SAFETY PRECAUTIONS

POSITIVE
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TU
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Disposal Action
RN

RECYCLE Pb

Charger settings are given in page No. 10 of this manual

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CONTENTS
Page No.
1. Introduction 1
2. Receiving the Shipment 1
3. Storage 2
4. Shifting of Batteries 3
5. Unpacking 3
6. Battery Installation & Commissioning 4
7. Power Plant Compatibility 8
8. Charge Settings & Recharge Durations 9
9. Acceptance Test 14

10. Performance of Batteries 14

11. Battery Monitoring 16
12. Important Points to avoid Premature Failure 17
of the Battery
13. Maintenance Procedures 19
14. Service Records 22
15. Conditions 24

APPENDICES

* Safety Precautions (Inside Front Cover)

* Do’s & Don’ts (Inside Rear Cover)
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Table 3.2.1
Ambient temperatre Storage period (Max)
27° C 6 months
36° C 3 months
45° C 2 months

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Table 8.3.1
Description Float application Cyclic application
Float charge
voltage @27° C 2.250 V/cell 2.270 V/cell

Boost charge
2.300 V/cell 2.350 V/cell
voltage @27° C
Equalizing charge 2.350 V/cell 2.350 V/cell
voltage @27° C
Charge current with
respect to rated C10 Min: 10% to Max: 20%
capacity
Logic for Float to Current drawn by the battery is > 3% of battery
Boost change over capacity
Logic for Boost to Current drawn by the battery is < 1% of battery
Float change over capacity
Low voltage
Shall be set @ 1.850 V/cell
disconnect
High voltage
Shall be set @ 2.400 V/cell
disconnect

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Recommended interval for

Application
giving equalizing charge
Float For every 6 months
Cyclic For every 1 month

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Table 8.5.1
Temperature Float charge voltage / Boost charge voltage /
cell (Volts) cell (Volts)
(° C)
± 0.005 ± 0.005
-10 to -20 2.350 2.370 2.400 2.450
0 2.331 2.351 2.381 2.431
5 2.316 2.336 2.366 2.416
10 2.301 2.321 2.351 2.401
15 2.286 2.306 2.336 2.386
20 2.271 2.291 2.321 2.371
27 2.250 2.270 2.300 2.350
30 2.241 2.261 2.291 2.341
35 2.226 2.246 2.276 2.326
40 2.231 2.261
45 to 55 2.200 2.220 2.250 2.300

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Recharge time to attain (Hrs)

Current: 10 % Current: 15 % Current: 20 %
0 43.3 41.1 38.8
20 40.8 39.1 37.4
40 38.6 37.4 36.1
60 35.8 35.4 34.9
80 33.0 32.9 32.8

Recharge time to attain (Hrs)

Current: 10 % Current: 15 % Current: 20 %
0 24.0 21.8 19.5
20 21.5 19.8 18.1
40 19.3 18.1 16.8
60 16.5 16.1 15.6
80 13.7 13.6 13.5

Recharge time to attain (Hrs)

Current: 10 % Current: 15 % Current: 20 %
0 12.8 11.5 10.2
20 11.4 10.4 9.4
40 10.1 9.4 8.7
60 8.5 8.2 8.0
80 6.9 6.8 6.7

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Discharge C/10 & C/9 C/8 C/7 C/6 C/5 C/4 C/3
Rate Above
0.43 0.45 0.47 0.50 0.54 0.58 0.62 0.68

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2.200
Open Circuit Voltage (Volts)

2.150

2.100

2.050

2.000

1.950

1.900
0 10 20 30 40 50 60 70 80 90 100 110

% State of Charge

Graph 11.1

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2.150
2.100
2.050
2.000
1.950
1.900
1.850
1.800
1.750
1.700
0 10 20 30 40 50 60 70 80 90 100 110

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Sl.No. Event /Activity

I - Fort night / Monthly checks

Measurement of battery terminal voltage (both on oat & boost

1
charge)
2 Checking of charge settings
3 Cleaning of battery bank
4 Measurement of individual cell voltage

1 Equalizing charge

2 Re-torquing of terminal bolts

4 Load current and typical duty cycle

1 Checking for error in measuring instruments of Charger/Power plant

3 Applying of petroleum jelly to cell terminals

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(To be generated & maintained by the user)
14.1.
1. Name of the Customer / User : _______________________
2. Address of the Customer / User : _______________________
3. Battery rating (Voltage & Capacity) : _______________________
4. Date of installation of the battery : _______________________
5. Application details : _______________________

6. Details of load / Duty cycle : _______________________

7. Expected backup time : _______________________

8. Power plant / Charger settings

Float Voltage: _________ Actual value (On battery): __________
Boost Voltage: _________ Actual value (On battery): _________
Battery path current limit: ________________________________
Logic used for Float to Boost &
Boost to Float change over:_______________________________
9. Average ambient temperature : _______________________
Following readings shall be measured with a calibrated Digital
Voltmeter for each cell.

Cell. Sl. No. Open circuit voltage in Float voltage in

Off-line condition (volts) On-line condition (volts)
1
2
,,
,,
24
Remarks : _________________________________________
Readings taken by: _________________________________________

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1. Name of the Customer / User : _______________________

2. Address of the Customer / User : _______________________

3. Battery rating (Voltage & Capacity) : _______________________

4. Date of installation of the battery : _______________________

5. Application details : _______________________

6. Details of load / Duty cycle : _______________________

7. Expected backup time : _______________________

8. Power plant / Charger settings

Float Voltage: _________ Actual value (On battery): __________

Boost Voltage: _________ Actual value (On battery): _________

Battery path current limit: ________________________________

Logic used for Float to Boost &

Boost to Float change over:_______________________________

9. Average ambient temperature : _______________________

Following readings shall be measured with a calibrated Digital
Voltmeter for each cell.

Float voltage (Volts) Onload voltages (Volts)

Cell. Sl. No.
Load Current: Amps
1
2
,,
,,

24

Remarks : _________________________________________
Readings taken by: _________________________________________
Make a photocopy of the form shown above so that additional
copies may be made at subsequent inspections.
Note: On - load voltages shall be recorded after a minimum period
of 15 min from the time of applying the load.

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DO’s & DON’Ts
Do ’ s
01.

02. Store the batteries in a cool and dry location.

03. Charge the batteries within 6 months for extending the storage
period.
04. Unpack the batteries as per the unpacking instructions.
05. Install the batteries in a cool and dry location.
06. Monitor the Charge and Float voltages of the Power Plant at
monthly intervals and adjust if required.
07. Check the tightness of all electrical connections at monthly intervals.
08. Check compatibility of Power Plant and replace/modify if
required before commissioning the battery.
09. Maintain monthly Service Record as per the format enclosed.
10. Provide adequate ventilation and illumination.
11. Ensure the cell orientation is as per the General Arrangement
Drawing.
12.
guidance.

Don'ts
01. Do not expose the packed batteries to rain.
02. Do not expose the packed batteries to sunlight.
03. Do not exceed the storage period without charging the batteries.
04. Do not install the batteries in rooms with varying temperature
pockets due to sunlight or ventilation ducts.
05. Do not short-circuit the battery or cells during assembly.
06. Do not charge the batteries in sealed cubicles.
07. Do not mix batteries of different types or makes.
08. Do not make tap connections.
09. Do not tamper with the cell vents.