This document describes the installation and operating instructions for FIAMM Energy Technology's Valve Regulated Lead Acid (VRLA) batteries, specifically those utilizing Absorbent Glass Mat (AGM) technology.
Function Description
FIAMM AGM batteries serve as a backup power source, crucial in high-technological environments to prevent losses and damages caused by mains power failures. They are designed to provide reliable and stable power throughout their service life. The batteries are primarily used in standby applications where they are kept in a fully charged state (float charging) and are ready to deliver power upon discharge. They are capable of handling various discharge rates and temperatures, with specific models optimized for different applications.
Important Technical Specifications
Construction Features:
- Plates: Both positive and negative plates are of the flat pasted type, made from a lead oxide paste with calcium and tin grids for corrosion resistance.
- Containers: Battery cases and lids are made of shock-resistant and flame-retardant ABS material, complying with American Standards UL 94 (V-0 or IEC 707, method FV0). They are designed to withstand internal pressure variations and feature reinforced walls and lids. Some models include handles for easier handling.
- Separators: Made of glass microfiber mats with high porosity and small pore diameters, ensuring maximum oxygen diffusion, high plate utilization, and low internal resistance. The plates are completely wrapped by the separator, which fully absorbs the electrolyte, preventing active material shedding.
- Electrolyte: Sulphuric acid with a specific gravity of 1.3 at 20°C, maintaining the purity characteristics of high-quality lead-acid batteries.
- Valves: Each cell has a one-way safety valve that releases gases if internal pressure exceeds 0.15-0.30 atmospheres (15-30 kPa).
- Terminal Posts: Feature threaded designs ('female' or 'faston' pole) with solid connectors for low ohmic losses. Posts to lid seals prevent leakage. Intercell connections are electrically welded through cell walls to minimize internal impedance. Special plastic terminal caps are provided for short-circuit protection during transportation.
- Connections: Solid connectors are made of tin or lead-plated copper, with insulated plastic covers made of ABS-V0. Front terminal connections for FIT range use a special "L" clamp.
- Remote Venting System (RVS): An optional central degassing system on the top lid is available for batteries installed in sealed cabinets, allowing gases to be conducted outside the cabinet.
Operating Features:
- Capacity: Rated in ampere-hours (Ah), dependent on active material quantity, discharge rate, temperature, and minimum voltage. Nominal capacity refers to 10-hour (C10) or 20-hour (C20) discharge rates at 20°C to 1.80 V/cell (C10) or 1.75 V/cell (C20).
- Capacity Range: FET AGM Lead Acid Batteries offer a wide range of capacities:
- FG: 1.2 to 70 Ah
- FGC: 12 to 42 Ah
- FGH: 5 to 18 Ah
- FGHL: 5 to 12 Ah
- FGL: 17 to 205 Ah
- FIT: 40 to 195 Ah
- FHT: 95 to 180 Ah
- SLA: 25 to 2000 Ah
- FLB: 26 to 235 Ah
- Temperature Dependence: Available capacity varies with temperature. A correction factor is provided for operation at temperatures different from 20°C.
- Internal Impedance and Short Circuit Current: Values are provided in the Product Sheet, calculated according to IEC 60896 part 21/22.
- Service Life: Considered at an end when delivering less than 80% of nominal capacity. Recommended operating temperature is 10°C to 30°C (FHT up to 45°C), with operation at higher temperatures reducing life expectancy.
- Gassing: High recombination efficiency (>98%) means virtually negligible gassing at 20°C under normal conditions. Gassing rates are 2 ml/Ah/cell/month at 2.27 V/cell float voltage and 10 ml/Ah/cell/month at 2.40 V/cell recharge voltage.
- Open Circuit Voltage (OCV): Provides an approximate indication of the state of charge when the battery is disconnected from the charger for at least 24 hours.
Charging:
- Floating Charge: Recommended voltage is 2.27 V/cell at 20°C. Float voltages vary with temperature (formula: -2.5mV/cell/°C). Normal float current for fully charged front terminal batteries at 2.27 VPC and 20°C is approximately 0.3 mA/Ah.
- Boost Charge: Used after discharge to restore full charge quickly. Constant voltage of 2.40 V/cell at 20°C with a maximum current of 0.25 C10. Limited to once per month to ensure maximum service life, with temperature remaining below 35°C.
Ventilation (EN 50272-2):
- Minimum air flow rate (Q) is calculated by Q = 0.05 x N x Igas x Crt x 10^-3.
- Igas is 1 mA/Ah for float batteries and 8 mA/Ah for boost charge batteries.
- Minimum free area of opening (A) for air inlet and outlet is calculated by A = 28 x Q.
- Forced ventilation is required if natural ventilation is insufficient, interlocked with the charger.
- A safety distance (d) from the battery is required to prevent sparking or glowing devices, calculated by d = 28.8 x √(N x Igas x Crt).
