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Transcript
APPLICATION GUIDE RESERVE POWER Introduction EnerSys® has optimised the very successful Thin Plate Pure Lead (TPPL) PowerSafe® SBS® battery range to create the revolutionary EON Technology®, a concept that utilises highest purity materials and state of the art manufacturing processes to deliver energy storage solutions that can meet the requirements of emerging applications whilst offering the end user enhanced performance in existing applications. Historically, the useful service life of reserve power Valve Regulated Lead Acid (VRLA) battery systems was measured by their float life but as applications evolve from pure standby to cyclic applications, some traditional VRLA technologies find that these new requirements push them beyond their scope of operation. PowerSafe SBS EON Technology monoblocs and cells retain the long float characteristics of standard PowerSafe SBS monoblocs and cells, with the added benefit of improved cyclic ability in both float voltage and fast charge applications. Table 3 provides a summary of the operating parameters (charging) that will deliver optimum service life and performance relative to the type of application. Application PowerSafe® SBS® EON Technology® Charge Parameter for Optimised Life and Performance Float charge (reliable AC power) Temperature compensated float voltage equivalent to 2.29Vpc @ 20°C Charge current - minimum 0.1C10A, maximum unlimited Float charge unreliable AC power (uncontrolled PSOC) Boost voltage equivalent to 2.40vpc @ 20°C to fast charge Charge current - minimum 0.1C10A, maximum unlimited Followed by float voltage with temperature compensation applied as required Hybrid operation to full state of charge Boost voltage equivalent to 2.40Vpc @ 20°C Charge current - minimum 0.1C10A, maximum unlimited Return to full state of charge between discharge cycles Optimum charge factor 103% of discharged Ah Hybrid operation in partial state of charge (controlled PSOC) example Boost voltage equivalent to 2.40Vpc @ 20°C to return to 95% state of charge. Charge current - minimum 0.1C10A Full recharge every 10 days EnerSys will consider variations in controlled psoc operation as necessary please contact your local representative to discuss details Applications PowerSafe SBS EON Technology solutions are well proven in stand by applications, recent developments have focused on improving robustness in harsh environments and challenging operating conditions, so that today EON Technology has higher cyclic performance, improved endurance at high temperature and the ability to operate in partial state of charge conditions, providing that the operating conditions are well understood. Float charge mode: Stable reliable grid, stable ambient temperature, compensation to float voltage for any temperature fluctuation and no or very little cyclic use (<10 cycles per year). Grid assist applications: Quite a stable grid and ambient temperature, medium level of cyclic use (50 to 100 cycles per year) with low risk for partial state of charge cycling. Partial state of charge: Unstable grid, warm ambient temperatures with uncontrolled cyclic use meaning high risk for partial recharge. Off grid applications: Typically diesel generator and battery hybrid, it can also incorporate renewable energy sources such as wind turbine or PV array to alternatively supply energy to telecoms equipment, where mains grid power is not available. Warm ambient temperature with regular cyclic duty – typically 1 cycle per day. Table 1 Off grid applications can be further split into two sub categories as shown in table 2. Controlled partial state of charge: An operating mode with regular cyclic duty where the battery is deliberately operated in partial state of charge to maximise operating expenditure savings. The battery is periodically returned to full state of charge when predefined trigger points are reached. Can be subjected to high ambient temperatures. Table 2 2 Operating Temperature Range The recommended operating temperature range for optimum life and performance is 20°C. However, PowerSafe SBS EON Technology monoblocs and cells can be operated in the temperature range -40°C to +50°C. In order to maintain mechanical integrity of the plastic components, the battery temperature in operation should not exceed +50°C. Storage Monoblocs and cells lose capacity when standing on open-circuit because of parasitic chemical reactions. The self-discharge rate of PowerSafe SBS EON Technology monoblocs and cells is very low because of the high purity of the grid lead and electrolyte. Monoblocs and cells should be stored in a cool, dry area. High temperature increases the rate of self-discharge and reduces storage life. Figure 1 shows the relationship between open-circuit voltage (OCV) and storage time at various temperatures. 