TYPE TEST REPORT - Master Battery, S.L. · 2019. 11. 14. · According to IEC 60896-21 & 22 ....

OPzV Type Test Report

Acc. to IEC 60896-21 & 22

Report: OPzV Type Test Report Issue date: Error! Reference source not found.5Page 1 by 53

TYPE TEST REPORT

OPzV CELLS AND BLOCK BATTERIES

According to IEC 60896-21 & 22

Upower Batteries, 66A Tzar Asen Srt. │Sofia, Republic of Bulgary

Report Type Project

OPzV Type Test Report OPzV Testing Acc. to IEC 60896-21/22, DIN 40742 & DIN

40744

Date Iss. by Appr. by Lang. Doc. Nr.

11/10/2015 Javier Julio EN 15.167.0014.00


Acc. to IEC 60896-21 & 22


INDEX

OPzV Type Test Report ..................................................................................................... 3

1 Discharge Capacity. ............................................................................................. 4

1.1 2V - OPzV 50Ah Plate ....................................................................................... 5

1.2 6V - OPzV 50Ah Plate ..................................................................................... 10

1.3 12V - OPzV 50Ah Plate .................................................................................... 15

1.4 70Ah Plate .................................................................................................... 20

1.5 100Ah Plate ................................................................................................... 25

1.6 125Ah Plate. .................................................................................................. 30

2 Short Circuit Current & DC Internal Resistance....................................................... 35

3 High Current Tolerance ....................................................................................... 36

4 Recharge Behaviour............................................................................................ 37

5 Protection against Ground Short Propensity ........................................................... 38

6 Charge Retention during Storage ......................................................................... 39

7 Gas Emission ..................................................................................................... 40

8 Material Identification ......................................................................................... 43

9 Valve Operation ................................................................................................. 43

10 Intercell Connector Performance .......................................................................... 44

11 Endurance in Cycles (Float Service with Daily Discharges) ....................................... 45

12 Impact of a Stress Temperature of 60 °C (Accelerated Test of Operational Lifetime) ... 46

13 Service life at an operating temperature of 40 °C ................................................... 47

14 Abusive over-discharge ....................................................................................... 47

15 Thermal Runaway Sensitivity ............................................................................... 48

16 Low Temperature Sensitivity ................................................................................ 49

17 Dimensional Stability at Elevated Internal Pressures and Temperatures .................... 50

18 Stability against mechanical abuse of units during installation .................................. 51

19 Content and durability of required markings .......................................................... 52

20 Protection against internal ignition from external spark sources ............................... 52

21 Flammability rating of materials ........................................................................... 52


Acc. to IEC 60896-21 & 22



This test report applies to all Upower OPzV cells and monobloc batteries of the valve regulated

type for float charge applications, (i.e. permanently connected to a load and to a d.c. power

supply), in a static location (i.e. not generally intended to be moved from place to place) and

incorporated into stationary equipment or installed in battery rooms for use in telecom,

uninterruptible power supply (UPS), utility switching, emergency power or similar applications

and also solar applications.

Table 1 shows the relation between the test type and the number of cells acc. to IEC60896-21.

The selection of the cell type Vs the test type was made in order to be able to extrapolate the

results to the whole OPzV range. In most cases, the selection was made by the possible worst

case scenario.

Test Clause According to IEC60896-21 Sample/test

6.1 Gas emission 6 cells

6.2 High current tolerance 3 cells

6.3 Short circuit current and d.c. internal

resistance3 cells/type

6.4 Protection against internal ignition

from external spark sources3 valves

6.5 Protection against ground short

propensity1 cell

6.6 Content and durability of required

markings3 samples

6.7 Material identification 1 cover-box

6.8 Valve operation 3 cells

6.9 Flammability rating of materials 1 sample / material

6.10 Intercell connector performance 6 cells

6.11 Discharge capacity 5x6 cells = 30 cells

6.12 Charge retention during storage 6 cells

6.13 Float service with daily discharges 6 cells

6.14 Recharge behavior 3 cells

6.15 Service life at an operating

temperature of 40 °C3 cells

6.16 Impact of a stress temperature of

55 °C or 60 °C3 cells

6.17 Abusive over-discharge 4 + 3 = 7 cells

6.18 Thermal runaway sensitivity 6 cells

6.19 Low temperature sensitivity 3 cells

6.20 Dimensional stability at elevated

internal pressure and temperature1 cells

6.21 Stability against mechanical abuse

of units during installation2 cells

Table 1 – Test type Vs Cell Type Acc. to IEC 60896-21


Acc. to IEC 60896-21 & 22


1 Discharge Capacity.

The purpose of this test is to confirm the capacity of the cells/batteries to a specific end-voltage

at the selected discharge rate. One cell type per 50Ah, 70Ah, 100Ah and 125Ah plate has been

selected. Regarding the 50Ah plate, the tests have been separated into two categories:

2V cells

Monoblock batteries

The reason for this categorization is the difference of the separator for these two types (the

plate remains the same but the monoblock batteries are using thinner separator comparing to

the 2V cells).

