Sonnenschein@home Assembly – and Operating instruction

Stationary valve-regulated lead-acid battery

Module Type SH24V8.0 Type SH48V8.0 System / Configuration SH24V16.0 – SH24V24.0 – SH24V32.0 SH48V16.0 – SH48V24.0 – SH48V32.0

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Content 1 Safety precautions ...................................................................................................... 3 2 Technical Data: ........................................................................................................... 4 3 Assembly instruction ................................................................................................... 5 3.1 Installation preconditions and preparations ................................................................. 5 3.2 Check of delivery ........................................................................................................ 5 3.3 Documentation ............................................................................................................ 5 3.4 Replacement of batteries ............................................................................................ 5 3.5 Measurement of open circuit voltage ........................................................................... 5 4 Cabinets with separately delivered block batteries ...................................................... 5 5 Operating instruction ................................................................................................... 7 5.1 Commissioning ........................................................................................................... 7 5.2 Operation .................................................................................................................... 7 5.2.1 Discharge .................................................................................................................... 7 5.2.2 Charging for operation with controlled partial state of charge (cPSOC-operation) ....... 7 5.2.3 Maintaining the full charge (float charge)..................................................................... 9 5.2.4 Alternating currents ..................................................................................................... 9 5.2.5 Temperature ............................................................................................................... 9 5.2.6 Temperature related charge voltage ........................................................................... 9 5.3 Battery maintenance and control ............................................................................... 10 5.4 Tests ......................................................................................................................... 11 5.5 Faults ........................................................................................................................ 11 5.6 Storage and decommissioning .................................................................................. 11 5.7 Transport .................................................................................................................. 11 5.8 Discharge data .......................................................................................................... 12 6 Module / Systems ..................................................................................................... 13 6.1 Module SH24V8.0. SH48V8.0 ................................................................................... 14 6.2 System SH24V16.0. SH48V16.0 ............................................................................... 15 6.3 System SH24V24.0. SH48V24.0 ............................................................................... 16 6.4 System SH24V32.0. SH48V32.0 ............................................................................... 17 7 Service report ........................................................................................................... 18 8 Annex ....................................................................................................................... 19

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1 Safety precautions

Observe these Instructions and keep them located near the battery for future

reference! Modules respectively systems must be installed maintained or repaired by

qualified personnel (electrically skilled person) only!

Do not smoke! Do not use any naked flame or other source of ignition in close vicinity of the

battery. Risk of explosion and fire!

While working on batteries wear protective eye-glasses and clothing. Observe the accident prevention rules as well as EN 50 727-2, EN 50 110-1.

Any acid splashes on the skin or in the eyes must be immediately flushed with

plenty of water. Then seek medical assistance. Spillages on clothing should be rinsed out with water.

Warning: Risk of fire, explosions or burns. Do not disassemble, heat above

60 °C, or incinerate. Avoid short circuits. Avoid electrostatic charges and discharges. / sparks.

Electrolyte is very corrosive. In normal working conditions the contact with the

electrolyte is impossible. If the block container is damaged do not touch the exposed electrolyte because it is corrosive.

Block batteries are very heavy! Make sure they are installed securely! Only use suitable means of transport! Block batteries are sensitive to mechanical shock. Handle with care! Do not lift or pull blocks on the poles.

Caution! Metal parts of the battery are always alive, therefore do not

place items or tools on the battery. Risk of short circuit or electric arc! Use insulated tools for working on battery terminals and cables!

Keep children away from batteries! Non-compliance with installation instruction, installations or repairs made with other than original accessories and spare parts or with accessories and spare parts not recommended by the battery manufacturer or repairs made without authorization (e. g. opening of valves on VRLA batteries) render the warranty void.

Spent batteries have to be collected and recycled separately from normal household wastes (EWC160601). The handling of spent batteries is described in the EU Battery Directive (2006/66/EC) and their national transitions (UK: HS Regulation 1994 No.232, Ireland: Statutory Instrument No. 73/2000). Contact your supplier to agree up-on the recollection and recycling of your spent batteries or contact a local and authorized Waste Management Company.

