DRY CELL Valve Regulated Lead Acid Battery

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Specifications

• Product: Dry Cell Battery Blocks
• Manufacturer: Discover Battery
• Country of Origin: Canada

Product Information

The Dry Cell Battery Blocks are designed for use in various
applications requiring reliable power storage. It is important to
follow the safety guidelines and installation instructions provided
in the manual to ensure proper operation and longevity of the
battery.

Product Usage Instructions

Safety

Before handling the battery, read through the safety section of
the manual carefully to understand the warnings, cautions, and
notes regarding fire risk, electric shock risk, and chemical risk
associated with the battery.

Delivery and Storage

Upon receiving the battery, perform a thorough receiving
inspection to check for any damages during transit. Store the
battery in a cool, dry place following the recommended storage
guidelines provided in the manual. When unpacking and handling the
battery, be sure to follow the safety precautions outlined in the
manual.

Installation and Commissioning

Ensure you have the necessary tools before proceeding with the
installation. Identify a suitable location for the battery
considering factors like ventilation and accessibility. When making
parallel connections, ensure consistency in cable resistance,
ampacity, and disconnect capabilities for each string.

Operation

Follow the instructions for charging, discharging, temperature
limits, and charge current limits provided in the manual. Pay close
attention to the charge curve and commissioning charge procedures
to optimize battery performance.

Battery Maintenance

Regular maintenance is essential to prolong the battery’s
lifespan. Refer to the maintenance guidelines in the manual for
proper care and upkeep of the battery.

Faults

If you encounter any faults during operation, refer to the
troubleshooting section of the manual for guidance on identifying
and resolving common issues.

Transport and Recycling

Adhere to the recommended transport guidelines to ensure safe
handling during transportation. When it comes to recycling, follow
proper disposal procedures as outlined in the manual to contribute
to environmental sustainability.

FAQ

Q: Can I modify or disassemble the battery?

A: No, it is important not to modify or disassemble the battery
as it can pose fire risks and lead to hazardous situations. Always
handle the battery with caution and follow safety guidelines.

Q: What should I do if I encounter a fault with the

battery?

A: In case of any faults, refer to the troubleshooting section
of the manual for step-by-step instructions on how to identify and
rectify common issues. If problems persist, contact qualified
personnel for assistance.

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Operating Manual
DRY CELL BATTERY BLOCKS

1. Safety 1.1 Warnings, Cautions and Notes 1.2 General Warning 1.3 Fire Risk 1.4 Electric Shock Risk 1.5 Chemical Risk 1.6 Do’s 1.7 Do Not’s
2. Delivery and Storage 2.1 Receiving Inspection 2.2 Storage 2.3 Unpacking and Handling
3. Installation and Commissioning 3.1 Tools 3.2 Battery Location 3.3 Racks and Mechanical Stability

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3.4 Parallel Connections

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3.5 Series Connections

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3.6 Series/Parallel Connections

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3.7 Electrical Connections

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4. Operation

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4.1 Charging

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4.1.1 Charge Curve

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4.1.2 Commissioning Charge

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4.2 Discharging

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4.3 Temperature Limits

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4.4 Charge Current Limits

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5. Battery Maintenance

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6. Faults

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7. Transport

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8. Recycling

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9. Troubleshooting and Frequently Asked Questions

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REV B

107 – 10550 42 Street SE, Calgary, AB, Canada T2C 5C7

+ 1.778.776.3288 info@discoverbattery.com

discoverbattery.com

Overview
The manual includes information about safety instructions, installation considerations, and other valuable topics to help you install, operate and maintain your Discover® Solar Dry Cell Battery. Please read through this guide completely before using your batteries, this will help protect your new investment and ensure the batteries are operating to maximum performance.
Certain configuration, installations, service, and operating tasks should only be performed by qualified personnel in consultation with local utilities and/or authorized dealers. Qualified personnel should have training, knowledge, and experience in:
· Installing electrical equipment · Applying applicable installation codes · Analyzing and reducing hazards involved in performing electrical work · Installing and configuring batteries
No responsibility is assumed by Discover for any consequences arising out of the use of this material.
Visit discoverbattery.com for the most recent version of published documents.

