AQ-OP-00004_E Aquion Energy S10-0080 and S10

AQ-OP-00004_E Aquion Energy S10-0080 and S10
 Operations Manual Battery Stack Models S10-­‐008F, S10-­‐0080 Aquion Energy, Inc. www.aquionenergy.com AQ-­‐OP-­‐00004_E Table of Contents 1. General Information ................................................................................................................................ 5 1.1 About This Manual ............................................................................................................................ 5 1.2 Contact Information ......................................................................................................................... 5 2. Product Information ................................................................................................................................ 5 2.1 AHI™ Battery Technology ................................................................................................................. 5 2.2 S10-­‐0080 Battery Stack Overview ..................................................................................................... 5 2.3 Physical Characteristics ..................................................................................................................... 5 2.4 Terminal Overview ............................................................................................................................ 5 3. Safety Information ................................................................................................................................... 6 3.1 General Safety Information .............................................................................................................. 6 3.2 Electrical Hazards .............................................................................................................................. 6 3.3 Electrical Safety ................................................................................................................................. 6 3.4 Chemical Hazards .............................................................................................................................. 6 3.5 Mechanical Hazards .......................................................................................................................... 6 3.6 Transportation Hazards .................................................................................................................... 7 3.7 Weight Hazards ................................................................................................................................. 7 3.8 Environmental Considerations .......................................................................................................... 7 3.9 Recycling and Disposal ...................................................................................................................... 7 3.10 European Union Recycling Instructions .......................................................................................... 7 4. Receipt of Equipment .............................................................................................................................. 7 4.1 Delivery Inspection ........................................................................................................................... 7 4.2 Hidden Damage ................................................................................................................................ 7 4.3 Actions .............................................................................................................................................. 8 5. Installation Procedures ............................................................................................................................ 8 5.1 Unpacking ......................................................................................................................................... 8 5.2 Installation ........................................................................................................................................ 8 5.3 Electrical Interfaces and Connections ............................................................................................... 8 5.4 Wiring Diagrams ............................................................................................................................... 9 5.5 Ventilation Guidelines ....................................................................................................................... 9 6. Operation ................................................................................................................................................. 9 6.1 Configuration and Operation Requirements .................................................................................... 9 2 AQ-­‐OP-­‐00004_E 6.2 Initial Charge ................................................................................................................................... 10 6.3 Discharge/Charge Cycles ................................................................................................................. 10 6.4 State of Charge ............................................................................................................................... 12 6.5 Record Keeping ............................................................................................................................... 