Each cell type was tested at the following rates (the following rates are according to IEC60896-

21):

Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Temperature (oC) 20 20 20 20 20 20 20 20

Final Voltage (V/cell) 1,6 1,6 1,7 1,75 1,8 1,8 1,8 1,85

Table 2 – Discharge rates and end voltages

The most common applications for the Sunlight OPzV batteries are:

Table 3 – Upower OPzV batteries applications

Deviation according to IEC: cells have been submitted initially to two C10 discharges (IEC

mentions that the cells shall not have been previously submitted to any discharges). In any

case, the results from the two initial discharges were successful with the actual capacity to be

≥95% of the rated capacity.


Acc. to IEC 60896-21 & 22


1.1 2V - OPzV 50Ah Plate

Instruction: IEC 60896-21, chapter 6.11

Test items: 6pcs, 2V - 5 OPzV 250

Specification: Actual Capacity Vs Rated Capacity Ca ≥ 95 % Crt

Test Result: Successful

Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Current (A) 371,0 174,6 76,6 34,8 28,0 15,73 7,33 3,02

Final Voltage (V) 1,6 1,6 1,7 1,75 1,8 1,8 1,8 1,85

Test Temperature (oC) 20 20 21 22 23 24 25 26

Nominal Capacity (Ah) 92,8 174,6 229,9 278,4 280,0 314,7 352,0 362,7

Measured Capacity (Ah) 126,67 180,97 250,05 287,87 290,05 329,72 359,69 366,42

Nominal Capacity (50 Ah Plate) 18,6 34,9 46,0 55,7 56,0 62,9 70,4 72,5

Measured Capacity (50 Ah Plate) 25,33 36,19 50,01 57,57 58,01 65,94 71,94 73,28

Result (%) 136,6% 103,7% 108,8% 103,4% 103,6% 104,8% 102,2% 101,0%

5 OPzV 250

Table 4 – Summary of test results for the 2V – 5 OPzV 250

Summary of test results: Tests were successful. In all the rates the following was

applied Ca ≥ 95 % Crt

The measurement curves are shown below:

100%

136,6%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

1,90

0 5 10 15 20 25

Vo

ltag

e (

V/

cell

)

Time (min)

2V 5 OPzV 250 \ C0,25 discharge curve

Figure 1. C0.25 Capacity Test


Acc. to IEC 60896-21 & 22


100%

103,7%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

1,90

1,95

2,00

0 10 20 30 40 50 60 70

Vo

ltag

e (

V/

cell

)

Time (min)

2V 5 OPzV 250 \ C1 discharge curve

Figure 2. C1 Capacity Test

100%

108,8%

1,65

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


100%

103,4%

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540

Vo

ltag

e (

V/

cell

)

Time (min)



100%

103,6%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540 600 660

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


100%

104,8%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 120 240 360 480 600 720 840 960 1080 1200 1320

Vo

ltag

e (

V/

cell

)

Time (min)



100%

102,2%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


100%

101%

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 720 1440 2160 2880 3600 4320 5040 5760 6480 7200 7920

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22

Report: OPzV Type Test Report Issue date: Error! Reference source not found.5 Page 10 by

53






Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Current (A) 402,7 200,7 87,3 38,8 30,9 17,1 7,85 3,18

Final Voltage (V) 4,8 4,8 5,1 5,25 5,4 5,4 5,4 5,55






Result (%) 145,6% 108,3% 108,0% 103,4% 105,8% 105,0% 103,6% 102,2%

6V - 6 OPzV 300





100%

145,6%

4,65

4,80

4,95

5,10

5,25

5,40

5,55

0 5 10 15 20 25

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

108,3%

4,65

4,80

4,95

5,10

5,25

5,40

5,55

5,70

5,85

0 10 20 30 40 50 60 70

Vo

ltag

e (

V/

cell

)

Time (min)



100%

108%

4,95

5,10

5,25

5,40

5,55

5,70

5,85

6,00

6,15

6,30

0 15 30 45 60 75 90 105 120 135 150 165 180 195

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

103,4%

5,10

5,25

5,40

5,55

5,70

5,85

6,00

6,15

6,30

0 60 120 180 240 300 360 420 480 540

Vo

ltag

e (

V/

cell

)

Time (min)



100%

105,8%

5,25

5,40

5,55

5,70

5,85

6,00

6,15

6,30

0 60 120 180 240 300 360 420 480 540 600 660

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

105%

5,25

5,40

5,55

5,70

5,85

6,00

6,15

6,30

0 120 240 360 480 600 720 840 960 1080 1200 1320

Vo

ltag

e (

V/

cell

)

