08_installation tbular opzs

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INSTALLATION AND COMMISSIONING PROCEDURE

FOREXIDE TUBULAR OPzS TYPE

STANDBY BATTERIES

COMPLETE WITH FIRST CHARGE INSTRUCTIONS AND

MAINTENANCE PRACTICE

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CAUTION :

In order to ensure safety, it is essential to operate and maintain your batteries inaccordance with the recommendations in this booklet.

a) ACID : Batteries contain dilute sulphuric acid which is poisonous andcorrosive. It can cause burns on contact with skin and eyes. If acid is spliton skin or clothing, wash with plenty of clean water. If acid gets in to theeyes, wash well with plenty of clean water and get IMMEDIATE MEDICALATTENTION.

b) GASES : Batteries can give off explosive gases. Keep sparks, flames andlighted cigarettes away from battery and battery room. Ensure connectionsare tight before switching on, using only insulated tools. Areas wherebatteries are kept or charged must be adequately ventilated.

c) ELECTRICITY : Use only insulated tools to make connections to a battery.Check the circuit to ensure it is safe before making a connection to thebattery. Before working on a battery, always remove personal metal effects,

such as rings, watches, bracelets, necklaces, etc.

ALWAYS PROTECT THE EYES.

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1. Loading / Unloading & Handling: Exide Tubular cells are generally dispatched from factory in packed condition. Careshould be taken during loading/unloading of the cases/pallets on/from the trucks. Itshould preferably be done with forklifts or suitable mechanical means, avoidingpressure on the sides. Cases should never be dropped or subjected to jerks ortilted or kept on its sides. Rough handling can damage the cells and othermaterials.

2. Storage & Preservation:

The maximum shelf life of dry and uncharged cells is 24 months from the date ofmanufacture, provided the cells are kept as advised below.

The cases / pallets having cells and cases having accessories to be stored in dryand cool place, away from direct sunlight and rain. The cells are to be stored insingle layer only. If the dry & uncharged cells are kept loose, adequate care shouldbe taken to keep the vent plugs totally closed and the vent holes kept closed withadhesive tapes. They should be kept in a covered place avoiding chance ofmechanical damage.

3. Unpacking / Handling:

Care should also be taken in the unpacking and subsequent handling of cells andother components of the battery.

It is advisable to unpack all the cases and crates as soon as possible upon arrivalat site It is preferable to unpack all the materials supplied in one go for checkingcorrectness of materials quantity wise and quality wise before erection rather thangoing for unpacking and erection cell by cell.

It is advisable to carry the packed cells in crate pallet upto the battery room floor byoverhead crane. The pallets are designed for lifting with sling wires. Care should betaken to avoid pressure on the sides of the crate pallet to avoid damage. The crates

should be opened in the battery room floor and shifted to the battery room withcare . Never handle cells using the terminals as this might create fatal damageto the cells.

To open the crate pallet, cut the hoop iron straps and lift the outer part of the cratefrom the top. Then cut the hoop iron straps of the inner crate and dismantle thecrate carefully by using crowbar / hammers etc, to avoid damages. Take out thecells one by one manually. Care should be taken in handling the cells and othercomponents to avoid damage. The cells are to be shifted to battery room byconvenient way ensuring no damages during such handling. Unpack and check allitems carefully against the accompanying delivery challan / material specifications.Report shortages/ damages promptly to Exide Industries Limited in writing within 30days of receipt. Request for free replacement would only be entertained if suchreports are received within the stipulated time period, provided the transit insuranceis covered by the Company. Arrange for repairs/ replacement of damaged/ short

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received materials to ensure the complete battery material is available wheninstallation commences.

Store the cells (with the vent plugs screwed on firmly), and other accessories in adry, cool and dust fee covered place.

4. Battery Room

The battery room should be well ventilated, clean and dry. A damp room isdangerous due to possible earth leakage from the battery. A notice should beexhibited in the battery room PROHIBITING SMOKING, ELECTRICAL OR ANYSPARKS AND USE OF NAKED FLAMES. The battery room should be well lit at alltimes of the day and night. Direct sunlight on the cells should be avoided. If it is notpossible to provide windows, good artificial light should be made available.

