NorthStar NSB BLUE+®

Owner’s Manual
About OutBack Power
OutBack Power is a leader in advanced energy conversion technology. OutBack products include true sine
wave inverter/chargers, maximum power point tracking charge controllers, and system communication
components, as well as circuit breakers, batteries, accessories, and assembled systems.

Applicability
These instructions apply to NorthStar NSB BLUE+® series batteries only.

Contact Information
Address: 17825 – 59th Avenue N.E.
Suite B
Arlington, WA 98223 USA
Website: www.outbackpower.com

Disclaimer
UNLESS SPECIFICALLY AGREED TO IN WRITING, OUTBACK POWER:
(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.
(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE, WHETHER DIRECT,
INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH
INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK.
OutBack Power cannot be responsible for system failure, damages, or injury resulting from improper
installation of their products.
Information included in this manual is subject to change without notice.

Notice of Copyright
NorthStar NSB BLUE+® Owner’s Manual © 2019 by OutBack Power. All Rights Reserved.

Trademarks
OutBack Power, OutBack Power logo, NSB and BLUE+ are trademarks owned and used by
EnerSys Corporation. These trademarks may be registered in the United States and other countries.

Date and Revision

January 2020, Revision A

Part Number
900-00264-01-001 Rev A
 Table of Contents
Important Safety Instructions ............................................................... 4
Additional Resources ...................................................................................................................... 4

Introduction ..................................................................................... 5
Audience ......................................................................................................................................... 5
NorthStar NSB BLUE+® .................................................................................................................. 5
Materials Required .......................................................................................................................... 6
Tools ............................................................................................................................................................6
Storage and Environment Requirements ........................................................................................ 6
Temperatures ...............................................................................................................................................6
Self-Discharge..............................................................................................................................................7
Storing NorthStar NSB BLUE+® Batteries ...................................................................................................7
Capacity .......................................................................................................................................... 7
State of Charge ............................................................................................................................... 8
System Layout ................................................................................................................................ 8
Battery Configurations .................................................................................................................................9
DC Wiring...................................................................................................................................... 11
Commissioning ............................................................................................................................. 13
OCV Recharge Time ..................................................................................................................... 13
Charging ....................................................................................................................................... 15
Bulk Stage ..................................................................................................................................................15
Absorption Stage .......................................................................................................................................15
Float Stage .................................................................................................................................................16
Equalization................................................................................................................................................16
Freshening Charge ....................................................................................................................................16
Notes on NorthStar NSB BLUE+® Charging ..............................................................................................16
Temperature Compensation ......................................................................................................... 17
Remote Temperature Sensor ....................................................................................................................17
Improper Use ................................................................................................................................ 18
Battery Voltage Records ............................................................................................................... 19

Troubleshooting and Maintenance ...................................................... 21

Periodic Evaluation ....................................................................................................................... 22

Specifications ................................................................................. 25

900-00264-01-001 Rev A 3
 Safety Instructions

Important Safety Instructions

READ AND SAVE THESE INSTRUCTIONS!
This manual contains important safety instructions for the NorthStar NSB BLUE+® battery. These
instructions are in addition to the safety instructions published for use with all OutBack products.
Read all instructions and cautionary markings on the NorthStar NSB BLUE+® battery and on any
accessories or additional equipment included in the installation. Failure to follow these instructions
could result in severe shock or possible electrocution. Use extreme caution at all times to
prevent accidents.

WARNING: Personal Injury

 Some batteries can weigh in excess of 100 lb (45 kg). Use safe lifting techniques when
lifting this equipment as prescribed by the Occupational Safety and Health Association
(OSHA) or other local codes. Lifting machinery may be recommended as necessary.
 Wear appropriate protective equipment when working with batteries, including eye or
face protection, acid-resistant gloves, an apron, and other items.
 Wash hands after any contact with the lead terminals or battery electrolyte.

WARNING: Explosion, Electrocution, or Fire Hazard

 Ensure clearance requirements are strictly enforced around the batteries.
 Ensure the area around the batteries is well ventilated and clean of debris.
 Never smoke, or allow a spark or flame near, the batteries.
 Always use insulated tools. Avoid dropping tools onto batteries or other electrical parts.
 Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing,
or eyes.
 Wear complete eye and clothing protection when working with batteries. Avoid touching
bare skin or eyes while working near batteries.
 If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters the eye, immediately flood it with running cold water for at least 20 minutes and
get medical attention as soon as possible.
 Never charge a frozen battery.
 Insulate batteries as appropriate against freezing temperatures. A discharged battery
will freeze more easily than a charged one.
 If a battery must be removed, always remove the grounded terminal from the battery
first. Make sure all devices are de-energized or disconnected to avoid causing a spark.
 Do not perform any servicing other than that specified in the installation instructions
unless qualified to do so and have been instructed to do so by OutBack Technical
Support personnel.