Time (min)



100%

103,6%

5,25

5,40

5,55

5,70

5,85

6,00

6,15

6,30

6,45

0 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

102,2%

5,40

5,55

5,70

5,85

6,00

6,15

6,30

6,45

0 720 1440 2160 2880 3600 4320 5040 5760 6480 7200 7920

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53






Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Current (A) 143,9 66,5 28,8 12,78 10,2 5,63 2,58 1,04

Final Voltage (V) 9,6 9,6 10,2 10,5 10,8 10,8 10,8 11,1






Result (%) 109,5% 101,5% 109,6% 102,9% 106,6% 106,8% 102,5% 103,0%

12V - 2 OPzV 100





100%

109,5%

9,30

9,60

9,90

10,20

10,50

10,80

11,10

0 5 10 15 20

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

101,5%

9,30

9,60

9,90

10,20

10,50

10,80

11,10

11,40

11,70

12,00

0 10 20 30 40 50 60 70

Vo

ltag

e (

V/

cell

)

Time (min)



100%

109,6%

9,90

10,20

10,50

10,80

11,10

11,40

11,70

12,00

12,30

0 15 30 45 60 75 90 105 120 135 150 165 180 195 210

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

102,9%

10,20

10,50

10,80

11,10

11,40

11,70

12,00

12,30

12,60

0 60 120 180 240 300 360 420 480 540

Vo

ltag

e (

V/

cell

)

Time (min)



100%

106,6%

10,50

10,80

11,10

11,40

11,70

12,00

12,30

12,60

0 60 120 180 240 300 360 420 480 540 600 660

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

106,8%

10,50

10,80

11,10

11,40

11,70

12,00

12,30

12,60

0 120 240 360 480 600 720 840 960 1080 1200 1320

Vo

ltag

e (

V/

cell

)

Time (min)



100%

102,5%

10,50

10,80

11,10

11,40

11,70

12,00

12,30

12,60

12,90

0 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

103%

10,80

11,10

11,40

11,70

12,00

12,30

12,60

12,90

0 720 1440 2160 2880 3600 4320 5040 5760 6480 7200 7920

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

1.4 70Ah Plate


Test items: 6pcs 2V - 6 OPzV 420



Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Current (A) 567 300,5 132,7 60,7 48,6 27,5 12,95 5,37

Final Voltage (V) 1,6 1,6 1,7 1,75 1,8 1,8 1,8 1,85






Result (%) 156,1% 104,2% 103,0% 103,1% 102,3% 101,8% 101,5% 101,9%

2V - 6 OPzV 420





100%

156,1%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

0 5 10 15 20 25

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

104,2%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

1,90

1,95

0 10 20 30 40 50 60 70

Vo

ltag

e (

V/

cell

)

Time (min)



100%

103%

1,65

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

0 15 30 45 60 75 90 105 120 135 150 165 180 195

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

103,1%

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540

Vo

ltag

e (

V/

cell

)

Time (min)



100%

102,3%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540 600 660

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

101,8%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 120 240 360 480 600 720 840 960 1080 1200 1320

Vo

ltag

e (

V/

cell

)

Time (min)



100%

101,5%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

101,9%

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 720 1440 2160 2880 3600 4320 5040 5760 6480 7200 7920

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

1.5 100Ah Plate


Test items: 6pcs 2V - 6OPzV600



Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Current (A) 682,0 416,8 188,8 86,6 69,0 39,3 18,6 7,81

Final Voltage (V) 1,6 1,6 1,7 1,75 1,8 1,8 1,8 1,85






Result (%) 149,8% 110,6% 104,1% 102,0% 102,5% 101,9% 102,6% 101,4%

2V - 6 OPzV 600

Table 8 – Summary of test results for the 2V – 6OPzV600




100%

149,8%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

0 5 10 15 20 25

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

110,6%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

1,90

0 10 20 30 40 50 60 70

Vo

ltag

e (

V/

cell

)

Time (min)



100%

104,1%

1,65

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

0 15 30 45 60 75 90 105 120 135 150 165 180 195

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

102%

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540

Vo

ltag

e (

V/

cell

)

Time (min)



100%

102,5%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540 600 660

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

101,9%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 120 240 360 480 600 720 840 960 1080 1200 1320

Vo

ltag

e (

V/

cell

)

Time (min)



100%

102,6%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

101,4%

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 720 1440 2160 2880 3600 4320 5040 5760 6480 7200 7920

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

1.6 125Ah Plate.