2.17 100 2.16 96 2.15 91 2.14 87 2.13 83 2.12 79 2.11 +40°C 2.10 Figure 1 0 +30°C 6 +25°C 12 18 +20°C 24 30 Months 74 +10°C 36 70 42 48 Approx. State of Charge (%) Controlled full state of charge: An operating mode with regular cyclic duty where the battery is returned to full state of charge between discharge cycles. The duty cycle is designed to optimized balanced battery life and operating expenditure savings. Can be subjected to high ambient temperatures. Table 3 Open Circuit Voltage per Cell Table 1 below gives description of the range of reserve power applications covering stable grid, unreliable grid and off grid applications – the superior performance characteristics of PowerSafe SBS EON Technology makes it the ideal solution to be used in these applications. The maximum storage times before a freshening charge is required and recommended open circuit voltage audit intervals are: Temperature (°C / °F) Storage Time (Months) OCV Audit Interval (Months) +10 / +50 +15 / +59 +20 / +68 +25 / +77 +30 / +86 +35 / +95 +40 / +104 48 34 24 17 12 8.5 6 6 6 4 4 3 2 2 Commissioning Charge Float Volts Per Cell Freshening Charge Charge the monoblocs or cells at a constant voltage equivalent to 2.29 to 2.4Vpc with 0.1C10 Amps current for a period of 24 hours. 2.35 2.34 2.33 2.32 2.31 2.30 2.29 2.28 2.27 2.26 2.25 2.24 2.23 2.22 2.21 2.20 2.19 Recommended Float Voltage Minimum Float Voltage Voltages >Recommended promote overcharge & high float currents resulting in accelerated end of service life Voltages <Minimum recommended result in undercharge, reduction in capacity and irrecoverable capacity loss leading to premature end of life 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Temperature (°C) Figure 4 Before conducting a capacity discharge or commencing cycling, the battery must be given a commissioning charge. In float applications the commissioning charge shall consist of 7 continuous days of float charge at the recommended float voltage (2.29Vpc at 20°C) with no load connected to the battery. In hybrid applications the commissioning charge shall consist of 24 hours charge at a voltage equivalent to 2.40 Volts/cell with no load connected. Float Operation EON Technology® is designed for continuous float operation on constant voltage chargers. Constant voltage charging is the safest, most efficient and recommended method of charging VRLA batteries. The recommended float voltage setting is 2.29Vpc at +20°C/+77°F. Therefore the system voltage setting equals the number of cells in series x 2.29Vpc. Battery life and charging characteristics are affected by temperature. Optimum battery life will be achieved when the battery is operating between +20°C/+68°F and +25°C/+77°F (see figure 2). Float Life (Float @ 55°C Using Recommended FV for 20°C) Float Charging Current Limit Due to the very low internal resistance, PowerSafe® SBS® EON Technology monoblocs and cells will accept unlimited current during recharge but for cost and practical purposes in float applications where recharge time to repeat duty is not critical, the rectifier current can be limited to the load plus 0.1C10 Amps. Fast Charging Operation In addition to the long life characteristics inherent in traditional PowerSafe® SBS TPPL battery designs, EON Technology® monoblocs and cells have been developed to provide high performance in applications where the battery is subjected to repeated cyclic duty, in challenging operating conditions (high temperatures, unreliable grids, remote locations, etc). Fast charge techniques are best utilised for frequent discharge cyclic applications. The high charge acceptance of EON Technology is suited for applications which require a faster recharge with reduced time to repeat duty. In such applications the rectifier voltage should be set at 2.40Vpc at 20°C. Figure 5 illustrates the time to full state of charge from varying depths of discharge (C10) as a function of charge voltage. Recharge Time to 100% State of Charge following C10 Discharge to Varying Depths of Discharge. Compare Float Charge with EON Technology® Recharge Regime (Current Limit 25% C10) 0 1 2 3 4 5 6 7 8 9 % Depth of Discharge (C10) Nominal Capacity (%) Temperature compensation is capped at +40°C/+104°F as at this temperature the compensated charge voltage approaches the natural open circuit voltage of the battery and there is insufficient overvoltage to keep the battery in a fully charged condition. Float Voltage Temperature Correction Monoblocs and cells must be given a freshening charge when the OCV approaches the equivalent of 2.10 Volts per cell or when the maximum storage time is reached, whichever occurs first. 