12 6.6 Operational Records ....................................................................................................................... 12 6.7 Long-­‐term Storage .......................................................................................................................... 13 6.8 Load Voltage vs. SOC ....................................................................................................................... 13 6.9 Energy Efficiency ............................................................................................................................. 16 7. Warranty ................................................................................................................................................ 17 8. Technical Support and Troubleshooting ................................................................................................ 17 9. Disclaimers ............................................................................................................................................. 17 Appendix A: Frequently Asked Questions ................................................................................................. 18 Appendix B: Product Specification Sheet .................................................................................................. 20 Appendix C: Operational Settings for Off Grid Power Control Electronics ................................................ 21 C.1 Operational Settings for Off Grid Power Control Electronics ......................................................... 21 C.1.1 Definitions .................................................................................................................................... 21 C.1.3 Voltage Limits vs. Temperature ................................................................................................... 21 C.1.4 How to Charge Aquion Batteries ................................................................................................. 21 C.1.5 About Temperature Compensation ............................................................................................. 22 C.2 Off Grid Device Specific Settings by Manufacturer ......................................................................... 22 C.2.1 Morningstar ................................................................................................................................. 22 C.2.2 Midnite Classic ............................................................................................................................. 23 C.2.3 Outback ........................................................................................................................................ 23 C.2.4 SMA Sunny Island ........................................................................................................................ 24 C.3 Grid Tied / UPS Device Specific Settings by Manufacturer ............................................................ 24 C.3.1 Morningstar ................................................................................................................................ 24 C.3.2 Midnite Classic ............................................................................................................................ 26 C.3.3 Outback ....................................................................................................................................... 26 C.3.4 SMA Sunny Island ....................................................................................................................... 26 C.4 Reference Cycles for Lab Use ......................................................................................................... 27 3 AQ-­‐OP-­‐00004_E 4 AQ-­‐OP-­‐00004_E 1. General Information 1.1 About This Manual This manual is intended to provide technical information and safe practices regarding receiving, installing, operating, and servicing the Aquion Energy S10-­‐0080 Battery Stack. For complete safety information, refer to the Safety Data Sheet (SDS) included with your product shipment. NOTICE: Failure to follow the instructions in this document could result in fire, electric shock, and/or other injury or damage. 1.2 Contact Information Aquion Energy, Inc. 32 39th Street Pittsburgh, PA 15201 412.904.6400 www.aquionenergy.com 2. Product Information 2.1 AHI™ Battery Technology Aquion Energy’s Aqueous Hybrid Ion (AHI™) batteries are optimized for stationary applications with greater than 4 hour charge/discharge rates. The batteries are designed for extremely long cycle life at full depth of discharge with minimal degradation, the ability to stand at partial state of charge with minimal self-­‐discharge or loss in function, and extensive fault tolerance. 2.2 S10-­‐0080 Battery Stack Overview The S10-­‐0080 Battery Stack (hereafter “Battery Stack”) is the base component of Aquion Energy’s scalable energy solutions. The Battery Stack is composed of eight B10 batteries connected in series, built to be voltage-­‐optimized for safety and system architecture. The S10-­‐008F includes an in-­‐line 15A fuse. Battery Stacks can be scaled in series or parallel for a wide range of stationary system requirements. For detailed specifications, please see Appendix B: Product Specification Sheet. 2.3 Physical Characteristics ●
For product physical characteristics and measurements, please see Appendix B: Product Specification Sheet. 2.4 Terminal Overview ●
