EnerSys Outback Power EnergyCell 1000XLC Owner's Manual
EnergyCell 1000XLC
Owner’s Manual
About OutBack Power
OutBack Power is a leader in advanced energy conversion technology. OutBack products include true sine
wave inverter/chargers, maximum power point tracking charge controllers, and system communication
components, as well as circuit breakers, batteries, accessories, and assembled systems.
Applicability
These instructions apply to OutBack EnergyCell 1000XLC series batteries only.
Contact Information
Address: 17825 – 59th Avenue N.E.
Suite B
Arlington, WA 98223 USA
Website: www.outbackpower.com
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,
INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH
INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
OutBack Power cannot be responsible for system failure, damages, or injury resulting from improper
installation of their products.
Information included in this manual is subject to change without notice.
Notice of Copyright
EnergyCell 1000XLC Series Battery Owner’s Manual © 2019 by OutBack Power. All Rights Reserved.
Trademarks
OutBack Power and the OutBack Power logo are trademarks owned and used by OutBack Power, an
EnerSys company. These trademarks may be registered in the United States and other countries.
Date and Revision
November 2019, Revision A
Part Number
900-0258-01-00 Rev A
Table of Contents
Important Safety Instructions ............................................................... 4
Additional Resources ...................................................................................................................... 4
Introduction ..................................................................................... 5
Audience ......................................................................................................................................... 5
EnergyCell 1000XLC ...................................................................................................................... 5
Materials Required .......................................................................................................................... 7
Tools (use insulated tools only) ...................................................................................................................7
Accessories ..................................................................................................................................................7
Storage and Environment Requirements ........................................................................................ 7
Temperatures ...............................................................................................................................................7
Self-Discharge..............................................................................................................................................8
Storing EnergyCell 1000XLC Batteries ........................................................................................................8
Capacity .......................................................................................................................................... 8
State of Charge ............................................................................................................................... 8
Installation ..................................................................................... 11
Battery Installation .....................................................................................................................................11
Pre-Installation Check ................................................................................................................................12
Installation Procedure ................................................................................................................................13
Operation ...................................................................................... 25
Commissioning ............................................................................................................................. 25
Charging ....................................................................................................................................... 25
Bulk Stage ..................................................................................................................................................25
Absorption Stage .......................................................................................................................................25
Float Stage .................................................................................................................................................26
Equalization ................................................................................................................................................26
Notes on EnergyCell 1000XLC Charging ..................................................................................................26
Temperature Compensation ......................................................................................................... 26
Remote Temperature Sensor ....................................................................................................................27
Improper Use ................................................................................................................................ 27
Troubleshooting and Maintenance ...................................................... 29
Periodic Evaluation ....................................................................................................................... 30
Cell Voltage Records .................................................................................................................... 31
Specifications ................................................................................. 33
900-0258-01-00 Rev A 3
Safety Instructions
Important Safety Instructions
READ AND SAVE THESE INSTRUCTIONS!
This manual contains important safety instructions for the EnergyCell battery. These instructions
are in addition to the safety instructions published for use with all OutBack products. Read all
instructions and cautionary markings on the EnergyCell battery and on any accessories or
additional equipment included in the installation. Failure to follow these instructions could result in
severe shock or possible electrocution. Use extreme caution at all times to prevent accidents.
WARNING: Personal Injury
Some batteries can weigh in excess of 100 lb (45 kg). Use safe lifting techniques when
lifting this equipment as prescribed by the Occupational Safety and Health Association
(OSHA) or other local codes. Lifting machinery may be recommended as necessary.
Wear appropriate protective equipment when working with batteries, including eye or
face protection, acid-resistant gloves, an apron, and other items.
Wash hands after any contact with the lead terminals or battery electrolyte.
WARNING: Explosion, Electrocution, or Fire Hazard
Ensure clearance requirements are strictly enforced around the batteries.
Ensure the area around the batteries is well ventilated and clean of debris.
Never smoke, or allow a spark or flame near, the batteries.
Always use insulated tools. Avoid dropping tools onto batteries or other electrical parts.
Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing,
or eyes.
Wear complete eye and clothing protection when working with batteries. Avoid touching
bare skin or eyes while working near batteries.
If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters the eye, immediately flood it with running cold water for at least 20 minutes and
get medical attention as soon as possible.
