Sacred Sun SPG Series - User Manual

This document is a technical manual for the SACRED SUN SPG Series Valve-Regulated Sealed Lead Acid (VRLA) Batteries.

Function Description

The SACRED SUN SPG Series batteries are VRLA batteries designed for various applications, primarily focusing on providing reliable power. The "Valve-Regulated" aspect indicates that these batteries are sealed and do not require regular water replenishment, as oxygen generated during charging is recombined within the battery. The "Sealed Lead Acid" nature signifies their construction using lead plates and sulfuric acid electrolyte, contained within a sealed casing. These batteries are suitable for applications requiring a stable and maintenance-reduced power source.

Important Technical Specifications

The manual provides detailed specifications for various models within the SPG series, including:

General Characteristics:

• Design Life: 12 years (at 25°C).
• EUROBAT Classification: Long life.
• Energy Density: High Power and High Energy Density.
• Charge Efficiency: Maximum charge efficiency.
• Gas Recombination Efficiency: High gas recombination efficiency.
• Self-Discharge Rate: Low self-discharge rate.
• Installation: Easy handling and installation, can be vertical or horizontal.

Design Features:

• Positive Plates: Flat pasted plate with lead-calcium-tin grid alloy.
• Negative Plates: Flat pasted plate with lead-calcium grid alloy.
• Separators: Microporous AGM (Absorbed Glass Mat) separator.
• Container & Lid: High-strength ABS (optionally available in Flame Retardant UL94 V0 version).
• Electrolyte: Absorbed sulfuric acid.
• Terminal Posts: High-conductivity terminals with threaded inserts.
• Posts Sealing: Double sealing structure.
• Vents: High-efficiency low pressure venting system.

Main Applications:

• UPS units (Uninterruptible Power Supply)
• Data Centers
• Generators starting
• EPS units (Emergency Power Supply)

Standards Compliance:

• IEC60896-21/22: 2004
• JIS C8702-1/2:2009
• Eurobat Guide
• Installation compliant with EN50272-2

Model-Specific Data (Examples from Table 1-1): The manual lists numerous SPG12 models with varying capacities and power outputs. Key parameters for each model include:

• Battery Voltage (V): All listed models are 12V.
• Rated Capacity (Ah, 25°C): Ranges from 42Ah (SPG12-175W) to 250Ah (SPG12-870W) at C10 (1.80V/cell).
• Rated W/pc (15 min at 1.67V/cell): Ranges from 175W (SPG12-175W) to 870W (SPG12-870W).
• Dimensions (mm): Length, Width, Height, Total Height are provided for each model.
• Weight (kg): Ranges from 13.9kg (SPG12-175W) to 77.9kg (SPG12-870W).
• Short Circuit Current (A): Ranges from 1600A to 6100A.
• Internal Resistance (mΩ, 25°C): Ranges from 7.50mΩ to 1.95mΩ.
• Terminal Type: M6xΦ16 or M8xΦ18.
• Layout: Different terminal layouts (A, B, C, D) are specified.

Discharge Characteristics:

• Discharge Curves: Graphs illustrate discharge capacity (%) versus temperature (°C) for various discharge rates (0.05C, 0.1C, 0.2C, 1.0C, 2.0C). Another graph shows voltage (V) versus discharge time (h) for different discharge rates (0.1C, 0.18C, 0.26C, 0.65C, C, 2C, 3C).
• Constant Current Discharge Data (Amperes, 25°C): Extensive tables provide discharge current values for various end voltages (1.60V/cell to 1.80V/cell) and discharge times (5min to 10h) for all SPG series models.
• Constant Power Discharge Data (Watts/cell, 25°C): Similar extensive tables provide discharge power values for various end voltages and discharge times for all SPG series models.

Charge Characteristics:

• Charge Curve: A graph shows Charge Voltage, Charge Capacity, and Charge Current over charge time (h) for a 0.15CA, 25°C charge.
• Floating Charge Service Life Curve: A graph shows capacity (%) versus service life (year) under specific conditions (Floating Voltage: 2.27V/cell, Temperature: 25°C).

Usage Features

• Electrochemical Reaction: The manual explains the charge and discharge reactions (PbO2 + 2H2SO4 + Pb ↔ PbSO4 + 2H2O + PbSO4) and the oxygen reduction cycle in VRLA batteries, which restrains hydrogen generation.
• Operating Parameters:
  • Ambient Temperature: -15°C to 45°C (optimal 25°C ± 5°C).
  • Ambient Humidity: Less than RH 92%.
  • Altitude: Less than 4500m (special reminder needed for higher altitudes).
• Temperature Effect on Capacity: Capacity decreases with lower temperatures (e.g., 85% at 0°C compared to 25°C) and increases slightly with higher temperatures up to 35°C (approx. 105%), with minimal increase beyond 35°C.
• Charge Methods:
  • Floating Charge: 2.27V/cell with limited current of 0.3 C10 (A). Voltage must be adjusted based on ambient temperature with a compensation coefficient of -3mV/cell/°C. A table provides recommended floating charge voltages for temperatures from 0°C to 35°C.
  • Cycle Application: 2.40V/cell with limited current of 0.25 C10 (A). Voltage adjusted with -4mV/cell/°C compensation. Charging ends when capacity reaches 105-110% of discharged capacity or after 3 hours of constant current in the final stage of constant voltage charging.
• Installation:
  • Batteries are delivered charged with protective caps. Unpack with care.
  • Avoid short-circuiting terminals.
  • Racks should be assembled according to instructions, ensuring stretchers and cross-members are interlinked, irregularities in floor surface are taken up with shims, and metal racks are earthed.
  • Cabinets must be strong enough for battery weight, insulated, and naturally ventilated.
  • Connections: Cells can be connected in series (U = V x N) or in parallel for higher current capability. Parallel connections should preferably use equipotential wiring for equal current distribution, with a recommendation not to exceed 4 strings for high discharge rates.
  • General recommendations include wearing protective eyewear and clothing, using insulated tools, placing cells from least accessible rows, consulting drawings for polarity (positive=red, negative=black), checking terminals before attaching cables, connecting positive to negative in series, using a damp cotton cloth for cleaning, tightening nuts/bolts to recommended torque, and always using insulated tools.