The terminal of each Battery Stack uses standard Amphenol H4CPC4DI (Helios H4) 12 AWG, male (positive) and female (negative) connectors. 5 AQ-­‐OP-­‐00004_E 3. Safety Information 3.1 General Safety Information ●
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Only qualified individuals are to service battery systems. The Battery Stack is designed to be compliant with ANSI/UL 1973 and certification is in process. Certification tests include: UL1973-­‐23 Vibration UL1973-­‐24 Shock UL1973-­‐25 Crush UL1973-­‐26 Static Force UL1973-­‐27 Impact UL1973-­‐35 Salt Fog UL1973-­‐36 External Fire Exposure 3.2 Electrical Hazards ●
●
Electrical hazards exist in the voltage and current ranges that are found in battery systems and associated electronics. Never place foreign objects or tools in or on the unit as the metal parts of the battery terminals are always live. WARNING: Connecting Battery Stacks in series can lead to dangerously high voltages. When connecting S10-­‐0080’s in parallel, 15 A branch fuses are recommended and should be placed as close to the Battery Stack positive (recommended) or negative terminal as possible. 3.3 Electrical Safety ●
Aquion recommends fusing S10-­‐0080 strings with 1000 V, 15 A fuses at the positive (+) lead of each string of battery stacks (or all battery stacks if they are all connected in parallel). The S10-­‐
008F already contains an in-­‐line fuse, and additional fusing at each stack is not necessary. 3.4 Chemical Hazards ●
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AHI battery materials are non-­‐toxic and contain no chemical hazards. Electrolyte spillage is not a concern with AHI batteries. The electrolyte is sodium sulfate-­‐based saltwater with a neutral pH. In the unlikely event that electrolyte comes in contact with eyes or skin, thoroughly wash out with water. Electrolyte residue on the battery terminal can be wiped away with a cloth. Reference the SDS for additional information. Overcharging the battery will result in venting of non-­‐flammable gas, primarily composed of CO2 and CO, through the pressure relief valve. 3.5 Mechanical Hazards ●
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AHI Battery Stacks are compressed and designed to never be dismantled. WARNING: Do NOT attempt to disassemble Battery Stacks. Do NOT remove the nut on the compression fixture on top of the Stack. Battery Stacks have been compressed to optimize battery performance. Releasing this load could result in poor battery performance, permanent 6 AQ-­‐OP-­‐00004_E damage to Stack components, and/or injury. 3.6 Transportation Hazards ●
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AHI battery products have no hazardous classifications and can be shipped as standard goods. The AHI battery has also undergone International Safe Transit Association Testing for shock, vibration, thermal shock, and altitude. Battery Stacks shall not exceed 15° tilt angle during transportation and placement. 3.7 Weight Hazards ●
The Battery Stack weighs 113 kg (249 lbs) and must be transported and handled with appropriate precautions. 3.8 Environmental Considerations ●
Under normal conditions, AHI materials are contained and pose no known risk to persons or the surrounding environment. The product is not classified as environmentally hazardous. 3.9 Recycling and Disposal ●
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AHI batteries are non-­‐toxic, non-­‐corrosive, and can be disposed of as ordinary trash or through proper recycling channels. Follow all local laws and regulations regarding disposal. Reference Aquion Energy’s website at http://www.aquionenergy.com/collection-­‐recycling-­‐
waste-­‐batteries for additional information. 3.10 European Union Recycling Instructions EU regulation 2006/66/EC requires that industrial batteries be collected and disposed of in compliance with a qualified recycling program at end-­‐of-­‐life. Please contact your Aquion Sales Representative or Aquion Headquarters to arrange for freight prepaid shipping or collection by an authorized recycler. Failure to comply with EU regulation 2006/66/EC may subject the end user of the Aquion batteries to significant sanctions. Do not dispose of or attempt to recycle Aquion products without contacting an Aquion representative for instructions. 4. Receipt of Equipment 4.1 Delivery Inspection ●
Immediately upon delivery, inspect all hard goods for signs of damage during transit. This may be evidenced by damaged pallets or packaging. Thoroughly document all instances of product damage and make a claim with the carrier as soon as possible. Contact Aquion Energy for further support. 4.2 Hidden Damage ●
Within 10 days of receipt, a visual inspection must be performed. If any damage is found, request an inspection by the carrier and file a hidden damage claim. Do not delay this step as it may result in a loss of right of reimbursement for hidden damages. 7 AQ-­‐OP-­‐00004_E 4.3 Actions ●
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If, upon delivery, equipment appears to be damaged, do not accept the shipment. If you have accepted shipment and equipment in the shipment appears to be damaged, please contact your appropriate support representative. For technical support contact information, please see Technical Support below. 5. Installation Procedures
5.1 Unpacking ●
Battery Stacks are shipped on pallets. All accessories needed for installation and use are packed in boxes and secured to the pallet. Unpack all items carefully and note quantities received. Contact Aquion Energy if any items are missing or damaged. 5.2 Installation ●