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1. SAFETY
1.1 Warnings, Cautions, Notes and Symbols WARNING
Important information regarding possible personal injury.

CAUTION
Important information regarding possible equipment damage.

1.2 General Warning

NOTE
Additional information concerning important procedures and features of the battery.
CAUTION
It is important to operate the battery with care to avoid undesirable consequences.

Do not throw batteries in the garbage. Do not dispose in fire. Use personal protective equipment when working with batteries. Additional information concerning important procedures and features of the battery. Read all the instructions before installation, operation and maintenance.
This product must be recycled and is made of recycled products.

1.3 Fire Risk

CAUTION
Do not disassemble or modify the battery. If the battery housing is damaged, do not touch exposed contents.
WARNING
Risk of fire – Do not expose batteries to flames, or sparks, as it may cause an explosion.

1.4 Electric Shock Risk 1.5 Chemical Risk

WARNING
Battery terminals and connector are always under voltage. Do not place tools or other metal objects on the battery. Avoid short circuits!
WARNING
Electrolyte is highly corrosive. Lead acid batteries are a chemical risk if misoperated, mishandled or abused.

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1.6 Do’s
· Do protect terminals from short circuit before, during, and after installation · Do wear electrically insulated gloves · Do use electrically insulated tools · Do wear eye protection · Do wear safety toe boots / shoes · Do handle battery carefully · Do secure battery safely
1.7 Do Not’s
· Do not add water to the battery · Do not immerse battery in water · Do not lift or carry the battery during usage or operation · Do not operate or store battery outside of operating limits · Do not short circuit battery · Do not puncture battery · Do not expose battery to flames, or incinerate · Do not open battery case or dissemble battery · Do not wear rings, watches, bracelets or necklaces when handling or working near battery · Do not drop or crush battery · Do not lift battery by the terminal cables · Do not vibrate battery · Do not expose battery to water or other fluids · Do not expose battery to direct sunlight · Do not dispose of battery · Do not connect with other types of batteries · Do not expose battery to high temperatures · Do not install with other battery types or brands
2. Delivery and Storage
2.1 Receiving and Inspection
· Inspect for missing components. · Check against the shipping/packing documents. · Inspect each package or pallet for integrity and electrolyte leakage. · Record receipt date and inspection data results, and notify your servicing dealer of any damage.Take photographs if
necessary.
2.2 Storage
· Store in a dry, clean, ventilated, cool and frost-free location. · Do not expose to direct sunlight as damage to the container and cover may occur. · Do not stack pallets on top of each other and on sharp-edged supports. · Storage on a pallet and wrapped in plastic material (shrink wrap) is permitted except when room temperature fluctuates
significantly, or when high relative humidity can cause condensation under the plastic. Condensation can cause a whitish hydration on the terminals to form and result in current leakage and self-discharge. · Protect against any risk of electric shock from short- circuiting poles/terminals with conductive objects or from the buildup of conductive dust. · Maintain the same storage conditions for all batteries within the same batch. Depending upon storage conditions and temperature, storage time may be limited. · If lead acid batteries are to be stored for extended periods of time, they must be placed fully charged. · To prevent over discharge during storage, do not store batteries for more than 6 months at 20°C/68°F or 3 months at 30°C/86°F before performing a re-fresh charge. Failure to observe these conditions may result in significantly reduced capacity and service life · Record dates and conditions for all charges during storage.