Although the battery shall have satisfactory performance between 5 0 C and 50 0 C,the most preferred operating temperature is between 20 0 C and 35 0 C. Highertemperatures shall decrease the life of the cells. Low temperatures, within theabove-mentioned range, will reduce the capacity available but do not harm thebattery so far as the life is concerned. A wash basin is to be provided in the batteryroom, suitably placed for washing of accidental acid splash on eyes, body,garments etc., for the personnel working in the battery room. Any spillage of acidon the floor is to be washed and neutralised, to avoid leakage path. It is advisableto provide acid proof tiles on the floors and on the sides of the wall. Alternatively,acid proof paints are to be provided which would require periodic renewal.

Proper exhaust fans should to be provided to remove hydrogen gas from thebattery room during boost charging. The ventilation system of the battery room hasto be designed accordingly. It is always better to pump in filtered cool air in thebattery rooms, having provision for natural exhaust, so that the battery room will beslightly at higher pressure. The capacity requirement of the exhaust systemdepends on the relative size of the battery room and the battery beingaccommodated in that. The exhaust calculation can be available from theGuaranteed Technical Particular of the specific installation. Site should demand acopy of the same from the procurement authority.

Warning signs should be put on the walls indicating dangers of explosion in case ofnaked flames or smoking inside the battery room.

The layout of the cells should be in line with the layout suggested by ExideIndustries Limited for the specific case. For any deviation and / or modificationplease contact Exide Industries Ltd.

3. Power Requirement:

A D. C. supply capable of delivering the constant current specified in the technicalspecifications will be required. The voltage required for initial charging is about 3times the number of cells in the battery bank, i.e. charger design to be 3 volts percell. This is required to charge the battery banks e.g. 12 Amps DC ConstantCurrent up to 2.36 vpc & 6 Amps DC Constant Current (finishing rate) up to 2.75vpc per 100 Ah C 10 capacity of the battery bank.

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4. Stands and Supports

Suitable Stands / Stillages are normally provided for the support of the cells and aredesigned in a manner so that each cell is easily accessible for inspection,maintenance etc.

Each installation shall have a dedicated relevant layout drawing of the battery. Theyshould be followed very carefully.

5. Charger

The charging system must be capable of providing a steady voltage within 1%V.

Battery charger should be available at site for necessary initial charging of the

battery bank. This should be a constant current charger capable of supplying 12Amps DC per 100 Ah C 10 capacity of the battery to start with and 6 Amps DC per100 Ah C 10 capacity of the battery at the finishing stages of charging. The chargershould be capable of providing 6% of the rated capacity of cells at 2.75 volts percell during boost charging. The charger should also have facility for float charge ata voltage of 2.230.02 volts per cell. For equalizing charge, the charger shall becapable of supplying 3 Amps DC constant current per 100 Ah C 10 capacity of thebattery.

Charger output or load induced current ripple can cause permanent damageand a reduction in battery life. The RMS limit is 5% in amperes of the C 10

capacity over the frequency range of 100 Hz to 360 Hz.

6. Polarity of Charging Leads

It is of utmost importance that the positive terminal of the battery is connected tothe positive lead of the charging source and the negative terminal with the negativelead of the charger.

To ascertain the polarity of the charging leads connect a lamp in series and dip theend in a glass of slightly saline water. Switch on the supply. Fine bubbles of gas willbe give off from the negative lead

The lamp connected in series eliminates the dangers of accidental short circuits.

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HYDROGENGAS


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7. Acid / Battery grade Water

i) The acid to be used in the battery for initial filling is battery gradeSulphuric Acid (H 2SO 4) of specific gravity 1.220 + 0.005, at 27 0 C,conforming to IS: 266 - 1993. This is normally supplied with the battery.

ii) Battery grade water (distilled or dimineralised) should conform to IS:1069 - 1993 for topping up of cells.

iii) If the acid is obtained in concentrated form it is necessary to dilute it to 1.220Sp. Gr. The acid as well as the distilled/ DM water to be used for dilutingthe acid should conform to Indian Standard Institution specification IS:266 1993 and IS: 1069 1993 respectively.

(iv) Caution:

1. All job to be done under supervision of authorised personnel only.

2. Clean vessels of hard rubber, plastics, porcelain or lead-lined MS tanks/ wooden boxes only should be used for storage and handling of acid anddistilled/ DM water. Do not use metal vessels other than lea d.