Additional Resources
These references may be used when installing this equipment. Depending on the nature of the
installation, it may be highly recommended to consult these resources.
Institute of Electrical and Electronics Engineers (IEEE) guidelines: IEEE 450, IEEE 484, IEEE
1184, IEEE 1187, IEEE 1188, IEEE 1189, IEEE 1491, IEEE 1578, IEEE 1635, IEEE 1657, and local
code and jurisdictions (various guidelines for design, installation, maintenance, monitoring, and
safety of battery systems)

4 900-00264-01-001 Rev A
 Introduction
Audience
This manual is intended for use by anyone required to install and operate this battery. Be sure
to review this manual carefully to identify any potential safety risks before proceeding. The
owner must be familiar with all the features and functions of this battery before proceeding.
Failure to install or use this battery as instructed in this manual can result in damage to the
battery that may not be covered under the limited warranty.

NorthStar NSB BLUE+®

The NorthStar NSB BLUE+® (pure lead carbon) is a front terminal 12Vdc battery combining
advanced Thin-Plate Pure Lead VRLA AGM technology with high-grade carbon added to the
negative active material (NAM). This carbon additive extends the battery’s life, boosts cyclic
performance and reduces the size of sulfate crystals on the negative plate during partial state of
charge (PSoC). The NorthStar NSB BLUE+® can withstand a very high rate of charge/discharge
as well as elevated temperatures. Specially designed for today’s demanding off-grid and self-
consumption applications, the NSB BLUE+® requires no periodic watering and no retightening
of terminal connections.

4.9”
22.0” (55.9 cm)
(12.6 cm)
Terminals

12.6”
(32.0 cm)

Carrying
Handles

Figure 1 Nominal Dimensions for NorthStar NSB BLUE+® (NSB190FT Model)

900-00264-01-001 Rev A 5
Installation and Operation

Materials Required
Tools (use insulated tools only)
o Digital voltmeter
o Socket wrench
o Torque wrench calibrated in inch-pounds
o Box end wrench
o Battery lifting equipment (handles) and fork lift to lift pallets of batteries
o Rubber gloves
o Full face shield
o Plastic apron
o Portable eyewash
o Spill kit
o Fire extinguisher (class C)

Accessories
o Interconnect bar (included)
o Terminal cover (included)
o Hardware (included)
o Interconnect cables as needed

CAUTION: Fire Hazard

Install properly sized battery cabling and interconnect cables. The cable ampacity
must meet the needs of the system, including temperature, deratings, and any other
code concerns.

Storage and Environment Requirements

Temperatures
o Optimal operating temperature is 68° to 86° F (20° to 30°C); maximum temperature range is
–40° to 149°F (–40° to 65°C).
o Do not allow a discharged battery to freeze, as this will damage them and could result in leakage.
o Do not expose batteries to temperature variations of more than 5°F (3°C). This leads to voltage
imbalance between multiple batteries (or between battery cells if there is a temperature differential).
o Batteries should be stored in a cool, dry location.

6 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

Self-Discharge
All NorthStar NSB BLUE+® batteries
will discharge over time once charged,
even in storage. Higher storage
temperatures increase the rate of self-
discharge. Fully charged, the natural
(“rest”) voltage of all NorthStar NSB
BLUE+® batteries is approximately
13.0 Vdc. A battery should have a
freshening charge (see page 16) if its
rest voltage is below 12.2 Vdc per
battery (2.03 Vdc per cell or VpC).
A battery should not be used if its rest
voltage is 12.0 Vdc or lower upon
Figure 2 State of Charge vs. Time
delivery. Contact OutBack Power
upon receiving a battery in this state.

Storing NorthStar
NSB BLUE+®
Batteries
The NorthStar NSB BLUE+® batteries
must be given a freshening charge
every 24 months when stored at
77°F (25°C). If stored in higher
temperatures, the charge should be
more often.
Figure 3 Temperature vs. Capacity
Capacity
Battery capacity is given in ampere-
hours or amp-hours (Ah). This is a
current draw which is multiplied by the
duration of current flow. A draw of X
amperes for Y hours equals an
accumulation of XY amp-hours.
Because a lead-acid battery’s chemical
reaction constantly releases energy, its
amp-hour capacity is affected less by
lighter loads. The battery has greater
capacity under lighter loads.
For example, if the NSB190FT BLUE+®
is discharged at the 20-hour rate to a
Figure 4 Cycle Endurance
voltage of 1.75 VpC (a load expected
to effectively drain 100% of its capacity
in 20 hours), it will be measured to have 202.4 amp-hours. However, at the 2-hour rate,
a heavier load, only 152.2 amp-hours will be measured. For all tested discharge rates and
amp-hours, see Table 3 on page 26.

