You are on page 1of 17

INSTALLATION AND COMMISSIONING PROCEDURE

FOR

EXIDE VRLA TYPE

STANDBY BATTERIES

COMPLETE WITH MAINTENANCE PRACTICE

-1-
GENERAL :

In order to ensure safety, it is essential to operate and maintain your batteries in


accordance with the recommendations in this booklet.

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

b) ELECTRICITY : Use only insulated tools to make connections to a battery.


Check the circuit to ensure it is safe before making a connection to the
battery. Before working on a battery, always remove personal metal effects,
such as rings, watches, bracelets, necklaces, etc.

ALWAYS PROTECT THE EYES.

-2-
PROCEDURE FOR INSTALLATION & COMMISSIONING

Loading / Unloading :

The modules are packed in such a manner so as to avoid rough handling by the
transporter.

Care should be taken during loading / unloading of the cases / pallets on / from the
trucks, preferably with forklifts or suitable mechanical means, without pressure on
the sides, jerk, tilt etc.

Unpacking & Handling

Modules are packed individually and are supplied to the customer as such. It is
advisable to unpack all the units and accessories before commencing to erect and
not unpack and erect module by module.

All units should be handled carefully to avoid any damage. Under no circumstances
should they be lifted by their terminal pillars. All the items should be carefully
checked against the accompanying packing list/invoice to ascertain if any are
missing and see whether any are damaged or broken. Any discrepancy, if
observed, should be notified to EXIDE immediately, within 7 days Of delivery of
material, in writing.

• General
Battery modules are packed vertically on a wooden skid. Top is protected with
thermocole & hard board cover: The whole assembly is stretch wrapped. Modules
are finally secured to the wooden skid with straps.

All handling during transportation, loading / unloading & storage shall be done with
the module in VERTICAL POSITION only.

• Unpacking
After cutting the metal strap, the stretch wrapped plastic sheet may be removed
carefully with a sharp knife.
The top hard board and thermocole sheet are to be removed and the module top to
the inspected for any mechanical damage.

• Handling
The design of the individual module are such that they can be handled with the help
of a portable crane or by hoist.

-3-
Fig. 1

Care of Material

Carefully clean off dust and packing material deposits from each of the units and
accessories. Wipe modules with a clean soft cloth dampened with clean water. If
necessary; a small amount of mild detergent maybe added to the clean water to
remove any greasy film.

Kindly note that scouring powders and solvents should not be used for
cleaning lids as scratching or damage to the surface of the plastic could
occur.

Storage and Freshening Charge

All VRLA batteries are delivered factory filled and charged and the month & year of
shipment is indicated on the modules. It is strongly recommended that these
batteries should not be stored for more than six months without a freshening
charge. In typical Indian conditions a freshening charge should be given
every three months of storage which would be Ideal for the performance and
life of the battery. For freshening charge connect modules in series appropriately
to form a 48V (nominal) unit (e.g. - 12 modules of 4V UPST 1000 modules. 24
modules of 2V UPST 2000 etc.) (POS-NEG-POS) and connect the respective
positive & negative terminals to the positive and negative leads of the charger. The
charger should be current limited constant potential type .

The freshening charge is to be given for a period of about 24 hrs. For optimum
charge efficiency the current output of the charger should be limited to 15% of the
10 hr. capacity rating of the battery.

-4-
Recommended charging voltage :

TABLE 1
Ambient Temperature Recommended float Maximum charging
(0 C) charging voltage per current (A)
cell (V)
-5 to 14 2.27 ± 0.01 0.15 C
15 to 24 2.25 ± 0.01 0.15 C
25 to 34 2.23 ± 0.01 0.15 C
35 to 40 2.20 ± 0.01 0.15 C
C : Nominal 10 hour capacity of the battery at 270 C

GUIDELINES FOR ERECTION OF BATTERY

A. Consideration of the Battery area


The battery room should be clean and dry. A damp room is dangerous due
to possible earth leakage from the battery. A notice should be exhibited in the
battery room PROHIBITING SMOKING, ELECTRICAL OR ANY SPARKS AND
USE OF NAKED FLAMES. The battery room should be well lit at all times of the
day and night. Direct sunlight on the cells should be avoided. If it is not possible to
provide windows, good artificial light should be made available.

A.1 Space
One of the preconsideration required for battery installation is to provide an
aisle, typically 1 m wide, at the front side of the battery to facilitate installation and
also for service.