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2 Technical Data:

Block battery with 6 cells, each 2 V, Type Sonnenschein@home SH12V2.0:

Type Nom. voltage

Norm. capacity C10 @ 1.80 Vpc

Nom. energy *

Dimensions Weight Terminal L W H

V Ah kWh mm mm mm kg

SH12V2.0 12 165 1.98 568 128 320 58.4 M-M8-45

Basic module Sonnenschein@home Equipped with 4 block batteries type Sonnenschein@home SH12V2.0

Module Nom. voltage

V

Dimensions

Weight***

kg

Hourly ventilation air flow

Q** m³ / h

Nom. energy*

kWh

H mm

W mm

D mm

SH24V8.0 24 900 600 400 280 1.6 7.92

SH48V8.0 48

Surface load: 1,170 kg/m² for each basic module Available systems / combinations

System Nom. voltage

V

Number of modules

Weight***

kg

Hourly ventilation air flow

Q** m³/h

Nom. energy*

kWh

SH24V16.0 24 2 560 3.2 15.84

SH48V16.0 48

SH24V24.0 24 3 840 4.8 23.76

SH48V24.0 48

SH24V32.0 24 4 1120 6.4 31.68

SH48V32.0 48

* at nom. voltage of module and C10 at 20 °C, the effective energy is 50 % of nominal energy

** Ventilation complying with DIN EN 50272-2 has to be ensured

*** Attention must be paid to the permissible area load at installation site

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3 Assembly instruction

3.1 Installation preconditions and preparations

Prior to commencing installation, ensure that the battery room is clean and dry. Pay attention to the following aspects: – Load bearing capacity and nature of the floor (transport paths and installation location).

– During normal use of valve regulated batteries electrolyte spillage is not to be expected. If an error occurs only few amount of some drops may leak. It is recommended to design the floor below the cabinet resistant to electrolyte.

– Do not use any source of ignition (sparking or glowing devices, electrical switches, fuses or other) in close vicinity of the battery. Observe a safety distance of at least 575 mm to the vent openings.

– Ventilation requirements refer to para. 2.

3.2 Check of delivery

Check delivery for complete and undamaged components. If necessary, clean all parts prior to installation.

3.3 Documentation

Follow instructions in the documentation supplied (e.g. installation drawings for battery, refer to enclosure).

3.4 Replacement of batteries

Prior to removing old batteries always ensure that all of the loads have been disconnected (load-break switches, fuses, insulations). This must be carried out only by personnel author-ized to perform circuit operations. WARNING: Do not carry out any unauthorized circuit operation!

3.5 Measurement of open circuit voltage

Carry out open circuit voltage measurements on the individual block batteries. At the same time, ensure that they are connected in the correct polarity. The open-circuit voltage of the individual block batteries should not vary themselves from the measured average value by more than ± 0.073 V (guide value). If the deviation is any higher, contact the supplier.

4 Cabinets with separately delivered block batteries

– Assemble cabinet, place and align at the assigned location (observe the accident pre-vention rules).

– Cabinets installed stacked or side by side must be jointly bolted. The upper of stacked cabinets must be affixed to the wall with a wall anchor (scope of delivery). Dowel and anchor bolt do not belong to the scope of delivery.

– Check block batteries for perfect condition (visual check, polarity).

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– If necessary, clean the contacting surfaces of the terminals and connectors.

– Allow sufficient side clearance (at least 600 mm) for installation, connecting and future maintenance and control of the block batteries.

– Place block batteries, using the ribbed plates supplied, in the cabinet in accordance with the installation plan, ensuring correct polarity.

– Align block batteries parallel to each other. Distance between block batteries shall be approx. 10 mm.

– Place and screw block connectors using an insulated torque wrench (for correct torque value refer to battery operating instructions). Apply the following torque for screw connectors: M-M8-45°: 8 Nm

– Place the series and tier connectors supplied and screw them together, observing the given torque values.

– Avoid applying any mechanical force on the battery poles.

– All end connectors of batteries which connect batteries among each other, with the load, the disconnector or fuses, must be installed inherently short-circuit-proof.

– Measure total voltage (nominal voltage: sum of open circuit voltages of the individual block batteries).

– Sequentially number the block batteries in a visible place (not on the valves) between the positive terminal of the battery and the negative terminal of the battery.

– Apply polarity signs for the battery leads.

– Attach safety marking, type label and operating instructions in a visible place. For completing the type label refer to para. 6.

– Fit insulating covers for block connectors and terminals.

WARNING: Prior to connecting the battery to the PV control unit, ensure that all instal-lation work has been duly completed Do not connect any other electrical appliances to the block batteries or terminals installed in the cabinet.

Observe also the assembly – and operating instructions of the PV control unit the battery shall be connected to.

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5 Operating instruction

In stationary valve regulated lead acid batteries of the series Sonnenschein@home the elec-trolyte is fixed in a Gel. During the whole service life it is neither necessary nor allowed to top-up water. Pressure valves are used for sealing and cannot be opened without destruction.