120 110 100 90 80 70 60 50 40 30 20 10 0 The recommended float voltage temperature compensation is: • 2.29Vpc +4mV per cell per °C below 20°C • 2.29Vpc -4mV per cell per °C above 20°C (refer to figure 4 for further details) 10 11 12 13 14 15 16 17 Calculated Life (Years @ 20°C) Figure 2 Battery life is reduced by 50% for every 10°C/18°F increase in temperature (see figure 3). Float voltage compensation reduces the charging current as battery temperature increases and partially negates the adverse effect of high temperature. Service Life as a Function of Temperature (Continuous Float Operation - Uncompensated FV) 110 100 90 80 70 60 50 40 30 20 10 0 EON Technology Fast Charge 0 2 8 10 12 14 16 As with float charge, temperature compensation for voltage is applicable to fast charge techniques. The profile below (figure 6) gives the recommended compensation to charge voltage for temperature. Fast Charge Temperature Correction 15.00 14.00 2.53 13.00 2.51 12.00 2.49 11.00 2.47 10.00 2.45 Volts Per Cell Service Life (Years) 6 Time to 100% State of Charge (Hrs) Figure 5 16.00 9.00 8.00 7.00 6.00 5.00 4.00 2.43 2.41 2.39 2.37 2.35 2.33 3.00 2.31 2.00 2.29 1.00 2.27 0.00 15 Figure 3 4 FV Recharge 20 25 30 35 40 45 50 55 60 65 70 2.25 10 Temperature (ºC) Figure 6 15 20 25 30 35 40 45 50 Temperature (°C) 3 Recharge time (hrs) = 2* ((0.8 x discharged Ah) / current limit) +1 Fast Charging Current Limit In addition to the influence of charge voltage, the available charge current will impact on time to repeat duty. The low internal resistance of PowerSafe® SBS® EON Technology® monoblocs and cells lends itself to absorption of unlimited in rush currents but can also be recharged with current limits equal to the standing load plus 0.1C10 Amps. Figure 7 illustrates the typical time to full state of charge (2.40Vpc) as a function of available charge current from varying depths of discharge. Fast Charge Cycling The high charge acceptance of PowerSafe SBS EON Technology monoblocs and cells that enables the use of fast charge techniques provides the user with the advantage of reduced time to repeat duty and further extends the number of cycles available during service life to unparalleled levels (figure 9). Fast ChargeF Cycle as a Function of Depth of Discharge 9000 8500 8000 7500 7000 6500 Number of Cycles In systems where control of charge factor is not possible, it may be possible to estimate time to full state of charge by using the calculation: 6000 5500 5000 4500 4000 3500 3000 2500 Time to Full State of Charge TIME TTO FULLL SSTATE O FFUL TAATE OF CHARGE CHAR RGE As a Function of CURRENT Current Limit and Depth of0Vpc Discharge LIMITT AND DEPTH OFF DISCHARGE at 2.40Vpc AS A FUNCTION FUNC CTION OF CURREN T LIMI (Recharge 2.40Vpc) 2000 1500 1000 500 0 18 10 25 30 35 40 45 50 55 60 65 70 % Depth of Discharge 0.3C10 Ampss 12 0.5C10 Ampss 1C10 Amps 10 0.2C10A 8 0.3C10A 6 0.5C10A 4 1C10A 2 0 0% 10% 20% 30% 40% 50% 60% % 70% 80% 800% 90% 100% 110% DEPTH DISCHARGE RGE Depth ofOFDischarge Figure 7 Cycling Float Cycling EON Technology has been developed to retain the long float life characteristics associated with standard PowerSafe SBS Technology and has the added capability to deliver high performance in harsh applications where cyclic duty predominates. The optimal cyclic performance shown in figure 9 is based on the battery being returned to full state of charge between cycles. It is possible to operate SBS EON Technology monoblocs and cells in controlled partial state of charge condition to improve site operating expenditure savings, however it is very important to ensure that the battery is periodically returned to full state charge to ensure that the battery does not suffer from reduced performance due to the build up of irreversible sulphation. It is recommended to contact your EnerSys® representative to obtain additional information and guidance for such PSOC applications. Extensive testing has shown that in traditional float cyclic applications PowerSafe SBS EON Technology surpasses the excellent performance of standard PowerSafe SBS battery designs, typically delivering a 33% increase in the number of cycles during evaluation to international benchmark standards (figure 8). SBS EON Technology delivers superior performance in grid assist float applications where mains power supply can be semi stable or in applications where power outages can be frequent and unscheduled leading to risk of uncontrolled partial state of charge cycling. F Float Cycle Life as a Function of Depth of Discharge 3000 2800 2600 2400 Number of Cycles 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 0 10 20 Figure 8 www.enersys-emea.com 30 40 50 60 70 80 % Depth of Discharge EnerSys World Headquarters 2366 Bernville Road Reading, PA 19605 USA Tel: +1 610 208 1991 +1 800 538 3627 Fax: +1 610 372 8613 EnerSys EMEA EH Europe GmbH Löwenstrasse 32 8001 Zürich Switzerland EnerSys Asia 152 Beach Road Gateway East Building Level 11 189721 Singapore Tel: +65 6508 1780 Contact: © 2013 EnerSys. All rights reserved. Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted. Publication No: EN-SBS-EON-AG-006 - December 2013 - Subject to revisions without prior notice. E.&O.E. Time (HRS) TIME(Hours) (HR RS) 20 Figure 9 0.2C10 Ampss 14 15 0.1C10A 0.1C10 Ampss 16