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Battery Stacks should be positioned on flat level surfaces rated for the appropriate weight of the Stacks. Battery Stacks should be installed in the vertical orientation and must not exceed 15° tilt angle. Do not stack Battery Stacks on top of each other. 5.3 Electrical Interfaces and Connections The negative (black) and positive (red) leads are the Amphenol H4CPC4DI (Helios H4) 12 AWG, male (positive) and female (negative) connectors at the top of the Battery Stack. 8 AQ-­‐OP-­‐00004_E 5.4 Wiring Diagrams The 12 AWG jumpers are 180mm cables with AEH4 connectors ordered from Aquion Energy (P/N: 410-­‐
0000001-­‐001). 5.5 Ventilation Guidelines ●
Per IBC and NFPA 1 guidelines, ventilation is required for installations in enclosed spaces equal to either six (6) air changes per hour or ventilation at 1 cfm/sq.ft of room size 6. Operation 6.1 Configuration and Operation Requirements The following system design configurations must followed. Contact Aquion before attempting to install a system outside of these parameters. ● Battery Stacks must be installed in a dry environment. ○ The S10-­‐0080 stack is IP22 rated. Direct exposure to water may cause shorting. ● The unit may be installed in coastal regions with atmospheric salt. ● Battery Stacks must not be operated or stored under direct exposure to sunlight. ○ Prolonged exposure to UV light may damage the battery casing and reduce product lifetime. ● Battery stacks may be stored at 0 – 100% SOC without significant performance loss. ○ For best results over long-­‐term storage, it is recommended to keep the battery at ≤50% SOC (<48V) and ≤40°C. ● Battery Stacks must be operated in temperatures between -­‐5C and 40C on a 24 hour average. 9 AQ-­‐OP-­‐00004_E ○
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Operation above or below these limits will cause advanced degradation of the battery chemistry. Battery stacks must be stored in temperatures between -­‐20C and 50C. ○ Storage above or below these limits may cause permanent damage to the stack. Battery Stacks must be kept between 40 and 59Vdc after initial charge. ○ Operation or storage above or below these voltage limits will cause damage to the battery chemistry. Battery Stacks must be charged or discharged with less than or equal to 15A of current. ○ If installed properly, there is a 15A fuse connected in-­‐line. Battery Stacks may be operated in systems up to 1000Vdc. Battery Stacks may be wired together in PARALLEL configurations up to 48 stacks per inverter or power control system. If wiring Battery Stacks in series, voltage monitoring must be performed on each stack to ensure that voltage limitations are followed. 6.2 Initial Charge The Battery Stack should arrive with an initial voltage greater than 32 Vdc. If the initial voltage is insufficient for charging power electronics, the Battery Stack can be charged using a battery charging device set to the operating limits of the Stacks as defined in Appendix B. Please note, most DC power supplies are not designed to charge batteries and lack sufficient reverse current protection. Use only power supplies designed to charge batteries. If the Stacks are to be installed in a series configuration, it is important to match the Stacks to be within 5% state of charge with each other. Ideally before Stacks are connected in series they should be taken to full discharge 40 +/-­‐ 1 V at open circuit. If Stacks or series strings of Stacks are to be wired in parallel, it is important to match the string voltages within 5 Vdc. The high impedance of the AHI battery limits the short circuit current of the battery. Care must still be taken however, when ‘live parallel bussing’ batteries with non-­‐equal open circuit voltages. The current created in this situation may still be sufficient to cause an arc or cause a fuse to blow. During its initial charge cycles, it is normal for the battery to accept more energy before it reaches its max voltage. This is the normal conditioning process that occurs in the battery. It is not necessary for a specific conditioning procedure to be used. 6.3 Discharge/Charge Cycles The AHI battery chemistry can accept any charge or discharge profile or algorithm that respects the operating limits defined in the Product Specification Sheet, Appendix B. For example, the battery can accept charging up to the recommended current limit as long as the upper voltage limit is not exceeded. 10 AQ-­‐OP-­‐00004_E 70
60
60
50
50
Stack Voltage (V)
Stack Voltage (V)
70
40
30
20
10
0
40
30
20
10
0
10
20
30
40
0
50
Charge capacity (Ah)
0
250
500
750
1000 1250 1500 1750 2000
Charge energy (Wh)
If a three stage charge profile is used, a higher voltage can be used for absorption charging, the following values can be used: Bulk Charge Current: 15 A max, recommended current for full charging: 4 A or less Maximum Voltage: 59 Vdc max Longest Duration at Max Voltage: Constant V to 1 A Long-­‐term voltage to prevent degradation (24 hours): 52.8 Vdc max It is not required to charge the battery to 100% SOC daily or periodically to maintain battery life. The AHI battery chemistry can be maintained at a partial or low state of charge indefinitely. The Stack can be discharged within its operating limits as well, as defined in the Product Specification Sheet, Appendix B. Please note that the AHI battery is designed for long duration charge/discharge. As a result of the high battery impedance, its voltage response to high current levels will be higher than equivalent capacity Lead Acid or Li-­‐ion battery solutions. It may be required to adjust supplemental charger settings (i.e. generator or grid tie) such that at low battery SOC, high inrush loads will not cause 11 AQ-­‐OP-­‐00004_E the power electronics into a low battery fault condition. 6.4 State of Charge S10-0080 Open Circuit Voltage [V]