3. When working with acid or electrolyte, always use protective goggles, rubbergloves and rubber apron.

4. Keep ready Bi-carbonate of Soda solution or 5% to 10% Ammonia solution

to take care of accidental spill / splash of acid on skin, eyes or garments.Remove garment immediately, neutralise spot with 5 to 10% ammonia orsoda solution and wash thoroughly in water. On skin / eyes, flush with largequantities of water. Seek medical aid immediately.

5. NEVER ADD WATER TO ACID. IT WILL SPURT DANGEROUSLY .ALWAYS ADD ACID TO WATER . Add the acid in a thin stream, slowly,stirring the solution with a long glass rod or tube.

6. Smoking, Welding Arcs, Electrical Sparks and Open Flame should be strictlyprohibited in the battery room.

7. Only insulated tools should be used for live parts. Extreme care should betaken while handling of metallic parts within battery room to prevent theiraccidental falling / touching of live parts and causing short circuit.

8. Temperature Correction

The specific gravity of the electrolyte varies with temperature. Any readingobserved on the hydrometer should therefore be corrected to 27 0 C, as allthe specific gravity values indicated by us are at 27 0 C.

The correction should therefore be made as follows:

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For every 1 0 C above 27 0 C add 0.0007 to the specific gravity as read on thehydrometer. Similarly, for every 1 0 C below 27 0 C subtract 0.0007 from thespecific gravity as read from the hydrometer.

9. Installation

The following should be kept in mind while finalising the battery layout:

a) Easy access to the individual cells of the battery

b) Locating the take-offs for easy connection to the charging equipment / load.

c) Keeping interior connections adjacent to walls for providing easysupport and keeping the passage in between clear. This is desirablefor easy access to the cells for allowing easy removal of cells forservice attention, whenever required.

d) The positive end of the battery has to be connected to the positiveoutput of the charging equipment and negative end of the battery tothe negative of the charger.

e) The positive and negative take-off of the battery should havesufficient space between them to avoid short circuits

(i) Place the cells in position on the Stand/ Stillage

Suitable insulators should also be used between the stand or Stillage andthe floor. Arrange cells in such a manner that the positive terminal lug of onecell adjoins the negative terminal lug of the next cell throughout the battery.Use a wooden spacer to ensure even spacing out of cells.

For Seismic stands no Stand/ Stillage Insulator required as these aremechanically fixed to the floor.

(ii) Fasteners

Before connecting up, apply an even coating of petroleum jelly to thethreaded portion of the bolts, connectors and terminal pillars. Cover thewhole length of each terminal pillar with petroleum jelly and tighten the bolt.

Note particularly that the positive terminal of one cell is connected tonegative terminal of the next cell throughout the battery leaving the positiveterminal of the first cell and negative terminal of the last cell of the batterybank free for connection to the charging source. Finally, check again thatthe cells are connected in the correct sequence. Charging a cell of the

whole battery in the wrong direction will cause permanent damage.

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(iii) Cells in Rows

If the cells are arranged in more than one row, ensure that the positiveterminal lug of the end cell of one row is connected to the negative terminallug of the end cell of the other row. The connection between the two rows

may be made with the necessary length of copper rod or bar or cable of thesize used between the switchboard and the battery.

Each end of the copper rod/ cable is soldered / crimped into the socket ofthe cable-ends provided or crimped type flexible cable connectors, the endsof the latter being bolted on the terminal lugs of the battery.

Clean off any flux and bind the exposed end of the cable with self adhesivetape starting well back on the cable insulation and ending just at the flatconnecting lead of the cable socket. Alternatively, heat shrinkable PVC tubeof sufficient length is to be inserted on the cable before the crimping is done.

This tube will grip the uninsulated end of the cable and cable end whenheated with a hot air gun and thus will create an insulation layer at that point.

All copper work should be painted with two coats of acid resisting enamelpaint before the cells are filled with acid.

(iv) Connecting to charger:

Connect positive terminal of the battery to the positive lead of chargingsource and negative terminal of the battery to negative lead of the charging

source after identifying the polarity of the connections.

12. INITIAL FILLING-IN OF ELECTROLYTE

Sufficient quantity of battery-grade sulphuric acid and a little spare must beavailable at the site for the initial filling of the cells. The sulphuric acid shouldbe 1.220 +/- 0.005 Sp. Gr. (at 27 0 C).