Rate C0,25 C1 C3 C8 C10 C20 C48 C120

Current (A) 3171 1967 892 407,5 324 183 85,5 35,40

Final Voltage (V) 1,6 1,6 1,7 1,75 1,8 1,8 1,8 1,85






Result (%) 129,4% 108,3% 107,1% 102,8% 102,6% 102,0% 103,4% 102,0%

2V - 24 OPzV 3000





100%

129,4%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

0 5 10 15 20

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

108,3%

1,55

1,60

1,65

1,70

1,75

1,80

1,85

1,90

0 10 20 30 40 50 60 70

Vo

ltag

e (

V/

cell

)

Time (min)



100%

107,1%

1,65

1,70

1,75

1,80

1,85

1,90

1,95

2,00

0 15 30 45 60 75 90 105 120 135 150 165 180 195

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

102,8%

1,70

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540

Vo

ltag

e (

V/

cell

)

Time (min)



100%

102,6%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 60 120 180 240 300 360 420 480 540 600 660

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

102%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 120 240 360 480 600 720 840 960 1080 1200 1320

Vo

ltag

e (

V/

cell

)

Time (min)



100%

103,4%

1,75

1,80

1,85

1,90

1,95

2,00

2,05

2,10

0 240 480 720 960 1200 1440 1680 1920 2160 2400 2640 2880 3120

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

100%

102%

1,80

1,85

1,90

1,95

2,00

2,05

2,10

2,15

0 720 1440 2160 2880 3600 4320 5040 5760 6480 7200 7920

Vo

ltag

e (

V/

cell

)

Time (min)




Acc. to IEC 60896-21 & 22


53

2 Short Circuit Current & DC Internal Resistance

The purpose of this test is to define prospective short-circuit value Isc and internal resistance Ri

of the specific OPzV units. The short circuit current is defined by determining two data pairs in

the following way:

a. First data pair (Ua, Ia)

After 20 s of discharge at the current Ia = 4 x I10, the voltage and current shall be recorded to

give the first data pair. The current shall be interrupted after 25 s maximum and, without

recharge and after an open circuit stand of 5 min, the second data pair shall be determined.

b. Second data pairs (Ub, Ib)

After 5 s of discharge at the current Ib = 20 × I10, the voltage and current shall be recorded to

give the second data pair.


Test items: 3pcs 2V - 5 OPzV 250, 3pcs 12V - 2 OPzV 100, 3pcs 6V - 6 OPzV 300, 3pcs

2V - 6 OPzV 420, 3pcs 2V - 6OPzV600 & 3pcs 2V - 24 OPzV 3000

Specification: values must be ±10 % of the specification values

Temperature: 20oC


The results are shown on the table below:

Cell type Cnom (Αh)DIN I1 (Α) (at 20sec) I2 (Α) (at 5 sec) U1 (V) U2 (V) Ri-test (mΩ) Isc-test (A) Ri-spec 10% (mΩ) Isc-spec 10% (Α) Ri-test/spec Isc-test/spec

2V - 5OPzV250 250 100 500 1,920 1,672 0,662 3026 0,710 2860 93,2% 105,8%

2V - 6OPzV420 420 168 840 1,926 1,617 0,487 4160 0,510 3980 95,5% 104,5%2V - 6OPzV600 600 240 1200 1,919 1,459 0,479 4246 0,465 4360 103,0% 97,4%2V - 24OPzV3000 3000 1200 6000 1,910 1,412 0,104 19602 0,110 18460 95,9% 106,2%12V - 2OPzV100 100 40 200 1,956 1,709 1,603 1266 1,650 1240 97,2% 102,1%6V - 6OPzV300 300 120 600 1,952 1,627 0,661 3061 0,630 3220 104,9% 95,1%

Rint & Isc

Table 10 – Rint & Isc Results


Acc. to IEC 60896-21 & 22


53

3 High Current Tolerance

The purpose of this requirement is the verification that the design of the internal current

conducting components is robust enough so to withstand short periods of abnormally high

discharge current which may occur before current limiting devices in the exterior circuit activate

(fuses etc.).


Test items: 3pcs 2V - 6OPzV600

Specification: Measure unit voltage (must be > 2 Vpc, inspect and document the status

of the top-lead and terminals of each unit after 30 s current flow

Result: Successful (no signs of heat on the pole and connectors were

observed)

Deviation according to IEC: Test was accomplished by using 2.500A for 1min (instead of

1349.7A for 30sec). The purpose of this test is to certify the durability of the pole – connector at

the specific high current. After the high current discharge, the examination of the cells shows no

defects and signs of melting and the voltage measurements are shown on the table below:

Vpc after 5min rest

V Cell1 V Cell2 V Cell3

2,115 2,103 2,110

Table 11 – Cell Voltages after the discharge and 5 min rest at open circuit


Acc. to IEC 60896-21 & 22


53

4 Recharge Behaviour

The purpose of this requirement is to define the capacity once more available following a long

duration discharge with both short (24 h) and long (168 h) periods of recharge under float

voltage settings. The result of this test documents the effective available capacity, as a percent

of the original capacity after a recharge for 24 h or 168 h using only the recommended float

voltage.