60
57.5
55
52.5
50
47.5
45
42.5
40
37.5
35
0
20
40
60
80
100
State-of-Charge [%]
(Relaxed open circuit voltage) 6.5 Record Keeping Aquion Energy recommends maintaining proper system documentation records. This includes: a single line diagram of the complete system and a log documenting system settings (inverter, charge controller, charge voltages, etc.). Record Description Frequency Single line system diagram complete AC and DC system diagram at installation or upon change System component settings charge voltage and current settings at installation or upon change 6.6 Operational Records Aquion Energy recommends maintaining proper and regular operating records which include: battery temperatures, maximum and minimum operating voltages, and maximum currents. For module based systems that include the optional Aquion Energy BMS, this data is logged automatically. Measurement Description Frequency Average Battery Temperature daily average temperature logged every 24 hrs 12 AQ-­‐OP-­‐00004_E Minimum Battery Voltage daily minimum voltage logged every 24 hrs Maximum Battery Voltage daily maximum voltage logged every 24 hrs Maximum Battery Current daily maximum current logged every 24 hrs 6.7 Long-­‐term Storage If the Battery Stack is to be stored for an extended period of time, remove all signal and power connections to prevent unintended self-­‐discharge and undetected ground faults. Keep any grounding in place. 6.8 Load Voltage vs. SOC SOC 100 99 98 97 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 Voltage (2A CC) Voltage (4A CC) Voltage (6A CC) Voltage (8A CC) Voltage (10A CC) 57.752 54.44 54.056 52.968 51.744 54.17314286 51.88138182 50.40114286 48.83211881 47.46171429 53.80510145 51.63005291 49.912 48.58531796 47.09828571 53.62787097 51.47113122 49.87718367 48.37881188 46.95537877 53.50114286 51.33995745 49.73371429 48.31214521 46.82644538 53.36205714 51.23512727 49.7352449 48.25009901 46.71402679 53.136 51.13542081 49.77681633 48.1459802 46.6257479 52.97548201 51.1106455 49.63670588 48.04528501 46.58444538 52.73691429 50.99538182 49.57401788 47.96191118 46.55923529 52.4952 50.90201058 49.55673469 47.88440924 46.48010084 52.4203871 50.81542081 49.42465306 47.80344257 46.38117542 52.33750725 50.72516364 49.31614286 47.7249901 46.30978151 52.21405714 50.64 49.22897959 47.65533844 46.21463866 52.10150538 50.54657014 49.09951918 47.57766337 46.13810714 51.9688 50.44596825 49.00187755 47.50115773 46.05257143 51.8712 50.34916364 49.00028571 47.41499835 45.98441117 51.7452043 50.256 48.84128571 47.33185911 45.91157143 51.60929032 50.16514027 48.75036735 47.24435644 45.8428 51.488 50.064 48.76065306 47.16888303 45.78523529 51.28150725 49.97904762 48.66042857 47.09611881 45.71730357 51.14726882 49.88 48.55967347 47.01930033 45.63690756 51.08045714 49.81765079 48.46744898 46.92705666 45.55973214 50.90852174 49.712 48.35731969 46.83891749 45.48264984 50.74322581 49.65085973 48.28057143 46.75369066 45.40746429 50.55874286 49.56 48.18444898 46.61953213 45.31260504 50.43062857 49.46025455 48.06697959 46.53598775 45.234 50.27896774 49.35068783 47.98883673 46.43889292 45.18063866 50.11389247 49.25085973 47.8817551 46.3674242 45.10309244 49.95314286 49.14861818 47.79118367 46.27776898 45.02663687 49.91428571 49.03625455 47.68461224 46.20091884 44.94645378 13 AQ-­‐OP-­‐00004_E 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 49.81083871 49.69965714 49.57165714 49.456 49.34034286 49.24614493 49.15853763 49.06451613 48.97668571 48.896 48.816 48.73913043 48.664 48.58830108 48.51768116 48.448 48.37419355 48.30408602 48.23222857 48.168 48.09797849 48.032 47.96 47.896 47.81828571 47.74102857 47.66976344 47.59965217 47.52 47.448 47.38563441 47.30605714 47.23405714 47.15544086 47.08 47.00457143 46.92 46.84708571 46.75907246 46.672 46.592 46.49750725 46.40948571 46.31019355 48.92057919 48.80198942 48.69149091 48.56901587 48.46457919 48.34887273 48.23604255 48.11315837 48.00596825 47.90887273 47.81141818 47.71315837 47.62112727 47.53104762 47.44112727 47.35026244 47.26741818 47.17744796 47.09866667 47.02139367 46.9373545 46.86229864 46.78516364 46.712 46.64857919 46.56232804 46.49258182 46.412 46.34457919 46.268 46.192 46.122 46.04684163 45.966 45.89141818 45.81934392 45.74226244 45.65904762 45.58283636 45.50255204 45.42196825 45.33773756 45.25333333 45.16655204 47.61338776 47.50224041 47.41134694 47.30644898 47.21189796 47.12530612 47.01885714 46.94428571 46.85142857 46.75942857 46.6792449 46.59310204 46.52118367 46.4204898 46.33467347 46.24530612 46.16359184 46.08740816 46.00816327 45.93453061 45.85561224 45.77910204 45.70538776 45.63167347 45.55804082 45.4852449 45.41061224 45.32089796 45.24544898 45.17616327 45.10783673 45.03759184 44.96830691 44.89477551 44.82906122 44.75534694 44.67363265 44.606 44.52871429 44.45142857 44.37414286 44.29714578 44.21963265 44.14179592 14 46.12910891 46.04562376 45.96088303 45.88517492 45.819229 45.74029654 45.65073201 45.57605272 45.49321899 45.41960396 45.34564165 45.26572937 45.19006432 45.10986139 45.04183767 44.96801318 44.88913531 44.81655446 