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2.3 Unpacking and Handling
WARNING
Read Safety Section 1 before handling the battery.
· Never lift batteries by the terminal posts, use carry handles. · Do not short circuit. · Check for damage. All batteries with visible defects should be reported. · It is recommended to check the OCV (Open Circuit Voltage) on arrival
3. Installation and Commissioning
WARNING
Read Safety Section 1 before handling the battery.
3.1 Tools
· Insulated tools · Voltmeter · Post cleaner and wire brush · Personal protective equipment
3.2 Battery Location
· Locate the batteries close to the inverter in order to minimize the length of the battery cables. · Battery performance and service life will be optimized when they are operated in an ambient temperature of 15°C to 25°C
(59°F to 77°F). · All electrical protective measures, devices, accommodation and ventilation of the battery installation area must be in
accordance with all local rules and governmental regulations. · The battery should be installed in a clean and dry area and protected against dropped items and dirt. · Avoid placing the battery in a hot place or in direct sunlight. · Avoid conditions that result in spot heating or cooling, as temperature variations will cause electrical imbalances in the
battery. For better cooling and temperature management the batteries should have a minimum of 0.50″ (12.7mm) of space to ensure adequate air flow around each battery. · The layout of the battery room or installation area must allow for easy access to the batteries. · Be sure to provide adequate space and lighting for inspection, maintenance, testing, and battery replacement. Space should also be provided to allow the operation of lifting equipment and for taking measurements (battery voltage and temperature) during service.
3.3 Racks and Mechanical Stability
· Approved and insulated battery racks are recommended for proper installation. Calculations should be performed to ensure that floor loading capabilities are not exceeded. Seismic forces should also be considered.
· The installation should provide for adequate structural support and exposure to the minimum possible vibration.
3.4 Parallel Connections
Discover® Solar Dry Cell may be connected in parallel to increase capacity, current capability and/or discharge durations. In the case of each parallel connected string, only use batteries of the same voltage, capacity, design and age.
The resistance and ampacity of the cables or connector bars in each string must be the same, e.g. same cross-section, same length and same conductor type (copper, aluminum). In addition, each string should be equipped with disconnect capabilities (circuit breakers) for maintenance and safety purposes.
Parallel Connection
Discover® recommends a maximum of 3 strings parallel:The following steps should be fulfilled to have battery string in parallel without reducing battery life or batteries getting out of balance:
· Same voltage drop must be realized from each string to the end connection (load and ground). This can be achieved by proper choice of cable lengths, cable diameters and arrangement for crosswise connection configurations.
· Same length connector cables for positive and negative terminals for each string.

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· Manually operated switching device that also automatically opens or breaks the circuit in the event of an over current (circuit breaker) for each string.
· Same number of batteries for each string. · Same heat or temperature potential for each string. · Always connect the individual series strings first and then check that the different strings are at the same potential before
connecting them in parallel.

3.5 Series Connections
Discover® Solar Dry Cell may be connected in series to increase system voltage. In the case of each series connected string, only use batteries of the same voltage, capacity, design and age.
· Same cables or connector bar resistance for each string e.g. same cross- section, same length and same conductor type (copper, aluminum)
· Disconnect capabilities (breakers) on each string for maintenance and safety.

3.6 Series/Parallel Connections
To increase both voltage and capacity, Discover Solar Dry Cell may be connected in series and parallel. Refer to diagram for series/parallel connections. Battery cables must be sized to the specifications required by the inverter charger and must be installed in accordance with the standards set by the authority having local jurisdiction.

Series Connection

3.7 Electrical Connections
Battery cables must be sized to the specifications required by the inverter charger and must be installed in accordance with the standards set by the authority having local jurisdiction.

· Ensure that the battery is installed and connected in the correct polarity

· If the battery circuit has a disconnect – open the disconnect to isolate battery

· Check that all contact surfaces are clean. If required, clean poles/terminals with a brass brush/pad.

· When using a washer to connect a battery cable to a battery terminal, it is very important to

ensure the battery cable is contacting the lead surface of the terminal and that the washer is

placed on top of the cable. Do not place the washer between the battery terminal and the battery cable, this creates high resistance and can cause terminal meltdown.