Never charge a frozen battery.
Insulate batteries as appropriate against freezing temperatures. A discharged battery
will freeze more easily than a charged one.
If a battery must be removed, always remove the grounded terminal from the battery
first. Make sure all devices are de-energized or disconnected to avoid causing a spark.
Do not perform any servicing other than that specified in the installation instructions
unless qualified to do so and have been instructed to do so by OutBack Technical
Support personnel.
Additional Resources
These references may be used when installing this equipment. Depending on the nature of the
installation, it may be highly recommended to consult these resources.
Institute of Electrical and Electronics Engineers (IEEE) guidelines: IEEE 450, IEEE 484, IEEE
1184, IEEE 1187, IEEE 1188, IEEE 1189, IEEE 1491, IEEE 1578, IEEE 1635, and IEEE 1657
(various guidelines for design, installation, maintenance, monitoring, and safety of battery systems)
4
900-0258-01-00 Rev A
Introduction
Audience
This manual is intended for use by anyone required to install and operate this battery. Be sure
to review this manual carefully to identify any potential safety risks before proceeding. The
owner must be familiar with all the features and functions of this battery before proceeding.
Failure to install or use this battery as instructed in this manual can result in damage to the
battery that may not be covered under the limited warranty.
EnergyCell 1000XLC
The EnergyCell 1000XLC is a high-performance Valve Regulated Lead-Acid (VRLA) battery
designed for long life, fast installation, and low maintenance. Featuring a carbon additive that
reduces sulfation on the negative plate, the 1000XLC has exceptional cycle life and a 10-year
warranty, combining the benefits of proven lead acid technology with advanced chemistry.
The 1000XLC is also designed for safety with minimal offgassing under normal charging
conditions and leak-proof engineering. These attributes and more make the 1000XLC an
excellent candidate for storing residential or light commercial renewable energy.
Flame
Arresting
Safety
Vent
900-0258-01-00 Rev A
6¾"
(17.2 cm)
1115/16"
(30.3 cm)
Terminal
Figure 1 EnergyCell 1000XLC
19½" (49.7cm)
5
Introduction
443/16" (112.5 cm)
Terminal
675/16"
(171 cm)
2113/16"
(55.5 cm)
6
Figure 2 EnergyCell 1000XLC Assembly
IMPORTANT:
The surface supporting the assembled cabinet must be designed to support
27.3 psi (1.92 kg/cm
with batteries is 4,574 lb (2,075 kg).
2
). Concrete is ideal. Total weight of cabinet assembly
900-0258-01-00 Rev A
Materials Required
Tools (use insulated tools only)
o
Digital voltmeter
o
Drill
o
Hammer
o
Level
o
Socket wrench
o
Torque wrench calibrated in inch-pounds
o
Box end wrench
o
Battery lifting equipment (eyebolts and straps) and fork lift to lift battery modules
o
Rubber gloves
o
Full face shield
o
Plastic apron
o
Portable eyewash
o
Spill kit
o
Accessories
Fire extinguisher (class C)
Introduction
o
Interconnect bar (included)
o
Terminal cover (included)
o
Hardware (included)
o
Support bars (included)
o
Beams (included)
o
Insulators (included)
o
Upper shield (included)
o
Bus bars and safety covers (included)
o
Dielectric grease (included)
o
Grounding Wire
o
Cables
CAUTION: Fire Hazard
Install properly sized battery cabling and interconnect cables. The cable ampacity
must meet the needs of the system, including temperature, deratings, and any other
code concerns.
Storage and Environment Requirements
Temperatures
o
Optimal operating temperature is 77°F (25°C); maximum temperature range is
–4° to 104°F (–20° to 40°C).
o
Do not allow batteries to freeze, as this will damage them and could result in leakage.
o
Do not expose batteries to temperature variations of more than 5°F (3°C). This leads to voltage
imbalance between multiple batteries (or between battery cells if there is a temperature differential).
o
Batteries should be stored in a cool, dry location.
900-0258-01-00 Rev A
7
Introduction
Self-Discharge
Unlike many conventional batteries, 1000XLC batteries won’t discharge significantly over time
once charged, even in storage. This is especially true if the batteries are kept relatively cool.