5.1 Commissioning

Check all block batteries for mechanical damage, correct polarity and firmly seated connect-ors. Apply the following torque for screw connectors: M-M8-45°: 8 Nm Fit insulating covers for block connectors and terminals Control of insulation resistance: New batteries: > 1M Ω Used batteries: > 100 Ω/Volt Connect the battery with the correct polarity to the charger (pos. pole to pos. terminal). The charger must not be switched on during this process, and the load must not be connected. Switch on charger and start equalizing charging according to para. 5.2.2.3 in order to ensure the battery is fully charged.

5.2 Operation

The following specification for operation and recharging must be met in order to achieve the number of specified cycles for the battery type Sonnenschein@home. GNB Industrial Power recommends asking the manufacturer or supplier to confirm that the PV control unit meets this specification. Alternatively the battery may be operated with a PV control unit deviating from the following specification, if it was released by GNB Industrial Power. For the installation and operation of stationary batteries EN50272-2 is mandatory.

5.2.1 Discharge

The state of charge (SOC) must not fall below 45 % of the nominal capacity C10 during dis-charge.

5.2.2 Charging for operation with controlled partial state of charge (cPSOC-operation)

In daily cPSOC operation the state of charge must not exceed 95 % of C10. All following voltage values refer to measurements at the battery terminals. In order to meet the following values for the charging voltages, the voltage drop on the con-nection between battery and charger must be kept as low as possible by using a sufficient cross section.

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If the charger has an input to compensate the voltage drop, e.g. by connecting a sense line connected to the battery terminal, GNB recommends using this feature.

5.2.2.1 Daily charge for cPSOC-operation

I-Phase: Charging with PV system current minus load current: max. 6 x I10, Duration: until cell voltage reaches 2.40 Vpc to 2.45 Vpc, then switch to:

U-Phase: Setting of the charging voltage: 2.40 Vpc to 2.45 Vpc.

Duration: 120 min +/- 12 min

5.2.2.2 Full charge

If the PV system current minus load current is not sufficient to fully charge the battery, charg-ing must be carried out with mains support. Remark: Hereby a state of charge of approx. 99 % of C10 will be achieved. Every 14 days, or at least after a capacity throughput of 10 times of the nominal capacity C10: Charging characteristic: IU I-Phase: average charging current I: 4 x I10 ± 10%

Duration: until cell voltage reaches 2.40 Vpc to 2.45 Vpc, then switch to: U-Phase: Setting of the charging voltage: 2.40 Vpc to 2.45 Vpc.

Duration: 300 min +/- 30 min

5.2.2.3 Equalizing charge

If the PV system current minus load current is not sufficient to fully charge the battery, charg-ing must be carried out with mains support. Remark: Hereby a defined state of charge of 100 % of C10 will be achieved. Every 90 days, or at least after a capacity throughput of 30 times of the nominal capacity C10: Charging characteristic: IU I-Phase: average charging current I: 4 x I10 ± 10%

Duration: until cell voltage reaches 2.40 Vpc to 2.45 Vpc, then switch to: U-Phase: Setting of the charging voltage: 2.40 Vpc to 2.45 Vpc.

Duration: 600 min +/- 60 min

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5.2.3 Maintaining the full charge (float charge)

Devices complying with the stipulations under DIN41773 must be used. They are to be set so that the average cell voltage is as follows (within temperature range 15 to 35 °C): Sonnenschein@home SH12V2.0: 2.27 Vpc ±1%

5.2.4 Alternating currents

According to the charging equipment, specification and characteristics alternating currents flow through the battery superimposing onto the direct current during charge operation. Al-ternating currents and their action from the loads may lead to an additional temperature in-crease of the battery, and strain the electrodes with possible damages, which can shorten the battery life. When recharging acc. to para. 5.2.2 the actual value of the alternating current is occasionally permitted to reach 10 A (RMS) / 100 Ah C10 capacity. In a fully charged state during float charge the actual value of the alternating current must not exceed 5 A (RMS) / 100 Ah C10 capacity.

5.2.5 Temperature

The recommended operation temperature range for the batteries Sonnenschein@home is +10 °C to +35°C, (best 20 °C ± 2 K). Higher temperatures will seriously reduce service life. The technical data are valid for the nominal temperature of 20 °C. Lower temperatures re-duce the available capacity and extend the charging time. The absolute maximum temperature of 55 °C must not be exceeded. Permanent tempera-tures higher than 35 °C shall be avoided.