For exact space consideration, however, particular layout drawing has to be


considered. Minimum space of 150mm should be provided between back end of
the modular assembly and wall.

A.2 Connecting Cables

A.2.1 Shortest electrical connection between the battery system and the operating
equipment results in maximising total system performance.

A.2.2 Cable size should be made optimal to minimize voltage drop between
battery system and operating equipment.

A.2.3 Certain situation may require paralleling of battery to obtain sufficient


capacity by the customer In that case, cables for all systems which are connected
in parallel to the load should be equal in length to keep the float voltage same and
also to maintain proper load sharing on discharge plus satisfactory recharge of
individual strings.

B. Location of Battery
Locating the batteries in direct sunlight, dust, rain, storms etc. is to be
avoided. Such exposures will cause damage to plastic components and reduce
battery life drastically. Ambient temperature of 20°C to 30°C results in optimum

-5-
battery life and performance. While temperature above 30°C results in reduction of
battery life, temperature below 20°C reduces battery efficiency. Please note that
the electrolyte temperature of VRLA Powersafe batteries cannot be measured but
lies within ±3°C of the ambient.

C. Ventilation
Almost all the gases under normal recommended charging in standby
applications generated in the VRLA Battery gets recombined in the battery. Hence,
no special ventilation is required. Normal ventilation in the battery room is sufficient.
There should be adequate arrangement for removal of heat generated by VRLA
Batteries. They are not to be placed in close proximity of any electronic equipment
which generates heat.

D. Installation of Modules

General
Modules are stacked upto a maximum of four times in horizontal orientation
depending on the size of battery. Multiple stacks placed side by side may be reqd.,
details of which are available in the respective system drawings.

All inter cell, inter module. interstack and also equalisation connections are
done with rigid copper flats. Connectors are fastened to the cells with the help of
lead plated brass fasteners (Upto 600 Ah: M8 & above 600 Ah: M12), provided with
appropriate washers. For module stacking arrangements, each module is fastened
to the module above it with the help of four number of MS fasteners (M10). Be sure
to tighten bolt and nut at torque specified in table below.

TABLE 2
Bolt and nut diameter Tightening torque (Nm)
M5 2.5 ± 0.5
M6 4.9 ± 0.5
M8 12.3 ± 0.5
M10 17.2 ± 2.5
M12 22.0 ± 2.5

In multiple stacking. the adjacent stacks are bolted to each other with the help of a
small tie plate and the same MS fasteners provided for inter-module bolting. The
lowest module of each stack are supported and bolted to I-beams at the two ends
as shown in the respective System drawings -similar to intermodule fastening.

The entire assembly will be free standing on the floor, on the battery room.
However, provision is also made for anchoring, if required, for any special
application, e.g.: if seismic conditions are expected.

-6-
Stacking Procedure
Please follow the stacking procedure as per the following diagrams and
steps shown.

Step 1
The battery site will be first have to be prepared by marking the appropriate
position of the location of the I-beams on the floor with reference to the respective
system drawings.

Step 2
Modules supplied will be marked A1, A2,……….. A4 to indicate their relative
position in the stack. The lowest module shall be A1 and the topmost module shall
be A3 or A4 depending on the number of such modules in each stack. For multiple
stacks, modules in adjacent stacks shall be designated at B1, B2,……………. B4,
C1, C2,…………….. C4 and so on.

To initiate stacking, the first operation comprise of fixing of 2 nos. I-beams


with modules A1 as shown in fig.1. Take care that the bottom end of the I-beam
shall be flush with the bottom of the module.

Fig 2

Step 3
The entire assembly is lifted with the help portable crane or overhead hoist
and positioned at the marked area, ready for final installation. (See fig. 3)

-7-
Fig. 3

Step 4
With the help of a portable crane or manually, the unit is gently titled and
made to rest on two nos. I-beams exactly at the location previously marked on floor.
(See fig. 4 & fig. 5).

Fig. 4 Fig. 5

-8-
Step 5
Ensure level of the module with spirit level and then only I-beam bolts are to
be tightened in position.