900-00264-01-001 Rev A 7
 Installation and Operation

State of Charge
The NorthStar NSB BLUE+® state of
charge (SoC) can be determined by
two methods. One is to measure its
voltage. This method is typically used
when batteries are in storage. This is
accurate only if the batteries are left at
rest (no charging or loads) for 12 hours
at room temperature (77°F or 25°C). If
these conditions are not met, then
voltage checks may not yield
accurate results. If they are met, then
on average, a battery at 13.0 Vdc will
be at 100% SoC. A rest voltage of
12.2 Vdc represents roughly 50% SoC. Figure 5 State of Charge vs.
Open Circuit Voltage (OCV)
The second method is when batteries
are in use, the most accurate method
to measure SoC is to use a battery monitor such as the OutBack FLEXnet DC. Using a sensor
known as a shunt, the monitor observes the current through the battery. It keeps a total of
amp-hours lost or gained by the battery and can give accurate SoC readings.
The NorthStar NSB BLUE+® can be discharged and recharged (cycled) regularly to a level
as low as 50% depth of discharge (DoD). This is common in a cycling application such as an
off-grid system. However, for optimal life, the best practice is to avoid ever discharging below
50%. Lower DoD levels can shorten the cycle life.
If operated in a range with consistent charge and discharge to no more than 50% DoD, the
NorthStar NSB BLUE+® will typically have a life of 2,050 cycles. With consistently lighter
discharge (10 to 30% DoD with proper recharge), the battery may have significantly
more cycles.

System Layout
CAUTION: Fire Hazard
Failure to ventilate the battery compartment can result in the buildup of hydrogen
gas, which is explosive.

o The battery enclosure or room must be well-ventilated. This ventilation protects against accidental
gas buildup. All NorthStar NSB BLUE+® batteries are valve-regulated and do not normally emit
noticeable amounts of gas. However, in the event of accidental leakage, the enclosure must not
allow the leaked gas to become concentrated.
o The battery enclosure or room must have adequate lighting. This is necessary to read terminal
polarity, identify cable color, and view the physical state of the battery as required.
o The battery should be installed with a minimum 2" for airflow and 36” (91.4 cm) clearance in front of
batteries or cabinet. This allows access for testing, maintenance, and any other reasons.
o Multiple batteries should have a minimum of ¼” (12.7 mm) clearance on either side (½" recommended).

8 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

Battery Configurations

Load – Load + Load – Load +

Series String (24 Vdc) Series String (48 Vdc)

Batteries are placed in series (negative to positive) for additive voltages. Batteries in series are known
as a “string”. A string of two NorthStar NSB BLUE+® batteries has a nominal voltage of 24 Vdc and
can be used for 24-volt loads. A string of four has a nominal voltage of 48 Vdc. Other voltages are
possible. However, batteries in series do not have additive amp-hours. A single string of any voltage
(as shown above) has the same amp-hours as a single battery.
When replacing batteries, a new battery should not be placed in series with old batteries. This will
cause severe stress and shorten the life of all batteries. All batteries in a string should be replaced at
the same time.
Figure 6 Series String Configurations

Batteries are placed in parallel (positive to positive, Parallel Batteries

Load Bus – Load Bus +
negative to negative) for additive amp-hour capacity.
Three batteries in parallel have three times the
amp-hours of a single battery. However, batteries in
parallel do not have additive voltages. A single set of
batteries in parallel (as shown in this figure) have the
same voltage as a single battery.
NOTE: Use caution when designing or building
systems with more than three NorthStar NSB BLUE+®
batteries or strings in parallel. The extra conductors
and connections used in larger paralleled systems can
lead to unexpected resistances and imbalances
between batteries. Without proper precautions, these
factors will reduce the system efficiency and shorten the
life of all batteries. For systems beyond three strings,
contact an OutBack representative.

Figure 7 Parallel String Configuration

900-00264-01-001 Rev A 9
Installation and Operation

Batteries are placed in both series and parallel for both additive voltage and amp-hour capacity.
Series strings placed in parallel have the same nominal voltage as each string. They have the same
amp-hour capacity of each string added together. Two parallel strings of two NorthStar NSB
BLUE+ batteries in series have a nominal voltage of 24 Vdc, twice the nominal voltage. They also have
double the amp-hour capacity of a single battery. Two parallel strings of four batteries in series have a
nominal voltage of 48 Vdc at double the amp-hour capacity of a single battery.
In a series-parallel bank, it is not recommended to connect the load to the positive and negative
terminals of a single string. Due to cable resistance, this will tend to put more wear on that string.
Instead, it is recommended to use “reverse-return” or “cross-corner” wiring, where the positive cable is
connected to the first string and the negative is connected to the last. This will allow current to flow
evenly among all strings.

