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EnergyCell RE Battery
Owners Manual
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Outback Power Systems EnergyCell RE Battery Owners Manual

EnergyCell Battery
Owner’s Manual
Address:
Corporate Headquarters
Arlington, WA 98223 USA
European Office
Schwabach, Germany
Telephone:
+1.360.435.6030
+1.360.435.6019 (Fax)
+49.9122.79889.0
Email:
Support@outbackpower.com
Website:
www.outbackpower.com
About OutBack Power Technologies
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.
Grid/Hybrid™
As a leader in off-grid energy systems designed around energy storage, OutBack Power is an innovator in Grid/Hybrid system technology, providing the best of both worlds: grid-tied system savings during normal or daylight operation, and off-grid independence during peak energy times or in the event of a power outage or an emergency. Grid/Hybrid systems have the intelligence, agility and interoperability to operate in multiple energy modes quickly, efficiently, and seamlessly, in order to deliver clean, continuous and reliable power to residential and commercial users while maintaining grid stability.
Contact Information
17825 – 59th Avenue N.E. Suite B
+1.360.618.4363 (Technical Support)
Hansastrasse 8 D-91126
+49.9122.79889.21 (Fax)
Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER TECHNOLOGIES:
(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.
Information included in this manual is subject to change without notice.
Notice of Copyright
EnergyCell Battery Owner’s Manual © January 2014 by OutBack Power Technologies. All Rights Reserved.
Trademarks
OutBack Power is a registered trademark of OutBack Power Technologies. The ALPHA logo and the phrase “member of the Alpha Group” are trademarks owned and used by Alpha Technologies Inc. These trademarks may be registered in the United States and other countries.
Date and Revision
January 2014, Revision D
Part Number
900-0127-01-00 Rev D

Table of Contents

Important Safety Instructions ........................................................................ 4
Additional Resources .......................................................................................................................................................... 4
EnergyCell Batteries ...................................................................................... 5
Welcome to OutBack Power Systems ........................................................................................................................... 5
EnergyCell GH Front Terminal ......................................................................................................................................... 5
EnergyCell RE ......................................................................................................................................................................... 6
Top Terminal........................................................................................................................................................................................... 6
Front Terminal ....................................................................................................................................................................................... 6
Materials Required ............................................................................................................................................................... 7
Tools........................................................................................................................................................................................................... 7
Accessories .............................................................................................................................................................................................. 7
Storage and Environment Requirements .................................................................................................................... 7
Temperatures ......................................................................................................................................................................................... 7
Self-Discharge ........................................................................................................................................................................................ 7
Capacity ................................................................................................................................................................................... 8
State of Charge ...................................................................................................................................................................... 8
System Layout ....................................................................................................................................................................... 9
Battery Configurations ....................................................................................................................................................................... 9
DC Wiring ............................................................................................................................................................................. 11
Commissioning .................................................................................................................................................................. 13
Charging (EnergyCell GH) .............................................................................................................................................. 13
Float Charge ......................................................................................................................................................................................... 13
Freshening Charge ............................................................................................................................................................................. 14
Charging (EnergyCell RE) ................................................................................................................................................ 14
Bulk Stage .............................................................................................................................................................................................. 14
Absorption Stage ................................................................................................................................................................................ 14
Float Stage ............................................................................................................................................................................................. 15
Freshening Charge ............................................................................................................................................................................. 15
Notes on EnergyCell RE Charging ................................................................................................................................................ 15
Temperature Compensation ......................................................................................................................................... 15
Remote Temperature Sensor ......................................................................................................................................................... 16
Improper Use ...................................................................................................................................................................... 16
Troubleshooting and Maintenance .............................................................. 17
Periodic Evaluation ........................................................................................................................................................... 18
Specifications ............................................................................................. 19
900-0127-01-00 Rev D 3
Safety Instructions
WARNING: Personal Injury
WARNING: Explosion, Electrocution, or Fire Hazard

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.
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.
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)
4 900-0127-01-00 Rev D

EnergyCell Batteries

4.9” (12.6 cm)
22.1” (56.1 cm)
11.1”
200GH
12.4”
220GH

Welcome to OutBack Power Systems

Thank you for purchasing the OutBack EnergyCell battery. EnergyCell is a series of absorbed glass-mat (AGM) batteries with a valve-regulated lead-acid (VRLA) design. They are designed to provide long, reliable service with minimal maintenance. Several versions are available, including front-terminal and top-terminal designs. All have high recharge efficiency and a compact footprint for higher energy density. All have a thermally welded case-to-cover bond to eliminate leakage, all are 100% recyclable, and all are UL-recognized components.