5.2.6 Temperature related charge voltage

The charging voltage shall be adjusted according to the battery temperature. For this the battery temperature has to be measured with a temperature probe, connected to the charger. Depending on the module configuration, the position of the temperature probe shall be car-ried out as shown in the drawing in the appendix. The battery must not be damaged by the temperature probe. Ideally the temperature related compensation shall be carried out as shown in curve A of Fig. 1 Alternatively the charging voltage can be linear temperature adjusted using a compensation factor of -0,0025 V/cell and K, relating to 25 °C, refer to curve B of Fig. 1. Example: The charging voltage of 2.40 Vpc at 25 °C corresponds to a voltage of 2.3875 Vpc at 30 °C, respectively 2.425 Vpc at 15 °C.

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Fig. 1 Charging voltage vs. temperature

5.3 Battery maintenance and control

Keep the battery clean and dry to avoid leakage currents. Plastic parts of the battery, espe-cially block containers, must be cleaned with pure water without additives. At least annually measure and record: – Battery voltage

– Voltages of all block batteries in discharge operation

– Surface temperature of all block batteries

– Actual battery room temperature

– Average battery room temperature

– Ampere-hour (Ah) - throughput

– Actual settings of the PV control unit at time of service

– Have the settings been modified? By whom? Reason for the modification?

Annual visual checks: – Battery installation and arrangement

– Ventilation

Charg

ing v

oltage [V

pc]

Temperature [°C]

B

A

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If the voltage of one or more block batteries during discharge is lower than 0.49 V of the av-erage block battery voltage or if the surface temperature difference between block batteries exceeds 5 K, the service agent should be contacted.

5.4 Tests

Tests have to be carried out according to DIN EN 60896-21. Capacity test In order to make sure the battery is fully charged prior to a capacity test (e.g. acceptance test on site), the IU-charge method according to para. 5.2.2 must be applied, using mains sup-port.

5.5 Faults

Call the service agent immediately if faults in the battery or the charging unit are found. In order to facilitate trouble shooting and remediation the following recorded data must be made available to the service agent: – Data of the annual control according to para. 5.3

– Commissioning date of the battery installation

– Settings of the PV control unit at time of commissioning

A service contract with your local installation company facilitates the timely detection of er-rors.

5.6 Storage and decommissioning

To store or decommission block batteries for a longer period of time they should be fully charged and stored in a dry and cold but frost-free room, not exposed to direct sun light. To avoid damage the following charging methods can be chosen: Option 1: Maximum storage time beginning at full charged state is 17 months at tem-

peratures ≤ 20 °C. At higher temperatures, (e.g. after 8.5 months at 30 °C) equalizing charges as detailed in para. 5.2.2.3 will be required.

Option 2: float charging acc. to para. 5.2.3 Irrespective of the aforementioned storage times recharging is required latest when the open-circuit voltage of the block batteries falls below 12.45 V..

5.7 Transport

Block batteries must be transported in an upright position. They must be protected against short circuits. Batteries without any visible damage are not defined as dangerous goods under the regula-tions for transport of dangerous goods by road (ADR) or by railway (RID). They must be pro-tected against slipping, upsetting or damaging. Block batteries may be suitably stacked and secured on pallets (ADR and RID, special provision 598). It is prohibited to stack pallets. No dangerous traces of acid shall be found on the exteriors of the packing unit. Block batteries

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with leaking or damaged containers must be packed and transported as class 8 dangerous goods under UN no. 2794. In case of air transport, batteries which are part of any equipment must be disconnected at their terminals, and the terminals must be protected against short-circuits. This is in order to avoid the risk of any incidents like fire etc.

5.8 Discharge data

Discharge data at different discharge times and final discharge voltage. All technical data refer to 20° C. SH12V2.0 – Discharge with constant current in A at 20 °C