Load Bus – Load Bus + Load Bus –

Load Bus +

Figure 8 Series/Parallel String Configurations

10 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

DC Wiring
CAUTION: Equipment Damage
Never reverse the polarity of the battery cables. Always ensure correct polarity.

CAUTION: Fire Hazard

Always install a circuit breaker or overcurrent device on the DC positive conductor
for each device connected to the batteries.

CAUTION: Fire Hazard

Never install extra washers or hardware between the mounting surface and the
battery cable lug or interconnect. The decreased surface area can build up heat.

Terminal Hardware
NorthStar NSB BLUE+® battery terminals consist of a threaded stud which receives a nut.
Terminal hardware is assembled as shown in below.

NOTE:
 Install the cable lugs (or interconnects) and all other hardware in the order
illustrated. The lug or interconnect should be the first item installed. It should
make solid contact with the mounting surface. Do not install hardware in a
different order than shown.
 To avoid corrosion, use plated lugs on cable terminations. When multiple
cables are terminated, use plated terminal bus bars.
 Tighten the terminals to a torque value of 71 in-lb (8 Nm).

M6 Nut

Flat Lock
Washer Washer

Cable Lug or
Interconnect

Battery Battery
Terminal Terminal
Stud Surface

Figure 9 Terminal Assemblies

Cleaning Battery Terminals

To minimize contact resistance, it is important that the brass terminals of the batteries are
cleaned of any oxidation that may have occurred during transportation and storage. It is most
convenient to clean them prior to placing them on the rack.

900-00264-01-001 Rev A 11
 Installation and Operation

Applying Grease to Terminals

Electrical grade conductive grease is applied directly to the battery terminals as a corrosion
preventative measure during manufacturing. In typical indoor installations no additional grease
is required to protect the terminals and other electrical connections after installation. The bus
bars and other hardware provided with the batteries are plated to protect from corrosion.

Voltage Check
Before connecting the batteries in series, the voltage variation must be checked and the
voltages recorded. If the voltage varies more than 0.15 Vdc between the highest and the lowest
battery voltage, the batteries should be charged individually before being connected in series.
Alternatively the batteries may be matched in each string so that all the batteries have a voltage
spread of less than 0.15 Vdc.

To make the DC connections:

Make certain to clean all terminals and contact
surfaces as described above.
If installing batteries in a rack or cabinet,
always begin with the lowest shelf for stability.
Place all batteries with terminals facing to the
most accessible side of the rack. If terminal
protectors are present, remove and save them.
In common configurations, the battery on one end
will be the positive (+) output for that string. This Interconnecting Flexible Link
battery should be designated [1]. Proceeding to
the other end, adjacent batteries in that string Figure 10 DC Connections
should be designated [2], [3], and so on.
If more than one string is present, designate the first string as A, the second as B, and so on. This
should be done regardless of whether the strings are on the same shelf or higher shelves. Number
the batteries in subsequent strings just as in step 2.
Install cables or bus bars for DC loads. Size all conductors as appropriate for the total loads. See
the manual for the battery rack or cabinet if necessary.
Repeat the process as appropriate for batteries [2], [3], and any others in the string. Connect the
proper number of batteries in series for the nominal voltage of the load.
If multiple series strings will be used, repeat this process for strings B, C, and so on.
Install parallel connections. Parallel connections are made from the positive terminal of one battery
or string to the positive of the next; negative connections are made similarly. (See Figure 4 on
page 7.) External cables or bus bars must be provided. Interconnecting bars cannot make parallel
connections.
Use a digital voltmeter (DVM) to confirm the nominal system voltage and polarity. Confirm that no
batteries or strings are installed in reverse polarity.
Install series connections. If an interconnecting bar was supplied, it should connect from the
negative (left) side of battery [1] to the positive (right) side of battery [2] as shown above (see
arrow). Top-terminal batteries require short interconnecting cables to be provided. Tighten
interconnect hardware “hand tight” only.
Before making the final battery connection, ensure the main DC disconnect is turned off. If this is
not possible, then do not make the final connection within the battery enclosure. Instead, make the

12 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

connection at the load or elsewhere in the cable system so that any resulting spark does not occur
in the battery enclosure.
Once hardware is installed and batteries are properly aligned, torque all connections to the
appropriate value for the battery model. (See the requirements on page 25.) Lightly coat the
surfaces with battery terminal grease. Reinstall the terminal covers if present.