Series/Parallel Connection

· Do not ground the terminals to any metal mounting, fixture, or body part

· Connect battery cables. Connect the ground cable last to avoid sparking

· Tighten terminal screws using the terminal torque values as in the table below and thinly coat connections and terminals

with dielectric grease or silicone to prevent corrosion

· If the battery circuit has a disconnect – close disconnect to reconnect the battery

Terminal Type (F10) M8 Button Terminal (F10) M10 Button Terminal AM Dual Terminal (AP and 5/16″ threaded stud) AT Dual Terminal (AP and 3/8″ threaded stud)

Terminal Torque 7 ft-lbs / 10 NM 12 ft-lbs / 16 NM 9 ft-lbs / 13 NM 10 ft-lbs / 14 NM

4. Operation

NOTE
All cable ends must be connected to battery terminals without any washers between terminal bushing and cable ends.
CAUTION! Review operating limits – see datasheets.

Before charging the battery make sure to read and understand the instructions that come with the Power Conversion device. Never attempt to charge a battery without first reviewing and understanding the instructions for the Power Conversion device being used.

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4.1 Charging

CAUTION!
Always make sure the charger is in the correct setting and compatible with the battery’s charging requirements; never charge a visibly damaged battery; never charge a frozen battery.

4.1.1 Charge Curve A battery charge profile (also known as an algorithm) contains all of the logic used to execute a multi-stage charging process, including the bulk, absorption and float phases. Charge profiles differ depending on the battery type, capacity, battery manufacturer, and even the application. It is extremely vital that a battery is charged with an appropriate charge profile. Not doing so, may cause the battery pack to be chronically under- or over- charged, resulting irreversible damage and premature end-of-life.
The Bulk charge accounts for charging the battery from anywhere between 0% up to 80% state of charge. The absorption phase charges the battery from 80% to nearly 100% state of charge. Lastly, a float charge supplies a controlled voltage and amperage to bring the battery to a complete full charge. Without a float charge, recharge can be terminated based on time (this will need to be determined as it will vary with depth of discharge and charge current) or percentage recharge (105%-108%).

NOTE!
Acceptable charging AC ripple voltages shall be less than 4% peak to peak ripple voltage (less than 1.5% rms voltage) of the DC System voltage with duration of less than 6 milliseconds.

WARNING!
Do not equalize charge DRY CELL Solar batteries! Equalizing is an “over voltage-over charge” performed on flooded leadacid
batteries after they have been fully charged.

To maximize battery life, a voltage regulated charger with temperature compensation is strongly recommended. The voltage settings displayed in charge algorithm graph and charge setting tables, corresponds to the set points at 25°C (77°F). For temperatures below 25°C, adjust +0.005VPC/°C (or 0.003VPC per °F). For temperatures above 25°C, adjust -0.005VPC/°C (or 0.003VPC per °F). As the temperature decreases, the voltage should increase and vice versa.

-0.005VPC

V=(T-25°C) x (

)

°C

NOTE!
If a temperature sensor is not used, you must manually adjust charging voltages based on the battery temperature
when in use.

If the charger has a preset charge profile for AGM type batteries, verify that these settings follow recommended charge settings.

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IUU CHARGE PROFILE

BULK
I1 = 0.25C20 (max) 0.10C20 (min)

ABSORPTION
U2 = 2.40VPC (+/-0.015VPC)

FLOAT

U3 = 2.25VPC 105%-108% recharge

14 HRS

8 HRS

NO TIME LIMIT

Maximum Charge Time (Must be Limited to 24 hrs)

Figure 1: Voltage Regulated Charge profile (IUU charger) at 25°C (77°F)

6 VDC

Bulk & Absorption Charge Voltage U2

7.2V

Recommended Charge Current I1

Float Voltage U3

6.8V

Table 2: Voltage Regulated Charger – Charge settings at 25°C (77°F)