Step 6
For multi stack arrangements, repeat the procedure as described above for
modules B1, C1, …..etc. as the case may be. Further; ensure exact alignment of
the two adjacent modules for easy fitment of inter modular tie-plates,

Step 7
After completion of installation of first tier, module A2 is to be fitted with
overhead hoist on any one of the upper channels. (See fig. 6)

Fig. 6

The module is gently tilted on its sides and made to rest, preferably on a
wooden pallet. Entire assembly is lifted and gently placed on the module A1,
carefully aligning the bolt holes of the two modules for easy fitment. (See fig. 6).

The procedure is to be repeated A1, A2…………A4 as the case may be to


complete the initial stacking procedure.

-9-
Step 8
Repeat the procedure for placement of modules B2, B1.

Step 9
Place the tie plates in appropriate position between A1 & B1, A2 & B2, B2 &
C2, A3 & B3………….etc. and with the help of fixing bolts, secure the inter modular
and inter stack assembly ( see fig. 7)

Fig. 7

- 10 -
Step 10
In this manner continue stacking module A3, B3, C3, A4, B4, C4……..till the
entire stack erection is complete.

Fig. 8

E. Electrical Connections

Refer to respective system drawings for connection detailing, connectors catalogue


number and also for the quantity of each type necessary for the completion of
battery connection.

Before connecting up, apply an even coating of petroleum jelly to the bolts, nuts,
washers, connectors and terminal pillars. Cover the whole length of each terminal
pillar with petroleum jelly and tighten the bolt connectors firmly as per table 2. 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 washers.

Note particularly that the positive terminal of one cell is connected to negative
terminal of the next throughout the battery leaving the positive terminal of the first
cell and negative terminal of the last cell of the battery bank free for connection to
the charging source. Finally, check again that the cells are connected in the
correct sequence. Charging a cell of the whole battery in the wrong direction will
cause permanent damage.

If the cells are arranged in more than one bank (B-B situation), ensure that the
positive terminal lug of the end cell of one bank is connected to the negative
terminal lug of the end cell of the other bank. The connection between the two
banks may be made with the necessary length of flexible cable. For cable length
etc. refer respective system drawings.
- 11 -
Follow the details given in the respective drawings to fit the appropriate terminal
take-off to the end cells of the battery.

F. Commissioning

Charging: Fully installed battery Is to be given Charging as per following


procedure.

Chargers: Current limited constant potential chargers are only recommended for
continuous operation.

Important Points of Charger :


a) Maximum charge volts : 2.40 vpc
b) Minimum charge volts : 2.20 vpc
c) Battery charging current shall be limited to a max. of 15% of the 10 hour
rated battery capacity in amps.
d) A.C.Ripple : 5% of r.m.s.
e) Ambient temperature : -5°C to 40°C (ideally)

Charger output or load induced current ripple can cause permanent damage
and a reduction in battery life. The maximum ripple voltage allowed is 1%
RMS under float condition.

Commissioning should be carried out, without any other load being connected to
the charger; as follows
a) Connect charger positive lead to battery positive terminal, charger negative
lead to battery negative terminal and switch on the charger.

Polarity of Charging Leads


It is of utmost importance that the positive terminal of the battery is
connected to the positive lead of the charging source.

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

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

BULB

HYDROGEN
GAS

- 12 -
b) Continue charging until the current flowing into the battery has fallen to a
minimum and stabilises so as to remain constant over 3 consecutive hourly
readings. Alternatively if it is not possible to measure the current, charge at the
recommended voltage for 72 hours.

After this activity. battery is ready to be put into service.

Further. this level of applied voltage is recommended for normal recharging of a


battery following a discharge. For recharging under these conditions, typically it will
require an excess of 24 hrs. continuous recharge to restore full capacity of a battery
which has previously been discharged to the extent of its 10 hr. capacity.

Recharge time can be reduced by increasing the level of applied charge voltage.

Typically the charge duration will be reduced to 16/17 hrs. by applying a voltage of
2.40 vpc to a battery previously discharged to an extent of its 10 hour capacity.
Hence the VRLA range may be recharged at an elevated voltage of 2.40 v pc if
charge time is constrained. However; using this charge regime will result in reduced
service life if it is used more than once per month.

For VRLA batteries operating under float application, recharge is recommended to


be done at float voltage only. An optional quick recharge at voltage levels of 2.33 -
2.40 v.p.c. may be used for recharge under exceptional condition.