IMPORTANT:
Before using the battery bank, commission the batteries as described below.

Commissioning
The commissioning charge applies when the batteries have been in transit or in storage for 24
months or more. (This applies at a storage temperature of 25°C or 77°F. The interval is shorter
at higher temperatures.) It is also needed when the battery system is intended for use at the
minimum float charging voltage or when the number of cells in series is greater than 24. Under
any of these conditions, it is recommended that the battery system is given a freshening charge
at 2.35 volts average per cell for 16 hours. This will assure higher initial performance and will
reduce the time period required for the cells to achieve proper voltage balance between the
individual units.
To apply a freshening charge:
Confirm the freshening (equalization) voltage from the charger/rectifier is set to a value equal to the
Absorb Charging Voltage shown on page 15.
Close the circuit from the charger to the battery and confirm that the battery accepts current.
Monitor the battery periodically and note that the operation is proceeding normally. Make certain
that the current acceptance is declining and that the batteries are not overheating (within ±5°F or
±2.8°C of each other and the ambient temperature). Make certain that the individual battery
voltages on equalization charge are 14.1 ± 0.50 Vdc.
Terminate the freshening charge in the case of any extraordinary situation or after 16 hours.

NOTE:
Never charge batteries in their packaging — always unpack and position with space
between batteries before charging.

OCV Recharge Time

Depending on the state of charge of the batteries it may take some time before they reach full
state of charge. See recommended charge times below based on OCV values of the batteries:
>12.80 Vdc 3 day charge 2.27 VpC
12.6 to 12.8 Vdc 3 day charge 2.27 VpC
12.3 to 12.6 Vdc 1 day charge 2.41 VpC
12.1 to 12.3 V dc 1 day charge 2.41 VpC

900-00264-01-001 Rev A 13
Installation and Operation
NOTES:

14 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

Charging
NorthStar NSB BLUE+® batteries are usually charged using a “three-stage” charging cycle: bulk
stage, absorption stage, and float stage. However, not all chargers are designed or
programmed the same way. The settings should be checked and changed to match the
recommendations below if necessary.

Charging Voltages
o Absorb Charging Voltage: 14.1 Vdc
o Equalize Charging Voltage: 14.4 Vdc (4 hours every 12 months)
o Float Voltage: 13.6 Vdc

Bulk Stage
The bulk stage is a constant-current stage. The charge current is maintained at a constant high
level. The battery voltage will rise as long as the current flows. This battery has a minimum
recommended charge current of (2 × I10-hour) with no maximum limit (per battery).
The charge rate (amps) is expressed as I10, where I10 is the current for a 10-hour discharge to
100% depth-of-discharge (DoD). For example:
o The 10-hour discharge capacity for the NSB190FT = 184.2 Ah (1.75 VpC@25ºC)
o I10, the 10-hour discharge rate = 184.2 Ah ÷ 10 hours = 18.4 Adc
o 2 x I10 = 2 x 18.4 Adc = 36.8 Adc

Absorption Stage
Absorption is a constant-voltage stage.
It is established upon reaching the Absorb
voltage setting. The charger limits the
current flow to only what is necessary to
maintain this voltage. A high current is
required to raise the voltage to the
absorption level, but less is required to
maintain it there. As long as the absorption
level is maintained, the requirement tends
to decrease, causing a tapering current.
The amount of absorption current will vary
with conditions, but will typically decrease to
a very low number. This “tops off the tank”,
leaving the battery at 100% SoC.
The battery is considered full when the
charge current tapers down to 0.5 to 1% of
the C20 rate (unlike traditional batteries,
which are considered full when charge
current reaches 2 to 3%, the BLUE+®
charge current will drop even lower
because of the purity of metals used). This
represents 100% SoC. The charger can Figure 11 Three-stage Charging
then exit the absorption stage.
900-00264-01-001 Rev A 15
 Installation and Operation

Not all chargers measure this in amperes. Many chargers hold the absorption for a timed period
(often two hours), assuming that the current will taper down by then. However, if the charge
ends before the current tapers to the desired level, the battery may not reach 100% SoC.
Repeated failure to charge the batteries to 100% will result in decreased battery life. If possible,
use a DC amp meter to observe and time the current as it tapers down. The absorption timer
can then be set accordingly.

Float Stage
The float stage maintains the battery at a full state of charge, counteracting the natural tendency
of a fully-charged battery to slowly discharge when sitting idle. During the float stage, the
battery is supplied with a constant voltage of 13.6 Vdc to keep it "topped off" at 100% SoC.

Equalization
To maintain optimal battery health, an equalization charge should be performed every 12
months. Equalize at 14.4 Vdc for 4 hours.