12 VDC

24 VDC

14.4V

28.8V

I1 = Min 10% C20 to Max 25% C20

13.5V

27.0V

48 VDC 57.6V
54.0V

4.1.2 Commissioning Charge Batteries lose charge while in transit or during storage. For this reason, a refresh charge should be given before putting the battery into service. Allow the charger to go through a full charge cycle before they are used.
During commission, measure the battery voltage and after commissioning, measure the battery voltage and surface temperature of each battery and log this data. Discover Commissioning Logs are online available online.
4.2 Discharging
No restriction on the discharge current up to the maximum allowable is required as long as the connections are properly sized and the battery temperature stays within the allowable limits.
With traditional stationary and renewable energy systems, Depth of Discharge (DOD) is set to operate between 20% and 50% to maximize the life of the batteries. By default, this may be set by power conversion manufacturer at 1.75 volts per cell (Vpc). Discover Dry Cell batteries deliver 50% of its rated capacity above 2.05 Vpc, this is also the recommended LVD to optimize battery runtime and longevity. Preventing batteries to operate at low voltages will increase cycle life expectancy. Standard RE warranty is reduced on system designs that continuously exceed 50% DoD.

6 VDC

20% DOD Reference LVD / I10
50% DOD

6.30V 6.15V

Table 3: Reference Low-Voltage-Disconnect / I10

12 VDC 12.60V 12.30V

24 VDC 25.20V 24.60V

48 VDC 50.40V 49.20V

4.3 Temperature Limits
The battery is designed to perform optimally at temperatures between 15-25°C. At lower temperatures the battery capacity is lower

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and at elevated temperatures the life is reduced. A maximum ambient operating temperature of 45°C/113°F must not be exceeded. Sub-zero temperatures may cause electrolyte freezing and irreversible damage when the battery’s state of charge (SoC) is low:

Electrolyte Freezing Point

State of Charge (SOC)

0%

Freezing point

-23°C / -9°F

25% -27°C / -17°F

40% -37°C / -35°F

75% -48°C / -54°F

100% -59°C / -74°F

4.4 Charge Current Limits
Charging current in general should not exceed 30A/100Ah C20 rating.
5. Battery Maintenance
VISUAL INSPECTION Check for any visible defects such as cracks, loose terminal posts and oxidized connectors.To avoid leakage currents and the associated risk of fire, keep the battery dry and clean. Do not use any solvents or detergents. Avoid electrostatic charges. Discover Maintenance Logs are online available online.
QUARTERLY MAINTENANCE · Check/record battery voltage · Deviation testing of battery voltages (deviations signal imbalance batteries) · Deviation testing of battery temperatures (deviations signal short circuit cells) · Check if connectors are firmly tightened · Confirm DOD per battery does not exceed the allowed limit · Confirm that charge settings correspond to recommendations
BI-ANNUAL MAINTENANCE Further to the bi-annual maintenance, do the following:
· Inspect racks/cabinets for corrosion or loss of integrity · Check/record if ventilation is sufficient. · Check/record battery room temperature · Check battery for cracks · Check ground connections
6. Faults
Should faults be detected in the battery or the charging device, contact your servicing dealer immediately. Keeping records of all measured data will simplify fault detection and corrective action. A service contract with your servicing Discover® dealer will help to detect faults in time.
7. Transport
Be sure that all batteries are protected against short-circuit. Be sure to document and transport all batteries according to local department of transportation rules and regulations. Material Safety Data sheets (MSDS) and Safety Data sheets (SDS) are available online.
8. Recycling
Discover’s lead acid batteries are recyclable products. All Discover Factory Warehouses and servicing dealers are qualified to accept and handle all used lead acid batteries. Contact Discover® or your servicing dealer for details.
9. Troubleshooting and Frequently Asked Questions
The following is a list of common concerns and questions regarding system setup, battery charging and maintenance procedures. Please refer to these as general guidelines. For further assistance with your specific system setup, please contact your installer.
WHAT CAUSES THE BATTERY TERMINAL TO MELT? Battery terminals melting is most common because of improper connections causing high resistance and heat generation.

