2.1 The distance between battery mold rack and wall should be greater than 100 mm; the distance between one
ends of output line and wall should be more than 300 mm.
3.2.2 If conditions permit, the battery mold rack distance with walls, doors, equipment should be greater than
1000mm;
3.2.3 If the user is required, the battery mold rack can be configured grounding wire, drawn-out position is the
expansion bolts at the bottom of the battery mold rack;

3.2.4 Battery mold rack using expansion bolts on the battery mold rack and ground fixed, in order to achieve the
purpose of prevent shock.
3.3 The placement location of battery mold rack:
3.3.1 Referring to the installation size of battery mold rack, select the appropriate placement position, and cleared
the ground.
3.3.2 Depending on the installation size of the battery mold rack on the ground crossed, crossed position is
consistent with the battery mold rack base dimensions.
3.3.3 Placing the base into the crossed position and adjust correct, well-marked (diagonal fixed) on foot hole
position, and then remove the base.
3.3.4 Impact drill with drill on marks position, and put expansion bolt.
3.3.5 After cleaning up ground again, reset the base and its fixed. Front and rear direction of the base as shown
below, and pay attention to the middle of the base support beams are flush with the upper surface
Foot expansion bolts
Note: placed flush side
facing forward

3.4 Battery mold rack assembly:
3.4.1 First, fix the bottom of the unit mold on the base.
3.4.2 Using the positioning pins to fix position when installation. Use two locating pins calibration two pairs of
diagonally arranged holes in 4 holes. After adjusting the relative position of unit mold and base, putting the
bolts into the other two holes to both fixed. Then out of the positioning pin, and insert the bolt fixed.
3.4.3 Followed by installation of several units above mold, the installation method is the same with and unit mold
and the base
Align the upper
surface
Opening toward the
front side
Positioning
pin to fix
position

3.4.4 When using back to back installation, the back to back mold also needs to be fixed together by bolts.
3.5 Battery installation
3.5.1 Refer to “Battery connection drawing”, put the batteries into the unit mold, and note the battery polarity.
3.5.2 1000Ah battery need to use auxiliary lifting board installation, pay attention to the battery tilt angle when the
lifting, as the below figure show.
3.5.2 Install the battery in place. If there are difficult to install, you can use the unloading valve toll to loosen the
safety valve to release the internal gas, until the battery in place to promptly re-tighten the valve
Placed back to back
Note: battery tilts
certain angle

3.5.3 Finally, put the battery barrier in place, between every two batteries need one barrier.
3.6 Terminal Block and the positive and negative cable installation:
3.6.1 Firstly need to install the terminal fixing plate to the battery pack's positive and negative leads to location,
installation firm and correct.
3.6.2. Then install the black insulating base to the fixed plate, need the 5 # Ball hexagonal wrench through copper
wiring rotating seat to fix the reserved bolts when installing.
3.6.3 After connected the positive and negative cable, and then put the protection cover at the location.
Unloading
valve tool
手
Safety valve
The method of
take-off safety
valve
Rubber
cap
The height of safety
valve is the same
with the external
The standard of tightness
Barriers

3.7 Battery connection
3.7.1 Refer to “Battery connection drawing”, installation battery connection accessories and bolts, the torque is less
than 17.5N.m
3.7.2 After connected the battery connection accessories, carefully check the bolts if there is loosening. Note the
spring flat must be flattened.
3.7.3 After installed the rigid connectors, install the rigid connector protection cover. There are two kind of rigid
connector cover, note do not bump and scratch.
Terminal block
fixed plate
Insulation base
placement
Align the
notches
installation
Note: place direction
is outward
Battery positive
connection
cable

3.7.4 The finished connected battery mold drawing as below.
Rigid
connector
Positive protection
cover is red,
negative is black