Freshening Charge
A maintenance or “freshening” charge should be given to batteries that have been in storage.
The freshening charge must be appropriate to the battery model. All charging should be
temperature-compensated (see page 17). With a multi-stage charger, the voltages for each
stage are set as noted on page 15.

Notes on NorthStar NSB BLUE+® Charging

The current requirements for the absorption stage are usually minimal; however, this will vary
with conditions, with battery age, and with battery bank size. (Larger banks tend to have higher
exit current values for the absorption stage, but they also have higher float current.) Any loads
operated by the battery while charging will also impact the requirements for the charger, as the
charger must sustain everything.
If using a battery monitor device such as an OutBack FLEXnet DC, program the charge
efficiency to 97%; return amps to 1% of capacity; and charge voltage to 0.4 Vdc below
absorption. It is highly recommended to use the NSB BLUE+® batteries in conjunction with a
battery monitor such as the FLEXnet DC and OPTICS RE for proper monitoring and data
recording. The programming may be used with the following settings:
Amp-Hours: Based on the 20-hour capacity
Charge Time: 1 minute
Charge efficiency: 97%
Return Amps: 1% Adc
Charge voltage: 13.7 Vdc

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 NorthStar NSB BLUE+ Batteries

Temperature Compensation
Battery performance will change when the temperature varies above or below room temperature
(77°F or 25°C). Temperature compensation adjusts the charging to correct for these changes.
When a battery is cooler than room temperature, its internal resistance goes up, the voltage
changes more quickly, and the charger reaches its voltage set points more easily. However, it
will not deliver all the required current and the battery will tend to be undercharged. Conversely,
when the battery is warmer than room temperature, its internal resistance goes down, the
voltage changes more slowly, and the charger does not reach its voltages as easily. It will
continue to deliver energy until the set points are reached, but this tends to be far more than
required. The battery will be overcharged. (See Improper Use on the next page.)
To compensate for these changes, a charger used with the NorthStar NSB BLUE+® battery
must have its voltages raised by a specified amount for every degree below room temperature.
They must be similarly lowered for every degree above room temperature. This factor is
multiplied if additional batteries are in series. Failure to compensate for significant temperature
changes will result in undercharging or overcharging which will shorten battery life.

NorthStar NSB BLUE+® Required Compensation

The factor is 2 mV per cell (0.024 Vdc or 24 mV per battery) per degree C above or below room
temperature (77°F or 25°C) when the battery is regularly cycled.

Remote Temperature Sensor

OutBack inverter/chargers and charge controllers are equipped with the Remote Temperature
Sensor (RTS) which attaches to the battery and automatically adjusts the charger settings.
When the RTS is used, it should be placed on the battery sidewall, as close to the center of
the battery (or to the center of the bank) as possible. See Figure 12. The RTS should be
checked periodically.
The charger determines the RTS compensation factor. All OutBack chargers are preset to a
compensation of 5 mV per cell. Currently, only the FLEXmax 100 and SkyBox products can
make system-wide adjustments to permit the 2 mV setting. If an RTS is not present or if a
different charger is in use, temperature compensation may not work correctly. It may be
necessary to adjust the main charger settings manually.

Lock
Washer

RTS

Figure 12 Remote Temperature Sensor Location

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 Installation and Operation

Improper Use
CAUTION: Equipment Damage
Read all items below. Maintenance should be performed as noted on page 22.
Failure to follow these instructions can result in battery damage which is not covered
under the NorthStar NSB BLUE+® warranty.

CAUTION: Equipment Damage

Do not exceed the specified absorption voltage when charging any NorthStar NSB
BLUE+® battery. Excessive voltage could result in battery damage which is not
covered under the NorthStar NSB BLUE+® warranty.

For any NorthStar NSB BLUE+® battery, if the charger settings are too high or too low, this will
cause premature aging of the battery, including loss of electrolyte due to gassing. The result
will be permanent loss of some battery capacity and decreased battery life. This is also true for
battery charging that is not compensated for high temperatures.
“Thermal runaway” can result from high ambient temperatures, charging at higher voltages over
extended time, incorrect temperature compensation, or shorted cells. When the buildup of
internal heat exceeds the rate of cooling, the battery’s chemical reaction accelerates. The
reaction releases even more heat, which in turn continues to speed up the reaction. Thermal
runaway causes severe heat, gassing, lost electrolyte, and cell damage. It usually requires
battery replacement. The process can be halted by turning off the charger. However, if cell
damage has occurred, shorted cells may continue to generate heat and gas for some time.
If a NorthStar NSB BLUE+® battery is not charged completely (or if the settings are too low), it
will not reach 100% SoC. Its total capacity will not be available during the next discharge cycle.
This capacity will become progressively less and less over subsequent cycles. Long-term
undercharging will result in decreased battery life. This is also true for battery charging that is
not compensated for low temperatures.