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· Loose connections · Over-tightened connections · Improper sized cables (too small). · Corroded connections · Improper use of washers/lock washers. · Too many connections on the same terminal
WHY DO THE BATTERIES BULGE? · Some case bulging can happen and is normal during battery charging. · If case bulging is a concern upon receipt of a new product, please notify your Distributor immediately · In the case of excessive bulging- your batteries may have been exposed to temperatures of over 50°C (122°F) or may have been overcharged. Both conditions may cause the plates/chassis to swell and expand. If this occurs, the batteries may fail prematurely. · The batteries may have frozen due to excessive exposure to cold temperatures.
To prevent excessive bulging, you need to take the following precautions: · Use the right type of charger and charge algorithm that is fully compatible with the battery · Ensure proper polarity when connecting the charger to the battery · Don’t short-circuit the battery · Don’t expose battery to temperatures of over 50°C (122°F) and prevent battery from freezing
WHAT CAUSES A BATTERY TO LOSE CAPACITY? Every lead acid loses capacity over its lifetime. A loss of capacity may indicate the battery is cycled out and reached its end of life.
Capacity loss may also occur due to sulphation, overheating, or over- discharging. If there is capacity loss, the battery bank may no longer support an increase in load. To prevent premature capacity loss:
· Use the right type of charger and charge algorithm that is fully compatible with the battery · Verify the temperature sensors are properly mounted and the operation settings are adjusted to the appropriate battery
temperature
WHY DOES THE VOLTAGE RISE QUICKLY CAUSING THE POWER CONVERSION DEVICE TO SHUT OFF WHEN I BEGIN TO CHARGE MY BATTERY BANK? This is often an indication of sulphated batteries which can be confirmed by completing a load test
· An increase in Absorption time may be necessary to sufficiently charge the battery to full SOC.
WHY IS THE CHARGING CURRENT TO THE BATTERY BANK SO LOW? The charging current will decrease as the batteries become fully charged. If the charge current is low, the end of charge cycle may have been reached. Verify that the charger is near the end of the Absorption phase or in Float voltage phase. If so, low current is normal at this stage of charging.
· The battery bank self-regulates charge current. The voltage can be controlled and adjusted to a high or low setting, however the amp output to the battery bank cannot be controlled and will drop as the batteries reach a full state of charge.
· When the charge current decreases to 1% of the battery C20 capacity, the charge is essentially complete.
WHY DOES THE VOLTAGE RISE QUICKLY CAUSING THE CHARGER TO SHUT OFF WHEN I BEGIN TO CHARGE MY BATTERY BANK? This is often an indication of sulphated batteries which can be confirmed by completing a load test.
· An increase in Absorption time may be necessary to sufficiently charge the battery to full SOC.
WHY DOES THE BATTERY BANK NOT REACH THE BULK VOLTAGE SETTING WHEN CHARGING? If the system is not reaching the Bulk voltage, the charger voltage and/or Amp output to the battery bank may be too low. To ensure sufficient charge, the output should be approximately 10%-25% of the C20 capacity rating of the battery bank. Another cause may be from DC loads running on the system during the charge cycle and reducing the current supplied to the battery bank.
· Verify that the charging settings meet the recommended charging parameters and that the charger output (Amps) is sufficient to meet the capacity requirements of the battery bank.
WHAT DO I DO IF THE BATTERY TEMPERATURES ARE VERY HIGH? If at or nearing 50°C (122°F), shut off the charger and allow the batteries to cool. If a single battery or cell in a string is hot, this may

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indicate a cell failure or short. Verify the voltage readings from each battery, and perform a load test to identity any cell failures.
WHAT DO I DO IF THE BATTERY IS FROZEN? Discover Dry Cell batteries can be stored in sub-freezing temperatures as low as 35 °C / -31°F as long as they are fully charged prior to storage. The self-discharge rate of fully-charged batteries is very low in these conditions and they will not require charging for many months. However, if your batteries do freeze, they may not always recover. To attempt recovery bring them inside and let them sit until the temperature of the battery reaches the temperature of the room, approx. 20°C / 68°F, then charge the batteries normally. You may have to cycle the battery a couple of times before making a decision on its final condition.
Updated: November 2019

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References

• Lithium & Lead Acid Battery Manufacturers/Suppliers | Discover Battery

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