1. Safety Cautions
For the safe use of storage batteries, it is essential to handle the batteries correctly and practice correct
maintenance and inspection procedures.
This instruction manual divides the items that, if not properly followed pose dangers of accidents resulting in injury
or death, into the three levels of Danger, Warning and Caution. Users are advised to closely read this manual to
gain a solid understanding of the labeling.
Storage batteries differ from general household products, in that the batteries themselves maintain
energy, while also exchanging energy duringthe discharge and charge stages. Because of these traits,
this is a product that can cause serious dangers if handled incorrectly.
Storage batteries will deteriorate and reach the end of their service lives depending upon the years of use
or the number of times of charge and discharge, and thus should be replaced before reaching the end of
such lifespans.
Danger: This label indicates that mistaken use ignoring the label is likely to result in the danger of
serious injury or even death to the user.
Warning: This label indicates that mistaken use ignoring the label poses the possibility of serious injury
or even death to the user, as well as high potential for suffering minor injuries or material
damage.
Caution: This label indicates that although mistaken use ignoring the label poses a low possibility of
serious injury to the user, while there is the danger of suffering minor injuries or material
damage.
Electric shock danger: This symbol alerts users of details requiring caution (including danger and
warning). The specific contents of the caution are displayed inside the symbol (in the case of this
example, “Electric Shock Danger”).
The “serious injuries” mentioned above refers to vision loss, physical injury, burns, electric shock, broken
bones, poisoning or other conditions in which complications remain, as well as conditions requiring hospitalization
or extended outpatient care.
“Minor injuries” refers to burns, electric shock and other mishaps that fail to meet the definition of serious injury.
“Material damage” refers to expanded damage to residences and household belongings, as well as livestock,
pets and other living creatures other than people.

2. Matters Requiring Safety Cautions
2.1 Explosions, Fires from Hydrogen Gas
Because storage batteries generate hydrogen gas, fire, short circuits between
the (+) and (–) terminals and other conditions can cause ignited explosions or fires.
Rooms should be well ventilated to maintain hydrogen gas concentration at
0.8% or less.
Vinyl tape or other insulation should be applied to torque wrenches, spanners
and other metallic tools.
Keep fires, cigarettes or other lit items away from the batteries at all times.
Never disconnect the vent plug located on top of the storage battery.
2.2 Burns or Vision Loss from Sulfuric Acid
The electrolytes in storage batteries consist of diluted sulfuric acid. If the battery is damaged andthe electrolyte
leaks out, do not touch it directly, and use soda or another neutralizer to neutralize the solution. Allowing the
solution to get in the eyes or on the skin or clothing can result in loss of vision, burns or other injuries. If the
electrolyte does get on something in this way, immediately wash it off with large amounts of water. In particular,
if the solution gets into the eyes or is mistakenly consumed, immediately arrange for an examination by a
physician.
2.3 Electric Shock from Touching Electric Conduction Portion
When conducting maintenance inspections, always wear rubber gloves, rubber shoes
and other protective gear. Allowing any part of the body to come into direct contact
with the conduction part (charging component) will result in electric shock.
2.4 Static Electricity Explosions
Always clean storage batteries with a damp cloth (a well-wrung rag, etc.).
Because storage battery containers and lids are made from synthetic resin,
cleaning with a dry cloth or duster can generate static electricity and cause
ignited explosions.
Never cover a storage battery with a vinyl sheet or other material capable
of generating static electricity. There is a threat that such items will generate
static electricity and cause ignited explosions.
Explosion Danger
Keep away from fire
Keep Away from Fire
Danger
Danger
Electric Shock Danger
Explosion Danger

3. Use Environment and Use Conditions
For the environment and conditions under which storage batteries are used, exercise caution on the following
points.
The surrounding vicinity temperature sphere under which this storage battery
may be used is from –0 to +45℃. Using the battery in temperatures other
than those in this range will accelerate degradation, cause freezing,
abnormal heating and other conditions that can result in breakage,
deformation or other problems
To maintain the storage battery in optimum conditions, use the battery in
the range of 5 to 35℃whenever possible.
Do not use the storage battery in locations with direct exposure to sunlight.
Such exposure can cause degradation in the battery’s components.
Do not use the storage battery in the vicinity of heat generating parts.
Heat may cause breakage in the battery or reduce its service life.
Do not allow the storage battery to become wet (either fresh or salt).
Water may cause damage or fire in the battery, and can also result
in corrosion in the terminals, connecting plates or connecting wires.
Do not use the storage battery in locations with large amounts of dust.
Dust may cause the battery to short circuit.
Do not place the storage battery in a location where it may be become
immersed in water. Immersion in water may cause electric shock or fire.
4. Handling When Commencing Use
4.1 Opening the Package and Inspecting
When the storage battery is delivered, check for any abnormalities in the packaging. Next, carefully open the
box near where the storage battery will be installed, taking care to avoid any bumping or other impact on the
battery.
Carefully open the package, to avoid any bumping or other impact on the storage battery. Such impact can
cause battery breakage.
After opening the package, alert the manufacturer of any container breakage, electrolyte leakage or other
possible abnormalities. Using the battery in such conditions can cause electrolyte leakage, fire or
breakage.
Never lift up the storage battery by the terminals to carry it. Such actions can cause breakage in the
battery.
When moving the storage battery, do not bump, drop or expose it to any other strong impact. Such impact
can cause breakage in the battery.
Because the control valve is incorporated under the vent plug, this plug should never be removed.
（1）This storage battery is a valve-regulated type model, eliminating any need for electrolyte level checks
or replenishment.
（2）After opening the package, confirm the volume and visual appearance of the storage battery and
Keep Away from
High Temperature
Electric Shock Danger
Explosion Danger