The approximate quantity of acid required per cell is given in the data sheet.The total quantity of acid required is obtained by multiplying the quantity percell by the number of cells adding 10% to compensate for spillage.

The acid should be brought to equilibrium with the room temperature and of1.220 Sp. Gravity. This acid should be carefully poured into the cells, up tothe maximum recommended level.

After filling in, allow the cells to stand for a period of minimum10-12 hours.The plates will absorb the electrolyte and the electrolyte level will drop.Restore the electrolyte level at the end of this 10-12 hours period by addingmore acid of 1.220 Sp. Gr. +/- 0.005.

After filling in all the cells, following are to be ensured prior tocommencement of initial charging: -

a) Checking of correct polarity of all the cells connected in the circuit.

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b) Recording of individual cell voltage.

c) Recording the total battery voltage and comparison thereof with thesum total of individual cell voltage.

The battery is now ready for initial charging.

Initial charging must commence with in 24 hours of electrolyte filling & itis therefore essential to ensure that the charger is in proper workingcondition prior to electrolyte filling of the cells.

13. First Charge

(i) Charging Equipment

Ensure that the charging equipment is in order and is capable of deliveringthe specified current and voltage.

(ii) Connections Polarity

Check and check again to ensure the cells are all connected in series and allfastenings and connections are tight.

Test polarity of the charging leads and connects the positive terminal of thebattery to the positive lead of the charger.

Caution: Charging a cell or battery in the wrong direction will ruin it.

(iii) First Charge

Commence charging 12 hours rest, but not later than 24 hours after filling inthe first cell with acid.

(iv) First Portion

The first portion of the charge should be given at any rate between thestarting/ finishing currents depending on the output of the charger. Reducecharging current if temperature of electrolyte exceeds 50 0 C . Charging at thisrate shall continue till the potential of the battery rises to 2.36 volts per cell.

At the completion of this portion of the charge, a rest of not more than 12hour and not less than 2 hours should be given.

(v) Second Portion

The second portion of the charge must be given at the finishing rate asmentioned in the relevant technical particulars. This stage should continuetill either the signs of completion of charge as described in clause 12(vii) areobserved or the minimum Ah input required (as mentioned in the relevanttechnical particulars) is administered , whichever happens later .

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This is very important for the life of the battery that the first charge be administered very carefully so far as the minimum Ah input and signs of full charge are concerned .

(vi) Pilot Cells

As pilot cells, select any one cell (except the end cell or regulating cell, ifany) out of every 24 cells or part thereof.

Voltage and specific gravity readings from the pilot cells will indicate thestate of charge of the whole battery.

During charge, take reading every 4 hours to 80% of charge followed by 1hourly readings of:

a. Specific Gravity,b. Voltage, andc. Temperature

till the cells are fully charged.

(vii) Completion of charge

The signs of the completion of charge are as under

a) Specific Gravity : For some hours after starting the charge,

the specific gravity of the electrolyte will fall after which it willbegin to rise slowly and continue to rise throughout the chargeuntil finally it ceases to rise and remains constant. The chargeshould be continued until the specific gravities have attainedconstant values for three (3) successive hourly readings in allcells.

b) Voltage : The cell voltage at the beginning of the charge will bea little over 2 volts and will rise during the charge finallyattaining a steady value. The exact figure is not so importantas long as a voltage around 2.65 volts is attained. Typical

figures range from 2.65 2.75 volts per cell at the finishing rateof charge, depending on the prevailing electrolyte temperature,which, when higher than 27 Deg C, tends to depress thevoltage slightly from the ideal top of charge of 2.75V at 27 DegC.

c) Gassing : The reduction of current during charge, asmentioned above, is to limit the amount of gassing, but at theend of the charge all the cells should gas freely and vigorously.If any cell fails to gas or is late in gassing or if it s gravity islower than that of other cells, it should be closely examined tofind the cause. When found and corrected, the charge shouldbe continued until the cell is brought upto the fully chargedstate like the others.

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d) Minimum Ah Input : Please keep track of total Ah fed into thebattery and ensure, minimum Ah input, as mentioned intechnical particulars, is given to the battery.