Usage Features
Installation:
- Handling: Avoid impact or shock. Lift individual units from underneath or by built-in handles, never by terminals.
- Placement: Install units in correct positions according to electrical layout. Maintain 5-10mm distance between cells/blocs for heat dissipation.
- Connections: Ensure proper tightening of bolted connections (torque values specified for different terminal types: M5 (5-6 Nm), M6 (7-9 Nm), M8 (10-12 Nm), M10 (20-25 Nm), Flag Ø5.5 (5-6 Nm), Flag Ø6.5 (6-7 Nm)). Insulate all connectors with plastic covers.
- Numbering: Affix cell number stickers, starting with #1 at the positive end of the battery.
- Orientation: Cells are usually designed for vertical installation; horizontal position may stress cells.
- Parallel Operation: For increased capacity, multiple strings can be connected in parallel. Use cells/monoblocs of the same type, model, manufacturing date, and quantity. Design a symmetrical layout to minimize resistance variations. Usually up to 4 strings can be connected in parallel, but more may be possible depending on voltage and cable length.
Storage:
- Conditions: Store in a clean, cool, dry area, avoiding direct sunlight and elevated temperatures. Optimum range is -10°C to +30°C. Avoid humidity >90% and chemical contaminants. Protect from dropping objects, falling, and short-circuits.
- Shelf Life: 6 months at 20°C. Higher temperatures reduce shelf life (e.g., 4 months at 30°C, 2 months at 40°C).
- Recharge: A refreshing charge is required when the maximum storage time is reached or when the OCV approaches 2.11 V/cell. Recharge at 2.4 V/cell for 24 hours at 20°C.
Maintenance Features
Battery Care:
- Cleanliness: Keep battery and surroundings clean and dry. Clean lids and containers with antistatic cotton cloths soaked in mild soap solution. Do not use synthetic cloths, detergents, or abrasive cleaners.
- Connections: Ensure bolted connections are properly tightened. "No-oxide" grease can be applied to increase corrosion protection. Remove any corrosion with diluted ammonia or baking soda.
- Charging Voltage: Maintain the recommended charge voltage.
- Ventilation: Ensure the battery room is well ventilated and its temperature is close to 20°C.
- Safety: Do not smoke or permit open flames near batteries. Do not attempt to open cover valves.
Voltage Checks:
- Perform voltage measurements after the battery has stabilized on floating (at least 7 days after installation or discharge/charge cycle).
- Measure and record individual block voltages annually. Blocks/cells should be within ±4% of the average at 20°C.
- Periodically check overall float voltage to verify charger or connection integrity.
Cell Appearance:
- Inspect for corrosion, container bulging, or high temperature in individual cells. Consult FET for expert advice on suspect cells.
Pilot Cell:
- For batteries with more than 60 cells, select one pilot cell for every 60 cells for regular monitoring.
Periodic Inspections:
- Maintain written records of battery maintenance.
- Every Six Months:
- Visual inspection of cells/racks for cracks, corrosion, or electrolyte leakage.
- Check and record overall float voltage at battery terminals.
- Measure and record pilot cell(s) voltage.
- Check room ventilation.
- Annually:
- Perform all six-month controls.
- Check and record voltage of all cells.
- Torque all connections according to the connection torque table.
- Clean the cells.
Battery Test:
- Preparation: Before any discharge test, batteries must be boost charged (2.40 V/cell for 24 hours at 20°C) to ensure full charge. Measure surface temperature of a pilot cell/block (15°C to 30°C).
- Service/Functional Test: Discharge the battery to the load or a dummy load to simulate a main failure. Record floating voltage, actual load, minimum admissible voltage, cell/block voltage, battery temperature, and discharge current at regular intervals. Ensure total battery voltage remains above the minimum.
- Capacity Test: Conducted to verify battery capacity to a specified end voltage and discharge rate (1, 3, or 10 hours). Discharge according to EN 60896-21/22. Record data every half hour initially, then every 10 minutes for the last half hour. Terminate discharge when tdisch or the first unit reaches Ufinal - (unit voltage/2) * 0.2. Recharge immediately after the test. Calculate capacity using C = discharge current × tdisch. Apply temperature correction factor for temperatures different from 20°C.
Safety:
- Protective Equipment: Use insulated tools, wear PPE (glasses, gloves, aprons), and ensure clothing/boots/gloves have appropriate surface/insulation resistance. Have a fire extinguisher and first aid equipment available.
- Precautions: Do not allow metal objects to rest on or fall across terminals. Do not wear rings or metal wrist bands. Do not smoke or permit open flames. Do not add water or acid to cells. Do not lift by terminals. Ensure adequate air exchange.
- Disposal: Dispose of lead-acid batteries according to country laws, preferably by sending them to a lead smelter for recycling. Batteries must be collected separately for waste disposal and marked with the Pb symbol according to EG-guideline 93/86/EWG.
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