attachments.
4.2 Installation and Connecting
Install batteries with the correct polarity ( ＋, －). Installing batteries with
the polarity reversed can result in fire or damage to the batteries or chargers.
Do not tighten the bolts and nuts to any torque other than the stipulated values.
Tightening to other torque can cause damage to the terminals through sparking
or deformation.
(1) Installation (In case that the batteries have already been installed into the unit)
①Installing the channel bases
Temporarily secure the channel bases to the floor by using the chemical anchor bolts (provided with the
product) according to the attached working drawing.
Level all the channel bases within ±1 mm by using the leveling plate.
Adjust the span of the unit battery mounting holes.
Tighten the anchor bolts to the torque specified in the table below.
Table 1: Chemical anchor bolt tightening torque
Nominal diameter
Specified torque N･m (kgf･cm)
M12
42.1 N･m (430 kgf･cm)
M16
107.8 N･m (1,100 kgf･cm)
Note: These values are the specified torques after hardening.
When using any anchor bolts other than the anchor bolts provided with the product, tighten them to the
torque specified in the instruction manual for the anchor bolts.
②Installing the batteries on the first stage
Use torque wrenches, spanners and other metal tools insulated with vinyl
tape or the like. The use of non-insulated tools can result in a short circuit
leading to burn injuries and the explosion of batteries or other damage to batteries.
Do not topple or strike single batteries and unit batteries. The batteries can break
or cause injury.
Mount the M12 eyebolt nuts to the channel at the upper edge of a unit battery and lift the battery with a
lifter or the like to put the battery on its side. (See Figure 1.)
Figure 1
Combustion Danger
Explosion Danger

Connect fabric belts to the M12 eyebolt nuts at four points in the channels of the unit battery placed on its
side. Lift the unit battery with a lifter or the like using the belts connected at the four points. (See Figure 2.)
Figure 2
See the working drawing or the layout drawing to confirm the polarity and slowly lower the unit battery
while aligning the unit battery mounting holes with the channel base mounting holes
Adjust the unit battery in the proper position. Insert the unit battery fixing bolts (M12×35 with two plain
washers) from below the channel bases through the unit battery mounting holes, and temporarily secure
the bolts using the nuts (with two plain washers). (See Figure 3.)
Figure 3
③Installing the batteries on the second and higher stages
Install the unit battery on the second stage in the same way as on the first stage. Temporarily secure the
upper and lower unit batteries together using the bolts and nuts with two washers.
Check again that the batteries have been placed with the correct polarity and tighten the unit battery fixing
bolts (M12) to a torque of 107.8±1 N･m (1100±10 kgf･cm).
After installing the battery on the second stage, install the unit batteries on the third and higher stages in
the same way.
After installing all unit batteries, check again that they have been placed with the correct polarity.