Specification: determine capacity after recharge with Rbf24h>90% and Rbf168h>98%

Result: Successful.

The results are shown on the table below:

2V - 6 OPzV 420

Rate C10 Rate C10

Current (A) 48 Current (A) 48

Final Voltage (V) 1,8 Final Voltage (V) 1,8

Test Temperature (oC) 20 Test Temperature (oC) 20

Nominal Capacity (Ah) 480 Nominal Capacity (Ah) 480

Measured Capacity (Ah) 523,6 Measured Capacity (Ah) 524,4

Rbf24h 515,3 Rbf168h 520,6

Result 98,4% Result 99,3%

Table 12 – Capacity result after 24h and 168h recharge respectively


Acc. to IEC 60896-21 & 22


53

5 Protection against Ground Short Propensity

The purpose of this test is to confirm the satisfactory resistance of the units toward phenomena

enhancing ground shorts such as the occurrence of an electrolyte break-through at seals, joints

or at terminals. An electrolyte break-through can be enhanced by gravity (horizontal position

operation mode) and d.c. voltage gradients (electro-capillarity phenomena).

Instruction: IEC 60896-21 6.5

Test items: 1pc 2V – 24 OPzV 3000

Specification: Operate units in different orientations and apply d.c. gradient

Result: Successful.

There is no evidence of ground short and leakage phenomena.


Acc. to IEC 60896-21 & 22


53

6 Charge Retention during Storage

The purpose of this requirement is to show the actual capacity retained after a set period of

time in storage of a unit filled with electrolyte and charged.


Test items: 6pcs 2V - 5 OPzV 250 & 2pcs 2V – 24 OPzV 3000

Specification: The charge retention factor must be Crf ≥ 70 % Crt to each individual

tested units

Deviations from the IEC Norm

Deviation: 2 pcs of 2V – 24 OPzV 3000 were additionally tested after storage of 3

months at 40oC

Result: Successful

After 180 days of storage at 22oC: Crf average = 92.6% and

Crf min = 91.2%

After 90 days of storage at 40oC: Crf average = 93.7% and

Crf min = 93.6%

Test procedure: The units were stored at an ambient temperature of 22°C and fully

disconnected from any external circuit. After 180 days of storage the units

were discharged without any prior recharge. Their actual capacity after

storage Cast was determined. The charge retention factor Crf is expressed

as percentage, and is equal to Crf = (Cast × 100) / Ca (%)

The following table presents the results Crf/Cell:

Cell 1st C3 C3 after 180 days at 22oC Crf

Cell 1 107,0% 99,8% 93,3%

Cell 2 107,0% 99,5% 93,0%

Cell 3 107,0% 99,5% 93,0%

Cell 4 108,0% 100,0% 92,6%

Cell 5 107,0% 97,6% 91,2%

Cell 6 107,5% 99,7% 92,7%

Cell 1st

C3 C3 after 90 days at 40oC Crf

Cell 1 105,0% 98,5% 93,8%

Cell 2 104,0% 97,3% 93,6%

2V - 5OPzV250

2V - 24OPzV3000

Table 13 – Capacity result after 180 days at 22oC and 90 days at 40oC


Acc. to IEC 60896-21 & 22


53

7 Gas Emission

The purpose of this requirement is the determination of gas emission volumes under normal

float (rated float voltage) and overcharge voltage (2.40Vpc) conditions.


Test items: 6pcs 2V – 24 OPzV 3000

Test Procedure: The cells are fully charged and then float charged for 72h at 2.25Vpc

(report the voltage after 72h at float charge). After the 72h of float

charge, the gas collection process begins and continues for four periods of

168h duration. The cumulative total gas volume collected over the four

periods of time is recorded with the ambient temperature and ambient

pressure at which the each determination of gas volume is made. Then,

the test samples are charged at 2.40Vpc for 24h duration. After the 24h

duration, the gas collection process begins and lasts 48h or till 1000ml of

gas is collected.