Maintenance Features

• Safety Instructions:
  • Do not open batteries.
  • Batteries contain lead and electricity, so installation, maintenance, and replacement must be done by skilled personnel.
  • Used batteries must be recycled properly; improper disposal is harmful.
  • Do not mix batteries of different specifications, manufacturers, or capacities.
  • All installations must comply with safety regulations.
• Cleaning Notes:
  • Keep battery appearance, terminal area, and working environment clean and dry.
  • Avoid electrostatic cleaning tools.
  • Clean with a damp cotton cloth; do not use gasoline, alcohol, or other organic solvents.
• Inspection and Maintenance: VRLA batteries are not entirely maintenance-free; regular checks are crucial.
  • Monthly Maintenance Inspection Items:
    • Temperature Detection: Measure and record battery terminal, container, and ambient temperatures using an infrared thermometer. Check if temperature compensation and room conditioning equipment are on.
    • Battery Float Voltage Measurement: Measure floating voltage across positive and negative terminals of the battery group with a multimeter. Check if monitoring module displays operating voltage differences within 0.05V. Replace or repair if inconsistent.
    • Battery Appearance: Inspect for bulging, leakage, damage. Confirm reasons for abnormalities and replace if affecting normal use. Clean dirt and dust with a damp cloth.
    • Joints: Inspect connection cables and terminals for oxidation, rust, or other abnormalities. Replace connecting wire if oxidation/rust found, swab terminal with Vaseline. Use hex or torque wrench to tighten loose bolts. If slight corrosion found, clean with cloth after removing bar; if severe, replace bar and clean terminal with sandpaper.
    • Safety Valve Testing: Inspect for white crystalline or liquid surrounding the safety valve. Clean with a dry cloth if crystalline or liquid, then check and tighten the safety valve.
  • Quarterly Maintenance Inspection Items (in addition to monthly items):
    • Measurement of each battery's floating voltage: Measure with a multimeter. Check if battery floating voltage differential pressure meets specified values (2V series: 90mV, 6V series: 240mV, 12V series: 480mV). If deviations, discharge the group, then equalizing charge. After equalizing charge, switch to float charge for two months. If deviations persist, replace and recycle.
    • Equalizing Charge: To recover batteries with lower capacity or discharge voltage, perform an equalizing charge for 10 hours or more. For severe deviations, perform charge/discharge cycles three times. If battery performance cannot be recovered, it must be replaced.
  • Annual Maintenance Inspection Items (in addition to quarterly items):
    • Discharge Test: Disconnect AC, perform load discharge or online discharge to check if capacity is minimum 30%-40% of nominal capacity. At end of discharge, battery voltage should be more than 1.90V/cell, and differential pressure must meet specified values (2V series: 200mV, 6V series: 350mV, 12V series: 600mV). If values are not met, discharge, equalizing charge, then float charge for 1-2 months. If still exceeded, contact technical team.
    • Capacity Test: Use an intelligent discharge device to discharge batteries until end voltage of 1.80V/cell. For backup use, capacity must be >80%; for energy storage, >60%. Recovery test: measure and record parameters from monthly/quarterly maintenance items and end voltage during discharge. Replace if performance cannot be recovered.
    • Measure and verify controller parameters: Measure limited charging current values. Check if equalizing charge starts and ends automatically. Verify automatic start of battery discharge protection. Arrange repair for power equipment/controller failures.
• Storage:
  • Store in a fully charged state; never store after discharge.
  • Storage location must be away from heat, sparks, and smoke.
  • Store in an upright position, avoiding impacts or abrupt loads. Safety valve should be tightened.
  • Do not stack without proper protective packaging.
  • Can be stored in -10°C to 45°C environment.
  • Freshening Charge Intervals:
    • -10°C to 30°C: Every 6 months.
    • 31°C to 45°C: Every 3 months.
  • Recommended Freshening Charge Method: Use constant current 0.1C10A~0.15C10A until battery average voltage rises to equalizing charge voltage, then switch to constant voltage charging. Charging time is generally 10-20h.
  • Maximum Storage Time (Shelf life): 18 months (at 25°C).
  • Store in a dry, ventilated, and clean environment.
  • Protect from harsh weather, moisture, flooding, direct/indirect sun radiation, organic solvents, corrosive substances, and gas.