When all the signs of completion of charge are observed, and the minimumAh input required (as mentioned in clause 12(v)) is administered, the chargeshould be terminated. After about one hour, when the gas bubbles havecleared away, the specific gravity and temperature should be recorded.

During charging the electrolyte temperature of the cell should not exceed50 0C. Suspend the charge if the temperature reaches 50 0 C and resumecharging after the battery has cooled to about 40 0C. If necessary, slightlylower the recommended charging rate in case of very high ambienttemperatures. Where ambient temperature is normally high, it isrecommended that charging be carried out during the night and suspendedduring the day. If necessary, use the finishing rate for the first portion of thecharge as well. When charging is suspended due to attainment of hightemperatures, such stoppages should be noted carefully and the durationshall be suitably extended to compensate for such stoppages.

(viii) Interruptions

The charging of the battery can be carried out either continuously or incycles of 8 hours charge and not more than 16 hours rest, till it is completed.

(ix) Electrolyte Level

Maintain the level throughout charging adding 1.220 Sp. Gr. Acid ifnecessary.

(x) Adjust Specific Gravity of Each Cell

If at the end of the first charge, the specific gravity of the electrolyte exceeds1.240 , withdraw some electrolyte and add pure water, continue the chargeso that the water and acid mix thoroughly.

If at the end of first charge the specific gravity of the electrolyte is below1.235 after both voltage and specific gravity have remained constant over 3consecutive hours, withdraw some electrolyte and add acid of 1.400 specificgravity continuing the charge in the meantime.

Never make an adjustment on cell which does not gas on charge .

Final specific gravity should be 1.240 +/- 0.005 at 27 Deg.C in all the cells.

Adjust the levels of electrolyte in all cells by adding 1.240 specific gravityacid or by withdrawing excess electrolyte, as required.

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(xi) Final Readings/ Record Book

After correcting specific gravity and electrolyte levels, start a record book forthe whole life of the battery. The first page should record the specific gravityreadings of each cell, and the temperature of the pilot cell, and a note thatlevels were correct in each cell. Record details of periodical charges anddischarges etc.

A record book is supplied with each battery of 60 volts and above; forsmaller batteries this can be obtained at nominal charge. If one copy of thisrecord sheet is sent periodically to the nearest office of the Company, freetechnical advice will be given so that the battery is maintained in optimumconditions.

The first charge sheet supplied with the battery should be filled up with thereadings obtained during initial charge and returned to the Company forcomments.

(xii) Cleaning up

Wipe down the outside of all cells and clean up any acid which may havedripped or have been split on the cell lids, stand on floor. Check generallythat everything is in order.

(xiii) Putting into service

After cleaning up the cells clean and dry, secure all connections. Clean upany acid which may have dripped or spilled on the cells, stand or the floor.

Check that the specific gravity of the electrolyte in all the cells is fairlyuniform and of correct value i.e. between 1.235 to 1.245 at 27 Deg C and thelevel of the electrolyte is at the Max line in the cells. The battery is thenready for service. It is important to operate and maintain the battery inaccordance with the instruction provided in the interest of trouble freeoperation throughout its service life.

At installations where the battery is likely to be on float for prolonged periodswithout discharge, it is preferable to carry out 3 charge / discharge cyclesbefore putting the battery into service.

(xiv) Storage

If the battery is to remain unused for 2 to 6 months after commissioning, givean extended charge at least once every month. Keep plates covered byadding pure distilled water to the prescribed level. Before using the batteryagain, give it an extended charge until the hydrometer shows a constantspecific gravity reading for 3 hours.

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If sufficient current is not available from the charger, the battery will run down andeventually fail to cater the back-up time. On the other hand, if more current thannecessary is furnished, the battery life will be shortened. It is therefore highlyimportant than the charging is proper for the life and proper performance of thebattery bank.

The battery is float charged from a D.C source. The output of which is controlled tokeep the voltage at the battery terminals at nominal value 2.23 vpc. Under theseconditions of constant voltage charging, the battery regulates its own chargingcurrent.

However, to protect the charging source from overload, an adjustable seriesresistance is installed to limit the current with a discharged battery.

Under normal conditions, the battery should always be in a full state of charge ready for an emergency discharge, and shall be drawing a low steady TrickleCurrent.

The value of the charging current, therefore, gives a rough indication of the state ofcharge, if charging voltage is maintained at the recommended float voltage.