Vpc 1 h 2 h 3 h 4 h 5 h 8 h 10 h 20 h

1.9 88.6 56.5 40.8 32.4 27.4 18 14.7 7.76

1.87 94.9 60 43 34 28.8 18.9 15.5 8.19

1.85 98.8 61.8 44.2 34.9 29.4 19.3 15.9 8.39

1.83 101 63.1 45.1 35.5 29.9 19.7 16.1 8.58

1.8 104 64.7 46.1 36.2 30.3 20 16.5 8.75

1.77 107 65.8 46.8 36.7 30.5 20.3 16.7 8.89

1.75 108 66.4 47.2 37 30.7 20.4 16.9 8.95

1.73 110 67 47.5 37.3 30.9 20.5 16.9 8.95

1.7 111 67.6 47.9 37.6 31.1 20.7 16.9 8.95

1.67 112 68.1 48.2 37.8 31.1 20.7 16.9 8.95

1.65 113 68.4 48.4 37.8 31.1 20.7 16.9 8.95

1.6 114 68.7 48.5 37.9 31.1 20.7 16.9 8.95

SH12V2.0 – Discharge with constant power in W / Block at 20 °C

Vpc 1 h 2 h 3 h 4 h 5 h 8 h 10 h 20 h

1.9 977 631 468 367 304 203 166 87

1.87 1048 668 494 387 320 213 174 92

1.85 1090 690 510 398 329 219 179 95

1.83 1125 708 522 408 337 224 183 98

1.8 1164 760 536 418 345 228 187 100

1.77 1184 766 542 423 348 230 189 102

1.75 1196 769 546 425 350 232 190 102

1.73 1205 772 549 427 352 232 190 102

1.7 1217 775 552 430 354 234 190 102

1.67 1228 778 555 432 354 234 190 102

1.65 1235 779 556 432 354 234 190 102

1.6 1250 783 557 433 354 234 190 102

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6 Module / Systems

Depending on the connection of the block batteries in the cabinet and the interconnection of the modules. the name plate has to be filled in as shown below:

Module / System Field 1 Field 2 Field 3

SH24V8.0 24 330 4

SH48V8.0 48 165 4

SH24V16.0 24 660 8

SH48V16.0 48 330 8

SH24V24.0 24 990 12

SH48V24.0 48 495 12

SH24V32.0 24 1320 16

SH48V32.0 48 660 16

Example for a module SH48V8.0

SH12V2.0

Field 1

Field 2

Field 3

SH12V2.0

48

165

4

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6.1 Module SH24V8.0. SH48V8.0

Dimensions: H 900 mm x W 600 mm x D 400 mm Total weight: 280 kg. incl. 4 block batteries SH12V2.0 Surface load: 1,170 kg/m² Standard: Terminal clamps for connecting flexible cables of 25 mm² to 70 mm² Option: Terminal clamps for connecting flexible cables of 90 mm² Terminal clamps for measurement of block battery voltages

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6.2 System SH24V16.0. SH48V16.0

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6.3 System SH24V24.0. SH48V24.0

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6.4 System SH24V32.0. SH48V32.0

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7 Service report

a) Total battery voltage: ................................................ V

b) Voltage and surface temperature of each block battery in discharge operation Discharge current / -power at time of recording ....................................... A / kWh (delete as applicable)

Block Voltage V

Temperature °C

Block Voltage V

Temperature °C

1 9

2 10

3 11

4 12

5 13

6 14

7 15

8 16

c) Battery room temperature: ..................................... °C

d) Average battery temperature ................................. °C (read from PV control unit)

e) Ampere-hour (Ah) – throughput ............................ ° C (read from PV control unit)

f) Settings of the PV control unit at time of commissioning

(read from PV control unit)

g) Modifications of the settings of the PV control unit at time of service (read from PV control unit)

By whom?

Reason for the modification?

________________________ _________________________

Date Signature

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8 Annex

Sequence of assembly. example for a module with door at right side:

Caution! Metal parts of the battery. free end of cables connected to the battery terminals are always alive. Risk of short circuit or electric arc! Therefore free cable ends shall be insulated until connection to terminal clamps, fuses. etc.

Do not place items or tools on the battery.

Always use insulated tools for working on battery terminals and cables!

1: Remove the screws of the cabinet cover and re-move the cabinet cover

2: Remove screws of the left side cover and remove it

3: Remove screws of the top and middle cross-tie and remove the cross-tie and middle shelf

4: Insert 2 block batteries from the top and align them in parallel. using the ribbed plates (not depicted)

5: Place and screw block battery connectors. series and tier connectors and terminal ca-bles together with washers. spring washers and fix them with nuts.

torque of the nut: 8 Nm

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6: Fit insulation covers 7: Insert the middle cross-tie followed by the middle shelf

8: Insert 2 block batteries from the top and align them in parallel. using the ribbed plates (not depicted)

9: Place and screw block battery connectors. series and tier connectors and terminal ca-bles together with washers. spring washers and fix them with nuts.

torque of the nut: 8 Nm Fit insulation covers as shown in fig. 7

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10: Install the terminal rail with the terminals in the door frame and connect the terminal wires

11: Install the terminal rail with the terminals for measuring of battery block battery voltages at the hinge side of the door frame and connect the measuring lines

12: Fix the top cross-tie Finally fit the cabinet side cover followed by the cabinet cover. The assembly work is now complete.

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GNB®INDUSTRIAL POWER

Exide Technologies GmbH Im Thiergarten D 63654 Büdingen Tel.: +49 (0) 60 42 / 81 343 Fax: +49 (0) 60 42 / 81 745 gnb.com

State August 2013