The results are shown on the following table (data from table 17):

CellGas ml/h/ah at

Vfloat (2,25Vpc)

Gas ml/h/ah at

Vover (2,40Vpc)

Cell 1 <0,001 0,00764

Cell 2 <0,001 0,00694

Cell 3 <0,001 0,00660

Cell 4 <0,001 0,00694

Cell 5 <0,001 0,00660

Cell 6 <0,001 0,00694

2V - 24OPzV3000

Table 14 – Gas emission results

The cell voltages after 72h of floating charge are the following:

Cell Vfloat after 72h

Cell 1 2,246

Cell 2 2,250

Cell 3 2,257

Cell 4 2,252

Cell 5 2,249

Cell 6 2,247

Table 15 – Voltage/cell after 72h of float charge


Acc. to IEC 60896-21 & 22


53

By following the procedure, the following tables present the gas emission (temperature and

ambient pressure were standardized to the below values) at the four 168h periods of time

during float charging (2.25Vpc):

CellGas Volume

Va1 (ml)

Ambient Temperature

Ta1 (K)

Ambient Pressure

Pa1 (kPa)

Cell 1 <0,001

Cell 2 <0,001

Cell 3 <0,001

Cell 4 <0,001

Cell 5 <0,001

Cell 6 <0,001

CellGas Volume

Va2 (ml)

Ambient Temperature

Ta2 (K)

Ambient Pressure

Pa2 (kPa)

Cell 1 <0,001

Cell 2 <0,001

Cell 3 <0,001

Cell 4 <0,001

Cell 5 <0,001

Cell 6 <0,001

CellGas Volume

Va3 (ml)

Ambient Temperature

Ta3 (K)

Ambient Pressure

Pa3 (kPa)

Cell 1 <0,001

Cell 2 <0,001

Cell 3 <0,001

Cell 4 <0,001

Cell 5 <0,001

Cell 6 <0,001

CellGas Volume

Va4 (ml)

Ambient Temperature

Ta4 (K)

Ambient Pressure

Pa4 (kPa)

Cell 1 <0,001

Cell 2 <0,001

Cell 3 <0,001

Cell 4 <0,001

Cell 5 <0,001

Cell 6 <0,001

293 101,3

293 101,3

293 101,3

293 101,3

Table 16 – Gas volume at the four 168h periods of float charge at 2.25 Vpc


Acc. to IEC 60896-21 & 22


53

After a 24h charging at 2.40Vpc, the gas emission procedure begins and lasts 48h. The results

are presented on the following table:

CellGas Volume

Va1 (ml)

Ambient Temperature

Ta1 (K)

Ambient Pressure

Pa1 (kPa)

Cell 1 1100 293 101,3

Cell 2 1000 293 101,3

Cell 3 950 293 101,3

Cell 4 1000 293 101,3

Cell 5 950 293 101,3

Cell 6 1000 293 101,3

Table 17 – Gas volume at the four 24h periods of overcharge at 2.40Vpc


Acc. to IEC 60896-21 & 22


53

8 Material Identification

The purpose of this requirement is to enhance the recycling of material

for environmental protection by ensuring that the plastic materials used for the units are

clearly identified with the ISO 1043-1 material symbol and legible throughout the service life.


Test items: one cell case

Specification: ISO symbol to be present

Test Result: Pass (ISO symbol present on the outside of the cover or case)

9 Valve Operation

The purpose of this requirement is to ensure that each valve on the unit is opening and

releasing gas before and after the high temperature (55 °C or 60 °C).


Test items: 6 valves

Test Procedure: The cells are fully charged and then float charged for 72h at 2.25Vpc

Test Result: Pass

Results can be seen analytically to the table below:

Valve

Opening

Pressure (mbar)

Closing

Pressure (mbar)

Valve 1 150 130

Valve 2 145 120

Valve 3 150 125

Valve 4 145 120

Valve 5 150 130

Valve 6 150 125

Table 18 – Valve release and reseal pressure


Acc. to IEC 60896-21 & 22


53

10 Intercell Connector Performance

The purpose of this requirement is to show the maximum temperature reached by the specified

intercell connector (the external conductor that connects individual units or monoblocs to form a

battery) under the high current.


Test items: 6pcs 2V - 6OPzV600, connector 95/160mm

Test Result: Intercell connector temperature was <70oC

Intercell Connector

(95/160mm)

Maximum

Temperatutre (oC)

1 57

2 58

3 57

4 58

5 58

Table 19 – Intercell connector maximum temperature


Acc. to IEC 60896-21 & 22


53

11 Endurance in Cycles (Float Service with Daily Discharges)

The purpose of this test is to define the aggregate capacity and cycling behavior of the battery

undergoing very frequent or even daily discharges such as experienced in areas with irregular or

insufficient main supply, and where recharge can be carried out only under float voltage settings

conditions.