EnergyCell GH Front Terminal

The EnergyCell GH (Grid/Hybrid) Series uses pure lead plates. It is intended to receive continuous float charging under normal conditions when utility power is present.
Intended for use with Grid/Hybrid™ systems, particularly grid-interactive or grid-backup (float service) applications
with occasional interruptions but minimal cycling
Pure lead plates for long float service life in battery backup applications Extended shelf life
(28.3 cm)
EnergyCell
(31.6 cm)
EnergyCell
Figure 1 EnergyCell GH Front Terminal Battery
900-0127-01-00 Rev D 5
Installation and Operation
13.4” (34.1 cm)
8.5”
6.8”
(17.3
Model
34RE
52RE
78RE
95RE
106RE (shown)
4.9” (12.6 cm)
11.1” (28.3 cm)
22.1” (56.1 cm) EnergyCell 170RE

EnergyCell RE

The EnergyCell RE (Renewable Energy) Series uses pasted lead-calcium-tin plates. It is designed for regular discharge/charge cycles. The EnergyCell RE is available in both top-terminal and front-terminal designs.
Intended for use in backup, off-grid, and renewable energy (RE) sites with OutBack inverters, charge controllers,
and other devices that require the use of deep-cycle batteries
Lead-calcium-tin alloy plates for long life in both cycling and float applications High-density pasted plates for high cycle life

Top Terminal

EnergyCell RE Top Terminal Dimensions
Length Height Width
6.8” (17.3 cm) 7.8” (19.7 cm) 5.2” (13.2 cm)
8.1” (20.5 cm) 9.0” (22.9 cm) 5.5” (13.9 cm)
(21.6 cm)
8.0” (20.3 cm) 10.8” (27.3 cm) 6.8” (17.3 cm)
8.1” (20.5 cm) 12.5” (31.8 cm) 6.8” (17.3 cm)
8.5” (21.6 cm) 13.4” (34.1 cm) 6.8” (17.3 cm)
Figure 2 EnergyCell RE Top Terminal Battery

Front Terminal

22.0” (55.9 cm) EnergyCell 200RE
EnergyCell 170RE
12.6” (32.0 cm)
EnergyCell 200RE
Figure 3 EnergyCell RE Front Terminal Battery
6 900-0127-01-00 Rev D
EnergyCell Batteries
CAUTION: Fire Hazard
and any other code concerns.
Figure 4 EnergyCell GH Shelf Life
0 6 12 18 24 30 36 42 48
2.17
2.16
2.15
2.14
2.13
2.12
2.11
2.10
Rest Volts per cell
Approximate %
100
96
91
87
83
79
74
70
40°C
4°F
30°C
25°C
20°C
10°C

Materials Required

Tools (use insulated tools only)

Torque wrenches
Voltmeter

Accessories

Interconnect bar (provided with front terminal batteries only)
Terminal cover (provided with front terminal batteries only)
Hardware kit
Interconnect cables as needed
Install properly sized battery cabling and interconnect cables. The cable ampacity must meet the needs of the system, including temperature, deratings,

Storage and Environment Requirements

Temperatures

EnergyCell batteries should not be operated in an environment where the average ambient temperature exceeds 85°F (27°C). The peak temperature of the operating environment should not exceed 110°F (43°C) for a period of more than 24 hours. High operating temperatures will shorten a battery’s life (see page 8).
Do not allow batteries to freeze, as this will damage them and could result in leakage.
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).
Batteries should be stored in a cool, dry location. Place them in service as soon as possible. The best storage temperature is 77°F (25°C), but a range of 60°F (16°C) to 80°F (27°C) is acceptable.