44.74740033 44.67808882 44.60737954 44.53419908 44.46384158 44.39431547 44.32568977 44.25646554 44.19679736 44.13351302 44.06793399 43.99762768 43.93330693 43.86818482 43.80224053 43.73520792 43.6725758 43.60247776 43.53472588 43.46558416 43.40139663 43.33383498 43.26330168 43.19189439 43.1211026 43.05002965 44.90098214 44.81868908 44.74341071 44.66052941 44.59627263 44.52373109 44.44216071 44.37847059 44.29460714 44.2257479 44.16209464 44.08692857 44.01841176 43.95358036 43.8782521 43.80921429 43.74902521 43.69673296 43.62796639 43.55542857 43.50164706 43.43257143 43.3735 43.3115205 43.2519375 43.19302521 43.1384375 43.07381513 43.013375 42.9667479 42.91139218 42.85164706 42.78271429 42.73793277 42.67561345 42.6013676 42.53958824 42.482125 42.42664706 42.3663125 42.29705042 42.23383929 42.19355626 42.13925 AQ-­‐OP-­‐00004_E 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 46.21205797 46.1 46.00498925 45.904 45.79851429 45.67886957 45.56077419 45.44102857 45.31292754 45.19466667 45.05954286 44.91542857 44.768 44.62205714 44.46194286 44.29445161 44.12040561 43.92896275 43.71284935 43.47655914 43.22793687 42.94480229 42.60031862 42.17944986 41.64064275 40.91034839 39.92 45.07487273 44.98660633 44.89487273 44.80495238 44.70687273 44.60713122 44.50287273 44.39512727 44.29003175 44.17513122 44.05195745 43.92683636 43.79656109 43.6626455 43.51663348 43.35602116 43.18568192 43.00085261 42.80685714 42.59143401 42.35266914 42.08456417 41.776 41.42572336 41.008 40.51098413 39.888 44.06008163 43.97695918 43.88873469 43.79902041 43.70930612 43.61338776 43.51435294 43.4162449 43.31816327 43.21602041 43.09665306 42.97983673 42.85963265 42.73706122 42.60357143 42.46071429 42.31768744 42.15852949 41.98713914 41.79871739 41.60144805 41.38542762 41.1403421 40.87379934 42.97614521 42.90336634 42.82791433 42.74898622 42.67326733 42.58928025 42.51176238 42.42941501 42.33937954 42.24992343 42.15093245 42.05535069 41.95409901 41.84888303 41.73017822 41.6169505 41.50597264 41.38067546 41.24982542 41.11685356 40.98230934 40.83347254 40.66679449 40.49525977 40.30467994 39.872 39.872 42.07976471 42.01 41.94310714 41.89566387 41.82923799 41.76770588 41.7076875 41.64315966 41.57392857 41.50494118 41.43507143 41.36667087 41.28916071 41.22043697 41.13280672 41.04985714 40.97602522 40.8907006 40.80607879 40.71811922 40.61823889 40.51779772 40.42015926 40.21663956 40.36985844 40 15 AQ-­‐OP-­‐00004_E 6.9 Energy Efficiency Current (A) 0C low SOC 0C 50% SOC 0C high SOC 10C low SOC 10C 50% SOC 10C high SOC 30C low SOC 30C 50% SOC 30C high SOC 40C low SOC 2 88.167 88.005 89.188 90.3 90.475 89.798 87.653 91.531 91.403 90.67 4 78.726 77.849 79.725 82.324 82.144 81.022 78.86 83.876 83.849 82.955 6 70.518 69.996 71.08 75.07 74.169 72.824 72.769 76.633 76.619 75.912 16 8 63.565 61.995 68.288 67.708 68.001 70.209 70.31 69.152 9.9 61.936 62.177 60.911 64.689 65.126 63.617 AQ-­‐OP-­‐00004_E 40C 50% SOC 40C high SOC 50C low SOC 50C 50% SOC 50C high SOC 91.205 90.915 90.826 91.119 92.048 83.375 82.839 83.054 84.219 84.948 76.232 74.986 75.975 77.563 77.762 69.161 67.066 70.498 71.248 72.113 63.702 65.611 66.339 67.06 7. Warranty Please see the Terms and Conditions and/or separate warranty documentation for warranty information. 8. Technical Support and Troubleshooting Please contact your sales representative for support. 9. Disclaimers Information depicted within this document is subject to periodic updates and changes. Upon any updates or changes to the above-­‐described material, Aquion Energy will provide new drawings and/or associated documentation that will supersede those contained in this document. Contents subject to change without notice. 17 AQ-­‐OP-­‐00004_E Appendix A: Frequently Asked Questions What sub-­‐string balancing issues, if any, must be managed when using AHI batteries? Other battery chemistries require battery equalization, hence the need for a BMS or string size limitations. The AHI chemistry does not require balancing and is considered to be self-­‐balancing. Although Aquion Energy offers a BMS for certain applications, AHI batteries do not require a traditional BMS. There are no passive or active balancing electronics in the Aquion Energy equipment. In products that do employ a BMS, Aquion Energy’s BMS serves as a monitoring and communication device. What do we require for conditioning-­‐based monitoring to ensure that the individual cells, batteries, Stacks, and modules are functioning properly? Due to the nature of the chemistry, AHI batteries do not require maintenance cycling or conditioning. The best way to verify proper functionality is to monitor the battery capacity during operation. Please reference the Product Specification Sheet, Appendix B as a reference for expected energy based on the charge and discharge duration. At high voltages, what are operational issues that can be expected with regard to the proper functioning of cells and batteries? Can you destroy an individual cell or battery? If so, what is the effect on the string? The amount of voltage is not an issue as long as the system is sized properly. With respect to voltage, the failure mode to be mindful of is overcharge. The voltage range of your product is specified in the Product Specification Sheet, Appendix B. AHI batteries can be sized to meet most voltage needs as long as the provided voltage window is followed. Excessive overcharge can destroy a battery and invalidate its warranty. Depending on the system configuration, doing so could either result