18 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

Battery Voltage Records

Date: Date: Date:

Battery 1
Battery 2
Battery 3
Battery 4
Battery 5
Battery 6
Battery 7
Battery 8
Battery 9
Battery 10
Battery 11
Battery 12
Battery 13
Battery 14
Battery 15
Battery 16
Battery 17
Battery 18
Battery 19
Battery 20
Battery 21
Battery 22
Battery 23
Battery 24

900-00264-01-001 Rev A 19
Installation and Operation

Date: Date: Date:

Battery 1
Battery 2
Battery 3
Battery 4
Battery 5
Battery 6
Battery 7
Battery 8
Battery 9
Battery 10
Battery 11
Battery 12
Battery 13
Battery 14
Battery 15
Battery 16
Battery 17
Battery 18
Battery 19
Battery 20
Battery 21
Battery 22
Battery 23
Battery 24

20 900-00264-01-001 Rev A
 Troubleshooting and Maintenance
Table 1 Troubleshooting

Category Symptom Possible Cause Remedy

Normal life cycle Replace battery bank when (or before) capacity
drops to unacceptable levels.
Reduced operating time
Defective cells Test and replace battery as necessary.

Excessively cold battery Carefully warm up the battery.

Undersized cabling Increase cable ampacity to match loads.

Performance
Loose or dirty cable Check and clean all connections. Physical
Excessive voltage drop upon
connections damage on terminals may require the battery to
applying load
be replaced. Replace hardware as necessary.

Undersized battery bank Add additional batteries to match loads.

Defective cells Test and replace battery as necessary.

Thermal runaway NOTE: Thermal runaway is a hazardous

Swollen or deformed battery condition. Treat the battery with caution. Allow
NOTE: A modest amount the battery to cool before approaching.
casing; “rotten-egg” or
sulfurous odor; battery is hot of swelling (or concavity) on Disconnect and replace battery as necessary.
the battery case is normal. Address the conditions that may have led to
External thermal runaway (see page 17).
Inspection
Damaged battery casing Physical abuse Replace battery as necessary.

Loose or dirty cable Check and clean all connections. Physical

Heat damage or melted
connections damage on terminals may require the battery to
grease at terminals
be replaced. Replace hardware as necessary.

Fully-charged battery High temperature Carefully cool the battery. An overheated

displays low voltage battery may contribute to thermal runaway.

Fully-charged battery Low temperature Carefully warm up the battery.

displays high voltage

Voltage Individual battery charging Shorted cell Test and replace battery as necessary.
testing voltage will not exceed A shorted cell may contribute to thermal
13.3 Vdc; high float current; runaway.
failure to support load

Individual battery float Open cell Test and replace battery as necessary.
voltage exceeds 14.5 Vdc;
failure to support load

Charging current to series Open connection or open Check and clean all connections. If battery
string is zero; failure to battery cell in string appears to have an open cell, test and replace
support load as needed. Replace hardware as necessary.

Current Charging current to series Batteries require additional Normal behavior; no action necessary.
testing string remains high over time time to charge

Charging current to series Shorted cell Test and replace battery as necessary.
string remains high with no A shorted cell may contribute to thermal
corresponding rise in voltage runaway.

900-00264-01-001 Rev A 21
 Maintenance

Periodic Evaluation
Upon replacement of a battery, all interconnect hardware should be replaced at the same time.
To keep track of performance and identify batteries that may be approaching the end of their
life, perform the following tests during on a quarterly basis following commissioning (see page
13). Tests must be made with a high-quality digital meter. Voltages must be measured directly
on battery terminals, not on other conductors. All connections must be cleaned, re-tightened,
and re-torqued before testing. If a battery fails any test, it may be defective. If this occurs under
the conditions of the warranty, the battery will be replaced according to the warranty terms.
Bring the batteries to a full state of charge before performing the following test.

Monthly Battery Inspection

o General appearance and cleanliness of battery, battery rack and battery area.
 Inspect for contamination by dust.
 Inspect for loose or corroded connections.
 If necessary, isolate the string/battery and clean with a damp soft cloth. Do not use solvents or
scouring powders to clean the batteries.
o Cracks in cell containers or leakage of electrolyte.
o Any evidence of corrosion at cell terminals, connectors or racks.
o Ambient temperature and condition of ventilation equipment.
o Current and voltage during charge cycle. Measure individual battery voltages at the battery terminal.
The measurements should be within 5% of the average.
o Voltage at end of charge cycle. Measure individual battery voltages at the battery terminal.
The measurements should be within 5% of the average.
o End of discharge voltage measured at the battery. Measure individual battery voltages at the battery
terminal. The measurements should be within 5% of the average.
o Record findings clearly. List the dates for all entries.