Test Result: 1616 cycles to reach 80% C10

Deviations from the IEC Norm

Deviation: The IEC 60896-2 (cl 5.3) Endurance in cycles was performed instead of

the IEC 60869-21 (cl 6.13) Float service with daily discharges

Test procedure: The test was performed under the following profile:

a. Capacity test at 10h DIN rate (I10 = 42A – 1.80V/c) every 100 cycles.

b. Discharge cycling settings: discharge with 2.0 x I10 for 3 hours. This

current corresponds to ~4h discharge DIN rate. The 3h discharge out

of 4h nominal yields 75% DoD for each cycle

c. Recharge per cycle: with Imax=2*I10 and Umax = 2.40 V/c for 21h

d. Average temperature: 25oC

The following figure shows the capacity development Vs the No of cycles:


Acc. to IEC 60896-21 & 22


53

Cycling test acc to IEC 896-2 (ch5.3): 6 cells 6OPzV420

Capacity evolution through cycles

0%

20%

40%

60%

80%

100%

120%

140%

0 200 400 600 800 1000 1200 1400 1600 1800Number of cycles

Ca

pa

city

(%

to

th

e D

IN n

om

ina

l)

Figure 49. Capacity Vs Cycles

12 Impact of a Stress Temperature of 60 °C (Accelerated Test of

Operational Lifetime)

The purpose of the requirement is to elicit information on how long units perform under

elevated temperature stress conditions. These stress conditions degrade the performance of the

units very rapidly as increased water loss and grid corrosion will result in increasing capacity

losses.


Test items: 6pcs, 2V - 6OPzV600

Test Result: Test result from 6 cells 6OPzV600:

Total days at 60oC achieved: 410 days

Equivalent life time at 20oC: 29.3 years

Test procedure: Capacity test at 3h DIN rate every after 30 days at 60oC with the battery

been fully charged. Test is terminated when actual capacity drops below

80%. The valid acceleration factor to extrapolate the service life at 20oC

from the achieved duration at 60oC is 26.1 times. This factor corresponds

to reduction of the lifetime to the half for every 8.5oK temperature rise.


Acc. to IEC 60896-21 & 22


53

Figure 50. Capacity Vs Time (days)

13 Service life at an operating temperature of 40 °C

The purpose of this requirement is to elicit standardized information about the service behavior

of the units under elevated but realistic operating temperatures and float voltage settings.


The determination of the expected service life is extrapolated from results of the accelerated

test at 60oC (see paragraph 1.12, figure 50) and equals to 29.3 years at 20oC and 5.7 years at

40oC.

Remark: The test at 40oC is still running.

14 Abusive over-discharge

The purpose of the requirement is to ensure that units, undergoing abusive over-discharges

during the service life, show a minimum of capacity recovery under specified conditions.



Acc. to IEC 60896-21 & 22


53

Test items: 7pcs, 2V - 6OPzV600

Test Result: Average Unbalanced Over Discharged Capacity Caod =92%

Cyclic Over-discharge Capacity Caoc:

Caoc1 =103%, Caoc2 =103%, Caoc3 =100%

Test procedure: Unbalanced over-discharge (Caod): four units were tested. One unit was

discharged at 20oC with I10 for 3h and then it was connected to the rest

three units. Afterwards, the string was subjected to a discharge with I10 at

20oC (Vfinal 1.80 Vpc) until the voltage of the three, initially fully charged

units reach a total voltage of Ufinal of 3 × n × 1.70 Vpc where n is the

number of cells in this substring. After the discharge and a 24 h stand in

the discharged state, the four unit string was recharged in series for 168 h

with a current limited to I = 2,0xI10 and a voltage limited to the float

voltage specified by the manufacturer for 20 °C. At the end of the 168 h of

charge, the four units were subjected to a capacity test with a constant

current of I = I3 to a Ufinal of 4 × n × 1,70 Vpc and the capacity Ca

corrected to 20 °C.

Cyclic over-discharge test (Caoc): three units were tested. Units were

discharged with I10 at 20oC till they reach 1.25Vpc. After the discharge,

units stand in the discharge state for 1h and afterwards were recharged

with at float voltage with 2*I10 for 168h. This procedure was repeated 5

times. At the end of the firth period, cells were subjected to a C3 test.

15 Thermal Runaway Sensitivity

The purpose of the requirement is to elicit standardized information about how soon units may

enter thermal runaway conditions when exposed to higher than normal voltages under specified

conditions.