Charging voltage:

This is controlled by means of suitable regulators. Under ordinary conditions,voltage should be adjusted between 2.20 to 2.26 volts per cell the exact valuedepending upon the ambient temperature of the installation. When properly

adjusted, the charger shall bring the battery to a fully charged condition promptlyand then furnish only the current to maintain it fully charged. It is, therefore, verynecessary that the voltmeter used is accurate. Any deviation from the standardsetting should be corrected immediately as a very small variation in voltage,produces a large variation in current.

Correct adjustment of the charging rate ensures:

a) Proper amount of charge without possibility of overcharge.b) Minimum water consumption.c) Safe limits of operating temperature.

d) Prolonged life.

The effect of HIGH and LOW voltage settings are:

HIGH VOLTAGE SETTING :

a) The battery will be overcharged.b) Water requirement will be high and possible fall in the level of electrolyte.c) Temperature will be high which in turn aggravates the condition (a) & (b)

above.d) Life of the battery will be shortened.

LOW VOLTAGE SETTING:

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a) Insufficient charge will cause starvation resulting in operational failure.b) Possible damage to the battery due to over-discharge and stoppages for

repairs.c) Shortened life.

Specific gravity is an indication of the state of charge of a flooded lead acid battery.In the fully charged condition, the specific gravity of the battery would read as 1.240 0.005 measured at 27 C. A higher specific gravity every time would indicateexcessive water loss possibly due to too high a voltage setting and a lower specificgravity would indicate that the battery is not receiving sufficient amount of charge.When temperature of the electrolyte differs from the standard temperature of 27 C,it is necessary to correct readings of specific gravity observed on the hydrometer tothe equivalent specific gravity at 27 C.

EQUALISING CHARGE:

During the operation of the battery, under constant potential charge, there is achance of imbalance amongst the cells in the bank. This may occur due to variousreasons, e.g. initial differences between individual cells, differences in chargeacceptance, or abnormal working conditions. As a result some cells shall remaincontinually undercharged.

If the Lead Acid cell remains under-charged over long periods, the resultingsulphation in the cells may become so heavy that the cells may go beyond repair.Equalising charge is an extended charge at low Amps (usually 3 to 4% of the ratedcapacity of cells) given in order to bring all the cells in the battery bank to a healthy

state.

Equalising Charge is to be administered to a battery bank standing on constantcurrent float charging for a long duration and the cell to - cell variation of the floatvoltage is of the order of 0.03 volts or the specific gravity variation is of the orderof 0.010. The battery should be charged at 6A DC per 100 Ah C10 capacity tothe top of charge voltage of 2.75 V/Cell or more till 3 consecutive hourly readings ofcell voltages are observed to be constant. This is to be followed by a further chargeat a constant current of 3A DC per 100 Ah C10 capacity for a period of 12-16hours. At the completion of this charge the battery bank may be put back on float.

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BATTERY MAINTENANCE

Routine maintenance must take into account of the following factors and includemaintaining proper record of critical parameters, which are inter-related and are ofequal importance :

1. Charging voltage across the battery.2. Specific gravity measurement.3. Water consumption.4. Proper cleaning.

INSPECTION & RECORD:

In order to determine the nature of routine maintenance needed in service, andparticularly the time interval between the inspections, these should be made initiallyat short intervals of a week or so and the results carefully logged and reviewed oneach occasion. Once this experience has been gained, the interval betweeninspections can probably be increased.

The batteries should not be allowed to over-charge. At the same time it should beensured that they do not depart from the fully charged condition for the reason thata partially discharged battery would not be a very reliable source of power in caseof emergency.

Systematic inspection programme and carefully kept records of the operation of thebattery and its charging equipment as found at each inspection are best-knownmethods of controlling battery maintenance. Symptoms of developing trouble canbe quickly detected by regular study of the battery records card and thenecessary corrective measures can be taken in time to prevent any serious trouble,which might possibly result in a service failure.

The Inspection Register should be kept in a holder located on each Battery Roomso that the desired information can be recorded. Each cell should be marked withan identifying number.

Batteries shall receive regular monthly and annual inspection in addition to anyother attention that the user may desire to give or which may be necessary.

GENERAL INSTRUCTIONS:

a) Do not work on battery bank unless main battery leads are disconnected.

b) Never allow a flame, sparks, lighted pipe or cigarette near the battery.