in the loss of a portion of the complete system’s capacity or even result in rendering the entire system useless. What are the concerns involving degradation? Overcharge will lead to early degradation problems. Loss of electrolyte from overcharge or from exposing the batteries to temperatures outside of the range specified in the Product Specification Sheet, Appendix B, will cause degradation in performance. Will the batteries be “dead” after they have been used more than the specified number of cycles in your Product Specification Sheet? No. End of life is considered a loss of 20% of a battery’s original capacity. The batteries do not experience a “death” at that point. They can be cycled further with a reduction of capacity. Are there any rules like the UN38.3 for the transportation of your batteries? No, AHI batteries can be shipped as standard goods. 18 AQ-­‐OP-­‐00004_E How much do the batteries self-­‐discharge? The self-­‐discharge of the Aquion AHI battery chemistry is highly related to the ambient temperature at which the battery is being held. Aquion batteries should be held within the temperatures ranges outlined in the product specification sheet (see Appendix B: Product Specification Sheet). Aquion batteries exhibit the following self-­‐discharge rates over the course of one (1) month: • -­‐5C: <2% self discharge capacity loss • 10C: 5% • 30C: 25% • 40C: > 35% It is important to note that for the AHI battery chemistry, self-­‐discharge is not an irreversible capacity loss -­‐ the capacity that is lost over a month can be recovered by simply recharging the battery to 100% state of charge. 19 AQ-­‐OP-­‐00004_E Appendix B: Product Specification Sheet To download the latest version of Aquion Energy Product Specification Sheets, please visit the Aquion Energy Customer Portal at: http://info.aquionenergy.com/customer-­‐portal 20 AQ-­‐OP-­‐00004_E Appendix C: Operational Settings for Off Grid Power Control Electronics C.1 Operational Settings for Off Grid Power Control Electronics The Aquion Energy battery is uniquely suited to off grid applications due to it’s INSERT good stuff. While the battery chemistry is very different from 2V/cell based lead acid batteries, the 8-­‐stack line is designed to be compatible with the majority of charge controllers and inverters desgined for lead acid technology. The common al Lead Acid charge profile of Bulk -­‐ Absorb – Float can be applied to the Aquion Energy battery if the proper voltage, time and temperature compensation settings are used. The Aquion Energy battery does not require a float current, as lead acid chemistries do – but there is a regulation voltage at which the battery can be held at following its absorption charge cycle. C.1.1 Definitions Bulk Current – maximum current which the battery can be charged. Absorption voltage– voltage at which battery can be maintained in the constant voltage ‘absorption’ stage of the charge profile. This condition allows the batter to charge at a faster rate. Absorption time-­‐ length of time that battery should be held at absorption voltage Hold Voltage aka float voltage -­‐ voltage at which the battery can be held following the absorption phase. The purpose of this stage is to allow the battery to maintain a full state of charge in conditions where the system is generating more power than is required by the system loads. C.1.3 Voltage Limits vs. Temperature The table below shows the appropriate voltage limits through the operating temperature range. Temp (⁰C) Vmax <10 67.52 10 65.92 <20 64 20 62.72 25 61.12 30 59.52 35 57.92 40 56.32 C.1.4 How to Charge Aquion Batteries All off grid devices power control devices which have temperature compensation have a battery temperature sensor accessory. Install the battery temperature sensor to the side of the uppermost battery, which is located in the center of the battery, as seen in the figure below. It is recommended 21 AQ-­‐OP-­‐00004_E that the sensor be attached with high quality tape, in addition the self adhesive which may be included with the sensor. C.1.5 About Temperature Compensation The Aquion battery is capable of operating at ambient temperatures higher than lead acid batteries. As such, the reference temperature for the battery is 30C, rather than the 25C typical of Lead Acid technologies. Since most off grid power electronics are designed to use 25C as the reference temperature and have varying temperature compensation functions, care must be taken when selecting the appropriate charge settings. For your convenience, the appropriate settings for several devices can be found below. If your device is not shown, please derive the settings from the table above or contact Aquion Energy applications engineering for assistance. C.2 Off Grid Device Specific Settings by Manufacturer C.2.1 Morningstar Several Morningstar charge controllers can be configured using their serial/Modbus adapter and the MSView software. The charge controllers operate in several voltage ranges ( 12/24Vdc or 24/48Vdc ) depending on the initial battery voltage when power is connected. Sunsaver MPPT Charge Settings Absorption Voltage Float Voltage Disable Float Float – Low Battery Threshold Float – Cancel Threshold Time Before Float Time before Float – Low Battery Time unit float exit Equalize Voltage Disable Equalize Days between Equalizations Equalize Duration Equalize Timeout Shared Settings Temperature Compensation Battery High Voltage Disconnect Battery High Voltage Reconnect Max. Regulation