④Connection of connecting plate
Install batteries with the correct polarity (＋,－). Installing batteries with the polarity reversed can result in
fire or damage to the batteries or chargers.
Do not tighten the bolts and nuts to any torque other than the stipulated values. Tightening to other torque
can cause damage to the terminals through sparking or deformation.
Avoid using a wire brush or other hard tools to polish the battery terminal and connecting plate surfaces.
Otherwise the lead plating can peel off, resulting in corrosion.
Lightly apply the enclosed lead acid battery use anticorrosion agent (white vaseline, etc.) over the entire
battery terminal area, and then attach the connecting conductor with a bolt and nut. After attaching, lightly
apply the enclosed lead acid battery use anticorrosion agent to the area around where the bolt and nut
and connecting conductor are fastened. Failure to apply the anticorrosion agent can result in the
generation of a high-resistance corrosion layer.
Polish surfaces of all battery terminals (surfaces in contact with the connecting plate) using a brass brush
or the like.
Polish the conductive connecting surfaces of the connecting plates (the interfaces between the terminals
and the connecting plates) using a brass brush or the like.
Apply a thin coat of the lead acid battery anticorrosion agent (provided with the product) on the polished
conductive contact surfaces of the connecting plates and battery terminals.
Sequentially connect the connecting plates by using M10 bolts (with a flat washer and a spring washer)
according to the working drawing.
Tighten all the connecting bolts to 17.2±2.5 N･m (175±25 kgf･cm).
Finally, check that all the bolts have been tightened and apply a thin coat of the lead acid battery
anticorrosion agent (provided with the product) around the tightened parts of the bolts, nuts and connecting
conductors.
Do not allow coated wire or sheets containing soft vinyl chloride or other plastic
to touch the container or lid. In addition, benzene, thinner, gasoline or other organic
solvents or detergents should also not be allowed to come into contact with the
container or lid. Such contact can result in container or lid breaking or cracks,
becoming the cause of electrolyte leakage.
⑤Installing the connecting plate covers
Install the intermediate connecting plate covers, the inter-row connecting plate covers and the terminal
connecting plate covers from the front side.
(2) Installation (In case that the batteries are installed into the unit on the site )
①Installing the channel bases
Carry out in the same way as described in the work of the Section 4.2 ,(1) , ①( "Installing the channel
base").
②Installing the unit on the first stage
Slowly lower the unit while aligning the unit mounting holes with the channel base mounting holes.
Adjust the unit in the proper position. Insert the unit fixing bolts (M12×35 with two plain washers) from
below the channel bases through the unit mounting holes, and temporarily secure the bolts using the nuts
(with two plain washers). (See Figure 3.)
Electric Shock Danger

③Installing the units on the second and higher stages
Install the unit on the second stage in the same way as on the first stage. Temporarily secure the upper
and lower unit together using the bolts and nuts with two washers.
Tighten the unit fixing bolts (M12) to a torque of 107.8±1 N･m(1100±10 kgf･cm).
After installing the unit on the second stage, install the unit on the third and higher stages in the same way.
④Inserting the batteries
Do not topple or strike single batteries. The batteries can break or cause injury
Insert batteries with the correct polarity (＋,－). Inserting batteries with the polarity reversed can result in
fire or damage to the batteries or chargers.
Insert the batteries in order from the first stage of the unit.
Insert the batteries slowly. Do not give a shock to the batteries.
Insert the batteries slowly, and do not strike the cover of the battery by the bottom plate of the unit.
If there is a risk of striking the cover of the battery, insert the batteries while laying synthetic resin plate of
about 1mm thick in the gap between the unit and the battery bottom. Be careful the top of the cover of the
battery so that it does not clash with the unit when the battery is inserted. Remove synthetic resin plate
then. (See Figure 4.)
Insert batteries with the correct polarity (＋,－).
Do not strike the terminals of the battery when the battery is inserted.
After inserting the batteries, put the retainer plate to hold the batteries.
Figure 4
⑤Connection of connecting plate
Carry out in the same way as described in the work of the Section 4.2 , (1) , ④( " Connection of
connecting plate ").
⑥Installing the connecting plate covers
Carry out in the same way as described in the work of the Section 4.2 , (1) , ⑤( " Installing the connecting
plate covers ").
4.3 Auxiliary Charge
Storage batteries will lose partial capacity as a result of self-discharge during transport or storage. Because of this,
auxiliary charge should be performed along the following guidelines.
(1) Perform auxiliary charges for about 5 hours per cell at 2.45V constant voltage (initial charge current of 0.1CA or
below).
Rack
Cell
Insert the batteries while laying synthetic
resin plate of about 1mm thick in the gap
between the unit and the battery bottom.
Put the wooden platform of the height
of the insertion of the first stage.