Self-Discharge

All EnergyCell batteries will discharge over time once charged, even in storage. Higher storage temperatures increase the rate of self-discharge. The EnergyCell GH has a longer shelf life than other VRLA batteries, including the EnergyCell RE. At room temperature (77°F or 25°C), the EnergyCell GH has a shelf life of 18 months before self-discharging to unacceptable levels. Figure 4 shows the rate of EnergyCell GH self-discharge at various temperatures.
Fully charged, the natural (“rest”) voltage of all EnergyCell batteries is approximately 12.8 Vdc. A battery should have a freshening charge (see pages 14 and 15) if its rest voltage is below
12.5 Vdc per battery (2.08 Vdc per cell). A battery should not be used if its rest voltage is 12.0 Vdc or lower upon delivery. Contact the vendor upon receiving a battery in this state.
No EnergyCell should self-discharge below 70% state of charge (SoC). Such as condition is highly detrimental and will shorten battery life. (This situation is not the same as discharging to 70% SoC or lower under load. See page 8.)
900-0127-01-00 Rev D 7
ever
be permitted to
10
86°F
77°F
68°F
Months
State of Charge
50°F
Installation and Operation
Figure 5 Battery Life
70°F 80°F 90°F 100°F 110°F 120°F 130°F 21°C 27°C 32°C 38°C 43°C 49°C 54°C
Temperature
100
20
% of Expected Life
Storing EnergyCell GH Batteries
The EnergyCell GH must be kept in storage no longer than the shelf life indicated in Figure 4 for a particular temperature. At the end of this time it must be given a freshening charge. That is, a battery stored at 104°F (40°C) should be stored no longer than six months, while it can be stored up to 48 months at 50°F (10°C) without a charge.
Stored batteries should be checked for open-circuit voltage at intervals. Any time the battery voltage is less than
2.10 volts per cell (12.6 volts per battery), it should be given a freshening charge regardless of the storage time.
At 104°F (40°C), the EnergyCell GH voltage should be checked every 2 months. At 86°F (30°C), the interval is 3 months. At 77° to 68°F (25° to 20°C) the interval is 4 months. At temperatures lower than 59°F (15°C), the voltage only needs to be checked every 6 months.
Storing EnergyCell RE Batteries
The EnergyCell RE must be given a freshening charge every six months when stored at 77°F (25°C). The charge should be every three months if stored at temperatures of up to 92°F (33°C). If stored in higher temperatures, the charge should be every month.

Capacity

Battery capacity is given in ampere-hours (amp-hours). 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, it tends to replenish its own charge to a minor degree. Smaller loads will deplete the batteries less than larger loads because of this constant replenishment. This means that effectively the battery has more capacity under lighter loads.
For example, if the EnergyCell 170RE is discharged at the 48-hour rate to a voltage of 1.75 volts per cell (a load expected to effectively drain 100% of its capacity in 48 hours), it will be measured to have 163.9 amp-hours. However, at the 4-hour rate, a heavier load, only 120.6 amp-hours will be measured. For discharge rates and amp-hours of all EnergyCell batteries, see the tables on page 20.
The EnergyCell models are named after their capacity at the 100-hour rate when discharged to 1.75 volts per cell.

State of Charge

The EnergyCell 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).
may not yield usable results.
If these conditions are not met, then voltage checks
If they are met, then on average, a battery at 12.8 Vdc will be at 100% SoC. A rest voltage of 12.2 Vdc represents roughly 50% SoC.
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 battery life, the best practice is to avoid regular discharge below 50%. The battery can be occasionally discharged as low as 80% DoD (20% SoC), as is common in emergency backup systems. However, the best practice is to avoid ever discharging below 80% DoD.
90
80
70
60
50
40
30
If operated in the recommended range, the EnergyCell will typically have a life of hundreds of cycles. With consistently lighter discharge, the battery may have thousands of cycles. For the anticipated cycle life of a particular model, see the OutBack data sheet for that battery. (The cycle life can be affected by temperature. Figure 5 shows the effect of ambient temperature on typical battery life.)
8 900-0127-01-00 Rev D
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