Fully charged, the natural (“rest”) voltage of 1000XLC batteries is approximately 52.0 Vdc
(2.2 volts per cell or Vpc). A battery should have a freshening charge (see page 25) if its rest
voltage is below 50.4 Vdc (2.1 Vpc). A battery should not be used if its rest voltage is 48 Vdc
(2 Vpc) or lower upon delivery. Contact Outback Power upon receiving a battery in this state.
Storing EnergyCell 1000XLC Batteries
The EnergyCell 1000XLC batteries must be given a freshening charge every 6 months when
stored at 77°F (25°C). If stored in higher temperatures, the charge should be more often.
Capacity
Battery capacity is given in ampere-hours or amp-hours (Ah). This is a current draw which is
multiplied by the duration of current flow. A draw of X amperes for Y hours equals an
accumulation of XY amp-hours.
Because the battery’s chemical reaction constantly releases energy, its amp-hour capacity is
affected less by lighter loads. The battery has greater capacity under lighter loads.
For example, if the EnergyCell 1000XLC is discharged at the 20-hour rate to a voltage of
1.75 Vpc (a load expected to effectively drain 100% of its capacity in 20 hours), it will be
measured to have 972 amp-hours. However, at the 2-hour rate, a heavier load, only 572
amp-hours will be measured. For all tested discharge rates and amp-hours, see Table 3 on
page 33.
Figure 3 Capacity vs. Temperature
State of Charge
The EnergyCell State of Charge (SoC) can be determined by two methods. One is to measure
its voltage. This is accurate only if the batteries are left at rest (no charging or loads) for 24
hours at room temperature (77°F or 25°C).
checks may not yield usable results.
(2.2 Vpc) will be at 100% SoC. A rest voltage of 48.8 Vdc (2.03 Vpc) represents roughly
50% SoC.
8 900-0258-01-00 Rev A
If these conditions are not met, then voltage
If they are met, then on average, a battery at 52.8 Vdc
Introduction
The more accurate method is to use a battery monitor such as the OutBack FLEXnet DC.
Using a sensor known as a shunt, the monitor observes the current through the battery. It
keeps a total of amp-hours lost or gained by the battery and can give accurate SoC readings.
The EnergyCell can be discharged and recharged (cycled) regularly to a level as low as 50%
depth of discharge (DoD). This is common in a cycling application such as an off-grid system.
However, for optimal life, the best practice is to avoid ever discharging below 50%. Lower DoD
levels can shorten the battery life.
If operated in a range with consistent charge and discharge to no more than 50% DoD, the
EnergyCell 1000XLC will typically deliver 3,800 cycles. With consistently lighter discharge
(10 to 30% DoD with proper recharge), the battery may have significantly more cycles.
The graph below indicates the battery's anticipated cycle life.
Figure 4 Anticipated Cycle Life
900-0258-01-00 Rev A 9
Introduction
This page intentionally left blank.
10 900-0258-01-00 Rev A
Installation
System Installation Considerations
CAUTION: Fire Hazard
Failure to ventilate the battery compartment can result in the buildup of
hydrogen gas, which is explosive.
o
The battery enclosure or room must be well-ventilated. This ventilation protects against accidental
gas buildup. All EnergyCell batteries are valve-regulated and do not normally emit noticeable
amounts of gas. However, in the event of accidental leakage, the enclosure must not allow the
leaked gas to become concentrated.
o
The battery enclosure or room must have adequate lighting. This is necessary to read terminal
polarity, identify cable color, and view the physical state of the battery as required.
o
The battery should be installed with a minimum 36" (91.4 cm) clearance in front. This allows access
for testing, maintenance, and any other reasons.
Battery Installation
The EnergyCell 1000XLC is designed for fast modular installation into an assembled cabinet for
a 48V battery bank. The batteries come in modules of 6 cells which can be stacked in 4 rows,
resulting in a neat, fully enclosed, and non-conductive cabinet. The assembled cabinet is
445/16" (112.5 cm) x 675/16" (171 cm) x 217/8" (55.5 cm). Use powered lifting equipment and the
puller kit shown in Figure 9, or if lifting equipment is unavailable remove the batteries from their
modules before stacking, then replaced one at a time.
IMPORTANT:
The surface supporting the assembled cabinet must be designed to support
27.3 psi (1.92 kg/cm
2
). Concrete is ideal.
900-0258-01-00 Rev A
11
Loading...