Test Result: PASS (the type is applicable for all stationary applications)

Test at 2.45V/cell - cell case temperature after 168 hours: 31.6 oC

Test at 2.60V/cell - cell case temperature after 168 hours: 31.6 oC

At 2.40Vpc we have the following figure:


Acc. to IEC 60896-21 & 22


53

24OPzV3000 - Thermal Runaway Test at 2,45 V/c

0

10

20

30

40

50

60

0 20 40 60 80 100 120 140 160 180

time at float (h)

Tem

pera

ture

(oC)

0

10

20

30

40

50

60

Curr

en t(

A)

Temp 1m away

Temp in the gap

Temp case

Float CurrentCell case temperature after 168 hours: 31,6 oC

Figure 51. Temperatutre Vs Time Vs Current at 2.45Vpc

At 2.60Vpc we have the following figure:

24OPzV3000 - Thermal Runaway Test at 2,60 V/c

10

20

30

40

50

60

70

0 20 40 60 80 100 120 140 160 180

time at float (h)

Tem

pera

ture

(oC)

10

20

30

40

50

60

70

Curr

ent

(A)

Temp 1m away Temp in the gap

Temp case surface Float Current

Case temperature after 168 hours : 57,5 oC

Figure 52. Temperatutre Vs Time Vs Current at 2.60 Vpc

16 Low Temperature Sensitivity

The purpose of this requirement is to ensure that units experiencing abusive low temperature

conditions during service life show a minimum of mechanical stability against freezing induced

forces and adequate capacity recovery under specified conditions.




Test Procedure: The test units were individually discharged with I10 and end voltage

1.80Vpc at 20oC. The discharged units were then placed in a test chamber

with a forced flow of air having a temperature of –18 °C. After 72h of

residence in the test chamber the units were withdrawn from the test


Acc. to IEC 60896-21 & 22


53

chamber and after 24 h of stand at open circuit, charged in a room

temperature of 20 °C for 168 h with a current limited to I =2*I10 and

voltage limited to the float voltage (2.25Vpc). The units were individually

discharged with a current of I=I3 to an Ufinal of n×1,70 Vpc and the actual

capacity Ca corrected to 20 °C.

The results are shown on the following table:

Cell

Cell 1

Cell 2

Cell 3

Cell Capacity Ratio Freezing Damage

Cell 1 99,5%

Cell 2 99,6%

Cell 3 99,5%

Discharge after freezing with I3 at n x 1,70Vpc

max bulging approx

3mm. It is temporary,

without implications

Discharge without freezing with I10 to n x 1,80Vpc

Capacity Ratio

103%

104%

104%

Table 20 – Capacity results before and after freezing

17 Dimensional Stability at Elevated Internal Pressures and

Temperatures

The purpose of this requirement is to provide an indication of the susceptibility of the unit to

“balloon out” or expand under certain conditions and may be of interest where cells/monoblocs

are to be installed in areas of restricted space.


Test items: 1pc, 2V - 6 OPzV 420

Test Result: Successful (max bulging approx 3mm. It is temporary, without

implications)


Acc. to IEC 60896-21 & 22


53

Test Procedure: The test unit was adapted with a pressure regulator to maintain a pressure

in all interior cavities equal to the maximum valve opening pressure

(110mbar) present in units and as specified by the manufacturer. This

specified pressure was maintained throughout the test. The pressurized

unit was then placed into a chamber with recirculating air at a temperature

of 50 °C. After 24 h of residence in the test chamber and under pressure,

the maximum outside dimension (width and length) of the cell case

difference was recorded in mm.

18 Stability against mechanical abuse of units during installation

The purpose of this requirement is to ensure that the unit design is mechanically robust enough

to withstand standardized mechanical stresses during unpacked transport and installation.



Test Result: Successful (No leakage detectable after two times two drops)

Test Procedure: The units were dropped according to the height prescriptions of IEC

60068-2-32 and amendment. Two “Free Fall”, for resistance against


Acc. to IEC 60896-21 & 22


53

leakages caused by two drops each onto a smooth, level concrete floor

from drop height 100 mm. This test proceeded as shown below:

19 Content and durability of required markings

The purpose of this requirement is to ensure the presence of essential product and safety

information on each unit and their legibility after exposure to a set of chemicals.


Test items: 3 labels


Information remain readable after exposure to chemicals


Acc. to IEC 60896-21 & 22


53

Remain technical information in place

Test Procedure: Test with water and aliphatic solvent: a) A label or marking was rubbed for

15 s with a piece of cloth soaked with water and again for 15 s with a

piece of cloth soaked with petroleum spirit, dried in air and then inspected

visually.

b) The petroleum spirit used for this test was n-hexane with an initial

boiling point of 65 °C, a dry point of approximately 69 °C, a density of 0,7

kg/l and a maximum aromatic hydrocarbon content of 0,1 % per volume.

Test with neutralizing solutions: A new label was rubbed for 15 s with a

piece of cloth soaked with a saturated solution of sodium carbonate

(Na2CO3) in water, dried in air and then inspected visually.

Test with electrolyte:

A new label was rubbed for 15 s with a piece of cloth soaked with a

solution of 40 % in weight of H2SO4 in water, washed with water, dried in

air and then inspected visually.

20 Protection against internal ignition from external spark sources


Test items: This test is certified by our suppliers

21 Flammability rating of materials


Test items: This test is certified by our suppliers

Date post:	23-Jan-2021
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