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Suitable stands / stillages should be provided for the support of the cells and should be arranged so that each cell will be easily accessible for inspection, topping up etc. 2. The acid to be used in the battery for initial filling is battery grade sulphuric acid of specific gravity 1.190 0.005 (at 27 C). 3. The Cells stand on porcelain / plastics insulators which will be supplied, 4 of these insulators each with a lead disc on top should be inserted between the feet of the container and the stand. Level the cell, if necessary, by placing one or more of the lead discs between the insulator and stand. Suitable insulator should also be used between the stand or stillage and the floor. Arrange cells so that positive terminal lug of one cell adjoins the negative terminal lug of the next throughout the battery. Use a wooden spacer to ensure even spacing out of cells. 4. If the cells are arranged in more than one row, ensure that the positive terminal lug of the end cell of one row is connected to the negative terminal lug of the end cell of the other row. The connection between the two rows may be made with the necessary length of copper of these used between the switch board and battery. After sweating on the copper, clean off any flux and bind the exposed end of the cable with self adhesive tape starting well back on the cable insulation and ending just
at the lead cable socket. All copper work should be painted with two coats of acid resisting enamel paint before the cells are filled with acid. 5. When the cells are in position on the stands, connect them together. Smear a little petroleum jelly on the threads, bolting faces and in the bolt holes before bolting up. If necessary, warm the petroleum jelly to ensure a thin even coating. After bolting- up the cells smear petroleum jelly over the nut, bolt head and washer. 6. The cool pure sulphuric acid of 1.190 Sp. Gr. Should be carefully poured into the cells till the level indicator in each cell rises to the maximum recommended level as indicated by the lower white band of the stem of the float indicator , being just visible above the back float guide. Replace the vent plugs on the cell but do not tighten leave them loose. After filling in alone the cells to stand for a period of 12-18 hours. The plates will absorb the electrolyte and the electrolyte level will drop. Restore the electrolyte level at the end of this 12-18 hour period by adding more acid of 1.190 Sp. Gr. The battery is now ready for initial charging. 7. Connection of polarity to be checked to ensure the cells are all connected in series and connection are tight. 8. During charging specific gravity, voltage, temperature, gassing,
electrolyte level to be checked. 9. Charge the battery at any rate within starting and finishing rate. 10. Once cell voltage reaches 2.0 V, reduce current to finishing rate and continue charging till the cells are fully charged.
11. Maintain temperature 40o C to 45o C (Max). 12. Cells are considered to be fully charged, once three successive hourly readings of cell voltage and electrolyte are found to be 2.75 V (Max) and final specific gravity should be 1.200 0.005 in all cells.
A)
Charging Setup
+
FLOAT CHARGER LOAD
3 415 V
Y B
+
BOOST CHARGER
TC BATTERY
B) Discharging Setup
+VE
-VE
AMMETER
SALT WATER
Testing Equipments. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
MOTORIZED MEGGER 500V - 5000V DIGITAL MULTIMETER FLUKE MAKE SECONDARY INJECTION KIT SINGLE PHASE VARIACS THREE PHASE VARIACS DC HI-POT TEST KIT 70KV AC HI-POT KIT 35KV BREAKER CONTACT TIMING KIT TRUNS RATIO BRIDGE KELVIN'S BRIDGE LUX METER EARTH RESISTANCE TESTER PHASE SEQUENCE METER AC/DC/ TONG TESTER 0-100-150-200A AC/DC/ TONG TESTER 0-2000 -2500 - 3000 DIGITAL FREQUENCY INDICATER DIGITAL TACHOMETER VIBROMETER (PORTABLE) DECODE RESISTANCE BOX RHEOSTAT 25 ohms, 5A RHEOSTAT 25 ohms, 10A RHEOSTAT 50 ohms, 5A
23. 24.
Mode of Equipment Erection All Mechanical erection will be carried out with Cranes of required capacities wherever approach for the said cranes is available and wherever approach is not accessible to cranes movement, erection would be carried out manually with the help of chain pulleys and electrically operated winch machines, etc.