- 13 -
G. Test Discharge

For batteries going for site acceptance test, after erection and subsequent fitment
to the appropriate float charger; allow a minimum of 72 hrs commissioning charge
to elapse to enable the battery to regain its full state of charge. The battery is now
ready for discharge. Discharge at the appropriate C 10 current to an end voltage of
1 .75 volt per cell.

The battery system may require upto 5 consecutive cycles of charge and discharge
to attain its full capacity. Recharge after every C10 discharge should be at the
recommended float voltage and current for a minimum period of 72 hrs. Under
special cases. recharge may also be done at an elevated level of 2.40 v/cell for a
minimum period of 36-40 hrs.

Battery is considered to be fully charged when 3 consecutive hourly readings of


current drawn by the battery is constant.

H. Battery Maintenance

Records and Readings

It is in the interests of the user that adequate records are kept during the service life
of the battery. In this respect it is recommended that readings of the type outlined in
the following chart are made on a regular basis, say every 3 months, but certainly
once every 12 months.

Record the terminal voltage of each cell or monobloc, together with the ambient
temperature. Voltage of all cells or units should be reasonably constant when
compared with their previous (3 monthly) reading.

Annually

For completion of records and to check battery health, it would be beneficial to


carry out a C 10 discharge followed by a recharge on an annual basis.

General

Record the details of any emergency or accidental discharge. During any recharge,
record the voltage at the terminals of the battery and the value of the charge
current, if possible, towards the end of the charge.

- 14 -
The following are tabular guideline for inspection and maintenance ;

Monthly Inspection
Item Method Standard Remedial action
Total battery Read the voltmeter Float charge Adjust the float
voltage on float reading on the voltage per cell x charge voltage per
charge charger panel number of cell cell x number of
cell

6-month Inspection
Item Method Standard Remedial action
Total battery bank Measure the total Float charge Adjust the charger
voltage on float battery bank voltage per cell x when the voltage
charge voltage with number of cell reading does not
voltmeter satisfy the
standard
Voltage of each Measure the Float charge If the voltage
cell during float voltage of each cell voltage to be as ranges are not
charge with voltmeter per Table 1 satisfactory contact
us
External Check the No structural Contact us
appearance of container and damage.
storage battery cover for damages
such as crack, No leakage
deformation and
leakage

Annual Inspection
Item Method Standard Remedial action
All connections Check bolts and To comply with Tighten properly as
nuts torque value as per per table 2
table 2

Storage

Keep the battery and surrounding clean and dry and ensure bolted connections are
tight. Keep connectors, pillars and bolted connections covered with petroleum jelly.
All cleaning is to be done by wet cloth only – no solvent is to be used under any
circumstances.

- 15 -
I. EMERGENCY INSPECTION

If battery failure or other difficulty is reported, include the following checks and tests
in sequence:

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

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

c) Read voltage of individual cells at the same time looking for any hot cells or
any other abnormal conditions.

If one or more cells are found reading low voltage, read their voltage under
load and if it is quite low in comparison with other cells, which is probably the
immediate cause of trouble. Rectify the low voltage cells / Replace with
spare Cells to get the battery in service quickly.

MISCELLANEOUS INSTRUCTIONS:

(i) 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.

c) Take particular care, avoid short circuit by bridging the terminals with
spanner while tightening terminal nuts & bolts.

d) Take precautions particularly during charging.

e) Keep battery and surroundings clean and dry.

f) Attend to weak cells immediately.

(ii) Instruments and Tools

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

a) Digital Multimeter: To enable voltage readings of individual cells as


well as total battery and main source voltage. Should be calibrated at
regular interval or should be compared with a standard meter
periodically to ensure accuracy.

b) Tong Tester: To enable readings the current flowing during charge,


Float and during discharge through the battery and form the main
source. Should be calibrated at regular interval or should be
compared with a standard meter periodically to ensure accuracy.

- 16 -
ADVICE AND INSPECTION :

It is of utmost importance to Exide Industries that our customers spend worryless


time whilst using our product. The company is ready to provide all supports and
assistance to its valued customers on various issues related to the battery banks in
use. Requests for such assistance should be addressed to the Head – Industrial
service & Customer Applications, Exide Industries Limited, Survey No. 246,
Chichuruganapalli village, Sevaganapalli Panchayat, Hosur 635 103,
Dharmapuri Dist., Tamil nadu, giving full details of the battery, inclusive of
reference number shown on battery.

- 17 -

You might also like