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c) Top up as often as necessary with battery Grade Water conforming to IS1069 (Latest Revision), to keep the electrolyte at the correct level.

d) Take particular care, avoid short circuit by bridging the terminals withspanner while tightening terminal nuts & bolts.

e) Leave no metal tools on the top of the cells.

f) Take precautions particularly during charging.

g) Give Equalising Charge as recommended, on periodical basis, at ConstantCurrent Charge only.

h) Do not exceed finishing rate, when cells are gassing freely

i) Keep battery and surroundings clean and dry.

j) Attend to weak cells immediately.

k) If the battery is to stand idle, first give it an equalising charge and if possible,repeat this equalising charge once in 20 days during idle stand.

INSTRUMENTS AND TOOLS

Some important instruments and tools that are necessary for proper maintenanceof battery are listed below: -

a) Digital Multimeter : To enable voltage readings of individual cells aswell as total battery and main source voltage a suitable digitalmultimeter/ voltmeter should be used. It should be calibrated atregular interval or should be compared with a standard meterperiodically to ensure accuracy.

b) Syringe Hydrometer: A clean and accurate syringe hydrometersuitable to read specific gravity readings from 1.100 to 1.300 should

be used.

c) Thermometer : An accurate thermometer of 0 C to 100 C rangeshould be used to read the electrolyte temperature.

d) Tong Tester: To enable readings the current flowing during charge,Float and during discharge through the battery and from the mainsource. Should be calibrated at regular interval or should becompared with a standard meter periodically to ensure accuracy.

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MAINTENANCE SCHEDULE

The maintenance schedule given here is divided in daily, fortnightly, monthly,quarterly, half-yearly and yearly maintenance.

A. DAILY MAINTENANCE

A daily general maintenance should include a check and record of thefollowing :

1. Overall float voltage measured at the battery terminals

2. Charger output current and voltage

3. Specific gravity, voltage and temperature of pilot cells. 2 nos cells outof every 60 cells to be chosen as pilot cells.

B. FORTNIGHTLY MAINTENANCE

A fortnightly maintenance should include all the items mentioned in dailymaintenance and the following :

1. Check voltage, specific gravity and temperature for all cells.

2. Visually check the conditions of each cell and battery bank. Anyabnormality observed to be immediately noted and observed for next15 days.

3. Visually check the cleanliness of battery, battery stands and batteryroom area for accessibility, cell integrity and acid leakage.

C. MONTHLY MAINTENANCE

A monthly maintenance shall include all checks listed under daily andfortnightly maintenance schedule and also the following :

1. Check condition and tightness of all vent plugs and connectors. Cleanall the cells with dry cloth to wipe out any dirt or dust accumulated onthe vent plugs.

2. Check electrolyte level in all the cells and note. Exide tubular cells arenot expected to show much of a water loss in a month but anyabnormal drop in electrolyte level should be noted and cause to beinvestigated.

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D. QUARTERLY MAINTENANCE

A quarterly maintenance shall include all checks listed under daily,fortnightly and monthly maintenance schedule and also the following :

1. If the specific gravity of most of the cells are found to be lagging by anaverage of 10 to 15 points, the battery bank would call for an constantcurrent equalizing charge at a current equivalent to 3% - 5% of itsrated C 10 capacity for 12 -24 hours to restore the state of charge tofull.

2. The temperature of the electrolyte normally is lower than the ambient.But for a bank, unless it has undergone a discharge within previous24 hours, the electrolyte temperature should lie within 3 5 deg. Chigher than the corresponding ambient temperature. In case of adeviation from this range, the charger needs to be checked for itsquality of power output in terms of the ripple contents in the chargingvoltage and current. Corrective action should be immediately taken toavoid any deterioration in the battery bank due to this anomaly.

3. The voltage and specific gravity data of all the cells from the previousfortnightly data sheets are to be observed. If any cell/s shows differentreadings compared to other cells in the bank, this/these cells shouldbe watched and monitored separately. Readings of such lagging cell

may be recorded and analyzed with pilot cells.

E. HALF YEARLY MAINTENANCE

A half yearly maintenance shall include all checks listed under daily,fortnightly, monthly and quarterly maintenance schedule and also thefollowing :

1. Remove all corrosion product and clean connector thoroughly. Useenough amount of petroleum jelly on the connectors to prevent farther

corrosion and put back shrouds in place.