Quarterly Battery Inspection

This should include the monthly observations, plus:
o End of charge voltage of every cell and battery terminal voltage measured at battery.
o End of discharge voltage of every cell and battery terminal voltage measured at battery.
o Electrolyte temperature in representative cell(s), typically one cell/tier distributed throughout battery.
o Record findings clearly. List the dates for all entries.

Annual Battery Inspection

This should include the monthly and quarterly observations, plus:
o Inter-cell / inter-unit connection integrity.
o Retighten terminals to specified torque values. See page 25 for specifications.
o Record findings clearly. List the dates for all entries.
o Perform an equalization (see page 16 for details).

22 900-00264-01-001 Rev A
 NorthStar NSB BLUE+ Batteries

Cleaning
Batteries shall only be cleaned using a dry soft cloth or cloth moistened with water — any other
substances should not be used or sprayed on the batteries. The plastic used for the batteries is
sensitive to many solvents and other substances. Avoid pesticides or insect repellent as these
are known to have caused the plastic to severely crack.

Determining Battery Manufacturing Date

The battery serial numbers are located in two places on the battery case. The first location is
on the front of the battery. The manufacturing date is also located on this label below the
serial number.

Figure 13 Battery Manufacturing Date

The second serial number location is on the positive terminal side of the battery, towards
the rear.

Figure 14 Battery Serial Number Location

Manufacturing codes are limited to 12 alphanumeric digits. The first two digits specify the model
of the battery. The remaining ten digits are a random, non-sequential serial number which is
unique to this particular battery and will not be duplicated.

900-00264-01-001 Rev A 23
Maintenance
NOTES:

24 900-00264-01-001 Rev A
 Specifications
Table 2 Specifications

NorthStar NSB BLUE+®

Cells Per Unit 6
Nominal Voltage 12 Vdc
Cycle Life (50% DoD) 2,050 cycles
Absorb Voltage (25°c) 14.1 Vdc
Absorb Time 4 hours
Float Voltage (25°c) 13.6 Vdc
Float Time Continuous
Equalize Voltage & Frequency 14.4 Vdc for 4 hours every 12 months
Re-Bulk voltage 12 Vdc
Max. Charge Current No Limit
(per battery)
Minimum Charge Current 2 x I10-hour rate
(per Battery)
Max. Operating Temperature –40° to 65°C
(w/Temperature Compensation)
Temp-Comp Factor (charging) ±2 mV per degree C per cell
Self-Discharge Time 24 months at 25°C (77°F) before a freshening charge is required
Terminal Hardware Torque 8.0 Nm (71 in-lb)
Warranty 3 years
NSB40FT NSB100FT NSB170FT NSB190FT NSB210FT
Terminal Type M8 M8 M6 M6 M6
~31 lb ~74 lb ~132 lb ~136 lb ~152 lb
Weight
(~14 kg) (~33 kg) (~60 kg) (~62 kg) (~69 kg)
9.8 × 3.8 × 8.2″ 15.6 × 4.2 × 11.3″ 22 × 4.9 × 12.6″ 22 × 4.9 × 12.6″ 22 × 4.9 × 12.9″
Dimensions (24.9 × 7.6 × (39.6 × 10.6 × (55.9 × 12.5 × (55.9 × 12.5 × (55.9 × 12.5 ×
20.8 cm) 28.7 cm) 32 cm) 32 cm) 32 cm)

900-00264-01-001 Rev A 25
 Specifications

Table 3 12V Ampere Hour Capacity to 1.75 Volts Per Cell at 77°F (25°C)

Discharge in Hours: 1 2 3 4 5 8 10 20 100

Northstar NSB40FT BLUE+® 29.5 32.4 33.9 34.8 35.6 37.1 37.8 40.4 40.4
Northstar NSB100FT BLUE+® 75.6 86 91 94.1 96.3 100 101.5 105.3 105.3
Northstar NSB170FT BLUE+® 117.4 136.9 147.3 154.1 159 168.2 172.1 182.3 182.3
Northstar NSB190FT BLUE+® 134.9 152.2 160.7 166.2 170.4 179.5 184.2 202.4 202.4
Northstar NSB210FT BLUE+® 148.1 168.9 178.6 184.6 188.9 179.5 201.6 216.5 216.5

26 900-00264-01-001 Rev A
 EnergyCell Batteries

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900-00264-01-001 Rev A 27
Masters of the Off-Grid.™ First Choice for the New Grid.
17825 – 59th Avenue N.E.
Suite B
Arlington, WA 98223 USA