Voltage Limit Max. Temp Compensation Limit Min, Temp Compensation Limit 15.2 13.5 Not Checked 12.0 9 120 120 60 14 ( Default) Checked 28 ( default) 60 (default) 180 min (default) -­‐.080 16.0 15.8 16.0 80C 16C 22 AQ-­‐OP-­‐00004_E Tristar TS-­‐60 MPPT Charge Mode – PWM,Temp Comp, &Reminder Absorption Voltage Absorption Time Enable Absorption Extension Battery Temperature Compensation Maximum Compensation Temp Minimum Compensation Temp Enable Maximum Regulation Limit Maximum Regulation Limit Enable Battery Current Limit Battery Current Limit Enable Battery Service Reminder Charge Mode – Float Settings Enable Float Float Voltage Float Timeout Enable Float Cancel Charge Mode – Equalize & HVD Settings Enable Equalize Enable Battery HVD High Voltage Disconnect High Voltage Reconnect 15.3 120 Disable -­‐.080 80C 16C Checked 16.0 enable 12A/Stack unchecked checked 13.6 disable unchecked checked 16.0 15.8 C.2.2 Midnite Classic T-­‐Comp Equalization Current Limit – CHARGE>LIMITS>Out Amps Absorb Voltage – CHARGE> VOLTS>Absorb Volts Equalize Voltage – CHARGE> VOLTS>Equalize Volts Float Voltage – CHARGE> VOLTS>Float Volts Absorb Time -­‐ -­‐.008 As Equalization is not needed, verify that CHARGE>EQ>AUTOEQ>AUTO = 0 12A/stack 60.7 60.7 54.0 120 minutes C.2.3 Outback Charger Menu Output Current Limit Absorb Voltage Float Voltage 12A/Stack 60.3 53.6 23 AQ-­‐OP-­‐00004_E EQ Battery Equalize Volts Battery Equalize Time Advanced Menu Absorb Time Limit Absorb End Amps Rebulk Voltage RTS Compensation – RTS Compensation – Upper Limit RTS Compensation – Lower Limit 60.3 0 120A 1A/stack Wide C.2.4 SMA Sunny Island 8 9 10 12 15 18 19 23 41 42 43 44 BatChrgCurMax BatChrgVtgMan BatCpyNom BatPro1Soc BatPro2Soc BatPro3Soc BatTmpCps BatVtgNom ChrgVtgBoost ChrgVtgEqu ChrgVtgFlo ChrgVtgFul 120A/Module 59V 489 Ah 25% 30% 25% 10 mV/degC 48 V 2.52 V 2.52 V 2.25 V 2.52 V C.3 Grid Tied / UPS Device Specific Settings by Manufacturer If the battery is to be used primarily in a grid tied, UPS type application there are different settings which should be used. In Off-­‐grid, solar/battery charged applications the goal is to charge the battery as fast as possible when power is available. In the UPS use case, the emphasis is on providing voltage settings which ensure the long term life of the battery and maximum available energy when required. In order to achieve this goal, the battery will be held at a slightly lower float voltage and a periodic equalize cycle will ensure the battery is held at a high state of charge. C.3.1 Morningstar Several Morningstar charge controllers can be configured using their serial/Modbus adapter and the MSView software. The charge controllers operate in several voltage ranges ( 12/24Vdc or 24/48Vdc ) depending on the initial battery voltage when power is connected. Sunsaver MPPT Charge Settings 24 AQ-­‐OP-­‐00004_E Absorption Voltage Float Voltage Disable Float Float – Low Battery Threshold Float – Cancel Threshold Time Before Float Time before Float – Low Battery Time unit float exit Equalize Voltage Disable Equalize Days between Equalizations Equalize Duration Equalize Timeout Shared Settings Temperature Compensation Battery High Voltage Disconnect Battery High Voltage Reconnect Max. Regulation Voltage Limit Max. Temp Compensation Limit Min, Temp Compensation Limit 15.2 13.5 Not Checked 12.0 9 120 120 60 14 ( Default) Checked 28 ( default) 60 (default) 180 min (default) -­‐.080 Tristar MPPT Charge Mode – PWM,Temp Comp, &Reminder Absorption Voltage Absorption Time Enable Absorption Extension Battery Temperature Compensation Maximum Compensation Temp Minimum Compensation Temp Enable Maximum Regulation Limit Maximum Regulation Limit Enable Battery Current Limit Battery Current Limit Enable Battery Service Reminder Charge Mode – Float Settings Enable Float Float Voltage Float Timeout Enable Float Cancel Charge Mode – Equalize & HVD Settings Enable Equalize Enable Battery HVD Disable 25 AQ-­‐OP-­‐00004_E High Voltage Disconnect High Voltage Reconnect C.3.2 Midnite Classic T-­‐Comp Equalization – As Equalization is not needed, verify that CHARGE>EQ>AUTOEQ>AUTO = 0 120 minutes Current Limit – CHARGE>LIMITS>Out Amps Absorb Voltage – CHARGE> VOLTS>Absorb Volts Equalize Voltage – CHARGE> VOLTS>Equalize Volts Float Voltage – CHARGE> VOLTS>Float Volts Absorb Time -­‐ C.3.3 Outback Charger Menu Output Current Limit Absorb Voltage Float Voltage EQ Battery Equalize Volts Battery Equalize Time Advanced Menu Absorb Time Limit Absorb End Amps Rebulk Voltage RTS Compensation – Wide RTS Compensation – Upper Limit RTS Compensation – Lower Limit C.3.4 SMA Sunny Island 8 9 10 12 15 18 19 23 41 42 BatChrgCurMax BatChrgVtgMan BatCpyNom BatPro1Soc BatPro2Soc BatPro3Soc BatTmpCps BatVtgNom ChrgVtgBoost ChrgVtgEqu 26 120A/Module 59V 489 Ah 25% 30% 25% 10 mV/degC 48 V 2.52 V 2.52 V AQ-­‐OP-­‐00004_E 43 44 ChrgVtgFlo ChrgVtgFul 2.25 V 2.52 V C.4 Reference Cycles for Lab Use It is common to perform reference cycles to verify the capacity of the battery in a lab environment. Due to the unique characteristics of the Aquion Battery, it is important to use a standard test plan in order to ensure the results can be compared to the manufacturer specifications. Please use the following parameters when performing reference cycles: step Mode Value End Type 1 Constant Current Charge 2A 60.8V 2 Constant Voltage Charge 60.8V 1A 3 Constant Current Discharge 2A 30.4V 4 Rest 0A 2 hours 27 AQ-­‐OP-­‐00004_E 
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