2. Retighten all the electrical connections between the cells andbetween battery bank and charger to the prescribed torque value.This would ensure proper connection and operation with the minimalloss of electrical energy.

F. YEARLY MAINTENANCE

A yearly maintenance should include all items listed under daily, weeklyand monthly maintenance schedule and also the following :

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1. Isolate the battery bank from the load. This would require matchingthe annual maintenance schedule with an annual shutdown.

2. The battery bank at this stage is almost at a fully charged condition.After isolation, the bank is to be put on charge in the constant currentmode at a current of 6% of the rated C 10 capacity of the bank ( 6Amps per 100 Ah). The battery bank is to be charged till all the cellsare gassing freely and the voltage and specific gravity readings ofpilot cells have become constant over 4 to 5 hourly reading. Thecharging however should run for a minimum period of 5 hours even ifthe fully charged conditions are achieved before that. The specificgravities and electrolyte levels of all the cells are to be measured andto be adjusted with DM water to specified values 4 hours after thecharging is switched off. The electrolyte level should remain near themaximum mark. After the adjustment the bank is to be charged againfor 1 hour at the same current to enable proper mixing of electrolyteand DM water.

3. After a rest of 12 hours from the time the charging is switched off, thebattery shall be discharged at C 10 current for 10 hours. The end ofdischarge voltage at the end of 10 hours is to be noted. Thetemperature and specific gravity readings are to be noted for theentire length of discharge for the pilot cells.

4. The discharged bank should immediately undergo recharge in theconstant current mode. The charging to start at the starting rate as

mentioned in the product catalogue for the respective size till thevoltage reaches 2.36 volts per cell followed by charging at finishingrate pertaining to the specific size of the battery as mentioned inmanufacturers catalogue. The charging to be stopped when the cellvoltage and specific gravity readings are constant for threeconsecutive hourly readings.

5. The expected end-of-charge voltage is of the order of 2.7 2.75 voltsper cell. During charging it has to be ensured that a minimum Ahinput of 125% of the previous discharged Ah is administered to thebattery. The temperature during charging should not increase beyond

45 0 C. In such cases, the charging to be stopped and the cells to beallowed to cool down till 40 0 C when the charging can be resumed.The timings are to be noted so that the duration of charge can becompensated accordingly to ensure that the minimum Ah inputrequirement is fulfilled.

6. After the charging is over, specific gravity and electrolyte level of allthe cells are to be adjusted to specified values after 4 hours of restperiod.

7. The battery bank, then, is to be given an equalisation charge at acurrent equivalent to 3% - 5% of rated C 10 capacity for 16-24 hrs.

8. The battery bank can be given back to the system after the equalisingcharge is over.

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EMERGENCY INSPECTION

If any failure or problem is experienced or reported, carry out the following checksand tests in sequence:

a) Measure total voltage of battery on open circuit and under load. If this isnormal, the actual failure is elsewhere than the battery.

b) Check all battery connections to ensure they are clean and tight.

c) Note and record specific gravity of all cells. If it is low as a whole, the batteryhas discharged. Recharge the battery. Locate the cause and rectify.

d) Note voltage of individual cells at the same time looking for any hot cells orany other abnormal conditions.

If one or more cells are found to have low voltages, note their voltage onload and if it is very low compared to other cells, which is probably theimmediate cause of trouble, rectify the low voltage cells or replace it withspare cells to put the battery back in service quickly.

SPARE BATTERIES STORAGE AND MAINTENANCE:

a) General care : Spare charged battery should be given regular goodhouse keeping care. A clean, cool dry place free from dust should beselected for storage space. Keep them with vent plugs firmly fitted inits position.

b) Testing : Spare charged batteries should be checked at regularmonthly intervals to determine the specific gravity. Batteries should becharged before the specific gravity drops 30 points below thespecified fully charged readings. High temperature will increase thefrequency of such charges.

c) Charging : When charging is required, use the finishing rate. Continuecharging until free gassing occurs. Charging should not be suspendeduntil specific gravities (corrected for temperature) of majority of the lcells have risen to the maximum and have shown no further rise forthree consecutive hourly readings.

08_installation tbular opzs

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